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Definition
Electric arc welding: A group of fusion welding processes that use an electric arc to produce the heat required for melting the metal and filler material.
1. SAW
2. ESW
3. EGW 4. PAW 5. ASW
Arc Welding Requirements How do these arc welding processes meet the three requirements of arc welding?
Shielding
Filler Material
FCAW
GTAW
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Heat
Constant potential Constant current Voltage drop Open circuit voltage Arc voltage Polarity Watt
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7. Ohms Law
How does changing the polarity change the application of the heat?
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Terms 4 - Ampere
Amperes: the unit of measure for current flow. One ampere is equal to 6.241509481018 electrons passing by a point per second. Electricity passing through a resistance causes heat. An air gap is a high resistance
Knowing these facts, how do you change the amount of heat at the weld?
What are the characteristics of an electrode that was used with excessive current density? What is the effect when the electrode was used with insufficient current?
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Terms 5 - Voltage
Voltage is the measure of electromotive force (Emf). Emf is measured in units of volts The voltage at the electrode for SMAW determines the ease of starting and the harshness of the arc.
If an arc welder has dual controls, what will the two controls adjust.?
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Terms 6 - Resistance
Resistance is the characteristic of a material that impedes the flow of an electrical current. Measured in units of Ohms ( ) When an electrical current passes through a resistance heat (BTU) is produced.
What determines the amount of heat that an electric current will produce? Is the resistance adjustable in the SMAW process? Is the resistance adjustable in the GMAW process?
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E = IR
E I= R
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Terms 7 - Ohms Lawcont. Ohms law also be used to teach a principle of electrical safety.
Amperage is the harmful portion of electrical current. Rearranging Ohms Law for amperage shows that amperage (current flow) is determined by the voltage divided by the resistance. Voltage is fixed by the circuit design. The higher the resistance, the less current that will flow for a given voltage.
E I= R
What should you do to keep you resistance high when arc welding?
If you accidently come in contact with electric current while arc welding the severity of the shock is determined by the voltage in the circuit and your resistance.
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Volts
The voltage has only a small change for a large change in amperage.
What does this mean for GMAW and FCAW?
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Terms 9 - Constant Current In a constant current power supply, the current (amperage) stays relatively constant over a narrow range of voltages.
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Terms 13 - Polarity
Polarity (positive & negative) is present in all electrical circuits. Electricity flows from negative to positive Controlling the polarity allows the welder to influence the location of the heat. When the electrode is positive (+) it will be slightly hotter than the base metal.
When the base metal is positive (+) the base metal will be slightly hotter than the electrode.
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Terms 14 - Watt
Watts are a measure of the amount of electrical energy being consumed. Watts = Volts x Amps The greater the Watts of energy flowing across an air gap the greater the heat produced.
Is the wattage for a weld controlled by adjusting the Volts or the amps?
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GTAW
What should be changed when switch a MIG welder between the GMAW and the FCAW process?
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Safe Practices
Arc welders need protection from:
Arcs rays Welding fumes Sparks Contact with hot metal
1. Maximum Amperage 2. Duty cycle 3. Amperage range 4. Amperage adjustment mechanism 5. Input power requirements 6. Initial cost and operating cost 7. Size and portability
8. Future needs for a power supply 9. Available skills 10. Safety 11. Manufacturer's support 12. Open circuit voltage
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1: Amperage Output
The maximum output of the power supply determines the thickness of metal that can be welded before joint beveling is required. 185 to 225 amps is a common size.
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2: Duty cycle
The amount of continuous welding time a power supply can be used is determined by the duty cycle of the power supply. Duty cycle is based on a 10 minute interval. Many power supplies have a sloping duty cycle. Note in the picture there is a circle around the 75 amp setting. Why is it there?
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Joints, Welds & Positions Electric arc welding uses the same five (5) types of joints and five (5) types of welds and five (5) positions discussed in fusion welding. Name the five (5) types of joints. Name the five (5) types of welds.
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Weld Defects
A weld defect is any physical characteristic in the completed weld that reduces the strength and/or affects the appearance of the weld. The mark of a good welder is the ability to identify weld defects and adjust the welding parameters to eliminate them. Defects that are not visible must be detect by using destructive or nondestructive testing. If the defects in a weld exceed the specifications, the weld must be removed and redone. Welds are removed by grinding, gouging and cutting. Eliminating a weld defect is time consuming and expensive -- you must be able to complete the weld correctly the first time.
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The weld metal is not completely fused to base metal or passes are not completely fused.
Weld material flows over, but is not fused with the base metal.
Slow speed
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Description
Weld bead does not extend to the desired depth.
Cause(s)
Low heat Long arc Incorrect joint design
Small indentions in the surface of the weld Small voids throughout the weld material.
Accelerated cooling
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Cause(s)
Accelerated cooling Constrained joint Small weld volume
Cracks in the transition zone between the weld and base metal
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