DOC NO.

5Q&A-002-SA1
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QUALIFICATION & CERTIFICATION BOARD
Date of Issue: 23 May 2011
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SA1 WELDING PROCESS AND EQUIPMENT
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ABN 69 003 696 526
QUESTION 1

1.1 Briefly describe the main arc initiation mechanisms for GTAW welding and give advantages and
disadvantages of each. 12 marks

Scratch Starting Method
As with MMAW the electrode is scratched on the work surface to start the arc, and then moved
away to the required arc length.
Lowest cost equipment.
Risk of tungsten contamination on work piece, and/or damage to electrode.
Welder must master the technique to avoid electrode sticking to the work.

High Frequency (HF) Ignition
A high voltage, high frequency current provides an ionized path for the welding current to follow
when the electrode is brought within about 5mm of work piece.
Less skill required than with scratch starting, and less risk of contamination.
Enables stable AC welding with sinusoidal wave form.
Requires a HF unit (built in or added to power source).
HF may adversely affect other electrical and electronic equipment.

Contact or Lift Arc Ignition
The electrode is brought into contact with the work, and then lifted off and the arc ignites. This is
done with electronic control that detects the short circuit situation and limits the current flow to very
low level. As soon as the electrode is lifted the arc is started.
No HF even with AC (square wave form).
Low skill, low risk of contamination.
Highest cost, only available on some modern power sources.

1.2 With the aid of graphs, discuss the power source characteristics and applicable welding processes
for:
a) Constant current drooping characteristic
b) Constant voltage characteristic 8 marks

Drooping:
The output voltage decreases as the output current increases;
Low (restricted) short-circuit current.
Suitable for the following processes
MMAW
TIG


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ABN 69 003 696 526

A Large change in arc length (Voltage) causes a small change in amperage (melting rate).
















Current

I1 I2
V2
V1
V
o
l
t
a
g
e

A constant current machine will vary its output voltage to maintain a steady current while a constant
voltage machine will fluctuate its output current to maintain a set voltage.

Constant voltage:
The output voltage remains substantially constant under output current alterations or a small change
in arc volts results in a relatively large change in welding current.
Suitable for constant feed electrode
GMAW (MIG/MAG)
FCAW (Flux cored arc)
SAW (Sub-arc)
Small change in arc length (Voltage) causes big change in amperage.















Current

V
o
l
t
a
g
e

V1
V2
I1 I2
V


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ABN 69 003 696 526

QUESTION 2

2.1 Briefly explain and describe the four main metal transfer mechanisms for GMAW welding with the
aid of sketches. 15 marks

Dip (short arc, short circuiting) transfer:









Low voltage and low current (14-20V and ~60-200A on steel). Metal deposited during rapidly occurring short
circuits (20-200/sec). Low heat input and narrow heat spread; weld metal 'freezes' rapidly. Spatter can occur
if the short circuiting is violent. Uses: thin sections, positional welding, root pass to bridge a root gap.


Globular transfer:









Typically occurs at ~20-26V and >180A (on steel).
Metal transfers in large globules at relatively low current density, sometimes during short circuits.
The droplet size is characteristically greater diameter than the electrode.
Uses: welding steel with CO
2
shielding gas.

Spray transfer:

High settings ~27V 180A (steel).
Droplets <wire .
Axial transfer.
High Ar content in shielding gas
High heat input.
High deposition rate.
Deep penetration.
Smooth weld surface.
Minimal spatter.
F and H positions


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ABN 69 003 696 526

Pulsed transfer
Controlled spray transfer at the selected wire feed rate.
Spray transfer at current levels that would normally produce dip or globular transfer.
Positional welding in spray, improved weldability of thinner sections

Extends the current range in which spray transfer will occur.
One form of improves the performance of dip (short arc) transfer. Synergic" power sources use electronic
control to manage the complex parameters.
Advantages include;
Electronic control and feedback give a very stable arc with minimal spatter, and low risk of wire burn
back or stubbing.
Simplified selection of parameters with power source containing programs for specific materials,
wire diameters and shielding gases.
Larger diameter electrode wire diameters can be used (cheaper and easier to feed).
















2.1 List an two advantages and two disadvantages of using argon based mixed shielding gas compared
to pure C0
2
shielding gas in MAG welding? 4 marks

Advantages:
Does not require a heating unit for the regulator
Less spatter
More stable arc

Disadvantages:
More expensive
Shallower and narrower penetration profile, thus greater risk of lack of fusion
Less tolerant of dirty steel

2.2 Discuss the differences between the three flame settings used in oxy-acetylene welding and
brazing, explain the features that distinguish them from each other and list an application where it be
used. Use sketches if necessary. 16 marks

Neutral flame
1:1 gas ratio approx.
High temperature (3200C), concentrated zone at the end of the inner cone.
adequate heat content
minimum chemical reaction with parent and filler metals.
Use for fusion weld steels, cast iron, stainless steel, copper, aluminium and for brazing.
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ABN 69 003 696 526

2.3 List two reasons why GMAW wires may be copper coated? Give one drawback of the copper
coating. 3 marks

Reason
It improves the current pickup between contact tip and the electrode.
Helps prevent rusting of the wire when it is exposed to the atmosphere.

Drawback
Copper inclusions

2.4 List an advantage and a disadvantage of using pure C0
2
shielding compared to in argon based
shielding MAG welding? 2 marks

Advantages:
Cheaper
Deeper and wider penetration profile, thus lesser risk of lack of fusion

Disadvantages:
Spatter
Heating unit required in the regulator
Unstable arc


QUESTION 3


3.1 Explain the effect of current and polarity of the GTAW process in terms of heat distribution,
penetration, electrode capacity, and cleaning action with the aid of a neat sketch. 10 marks











Current
Polarity
DCEN DCEP AC
(Balanced)
Oxide Cleaning
Action
No Yes Yes once
every cycle
Heat balance 1/3 electrode
2/3 work
2/3 electrode
1/3 work
50/50
Penetration Deep, narrow Wide, shallow Medium
Electrode
capacity
Excellent Poor Medium


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ABN 69 003 696 526

3.2 Explain the principles of the SAW process with the aid of a neat sketch. 10 marks

Process Principles
















In the submerged arc welding (SAW) process the arc is established between a continuously fed wire
electrode and the work. The arc is "submerged" under a layer of granular flux.

Arc Characteristics

Once the arc is established the flux melts and forms a liquid bubble around the arc, periodically expanding,
bursting and then reforming. Metal transfer is irregular, but confined to the flux bubble so no spatter is
formed. A cavity at the front of the weldpool creates a strong rearward flow so that the weldpool is
significantly elongated.

Arc
Weldpool
Weld
Solidified
Flux recycling
system
Wire
Power
source
Granular flux
Work
Wire
drive
Hopper
slag

Granular flux
Solidified slag
Molten slag
Weldpool
Arc cavity
Electrode
Solidified weld metal
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ABN 69 003 696 526

QUESTION 4

4.1 Explain, with the aid of a sketch, the principles of the MMAW Process. 10 marks

Process Principles

Electrode Core wire
Flux coating
Arc
Slag coated
metal droplet
Weld pool
Solidified slag

Weld deposit

Gas shielding
Power
Source

The tip of the electrode is brought into contact with the work and then drawn a short distance away to form
an arc. The heat of the arc (<6000C) forms the molten weld pool on the work and the core wire of the
electrode melts, transferring molten droplets across the arc to provide the filler metal. The arc and weld pool
are shielded from the atmosphere by the decomposing flux coating on the electrode. The flux provides
shielding by gases (such as CO, CO
2,
, H
2
) and molten slag.

4.2 State two functions of an electrode flux coating for MMAW. 2 marks

To create a slag
To create a gas shield
To transfer elements into the weld pool metallurgical
To transfer elements to the weld pool volume increase
To protect the core wire.

4.3 List two limitations of MMAW. 2 marks

Limitations of MMAW
Low deposition rates compared to other manual processes.
A high skill level required high quality welds, especially for work such as positional welding on
structural steel work or for pressure pipe welding. Many welders require several years experience to
become truly competent in this type of work.
Consumables must be stored and handled correctly for low hydrogen welds. J oint set-up and
cleanliness is critical for top quality welds.


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ABN 69 003 696 526

4.4 Identify a surface characteristic imparted by surfacing or spraying. 1 mark

Wear resistance
Heat resistance
Oxidation resistance
Corrosion resistance
Electrical resistance
Electrical conductance
Restoration of size

4.5 Explain, with the aid of a sketch, the principles of the FCAW Process. 10 marks

Flux-cored arc welding (FCAW) is a semi-automatic or automatic arc welding process. FCAW requires a
continuously-fed consumable tubular electrode containing a flux and a constant voltage or, less commonly, a
constant electric current welding power supply. An externally supplied shielding gas is sometimes used, but
often the flux itself is relied upon to generate the necessary protection from the atmosphere. The process is
widely used in construction because of its high welding speed and portability.




FCAW Equipment



The FCAW Process
Welding
gun
Power
source
Wire feed
unit
Shielding
gas
l
Weld
Shielding
gas nozzle
Electrod
Contact
tip
Arc
Gas
shielding

QUESTION 5

5.1 Define the following terms:

i) Duty Cycle (Power Source). 2 marks

The percentage of time, for an arbitrary test period, during which power supply can be operated at
its rated output without overloading.

ii) Deposition Efficiency of a Welding Process 2 marks

Deposition efficiency in arc welding is the ratio of the weight of the weld metal deposited to the nett
weight of the filler material used.

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ABN 69 003 696 526

5.2 State the effects of the following on weld quality

i) Arc length that is too long using GMAW 2 marks

Increase spatter levels
Increase the chance of undercut.
Produce an erratic arc.
Increase the chance of contamination from the surrounding air.
Increase the voltage.

5.3 Explain the process principles of Friction Welding with the aid of a sketch. 4 marks












Friction welding is a solid-state joining process that produces a weld under compressive
force between the contacting surfaces of work pieces moving or rotating relative to one
another. Heat is produced and material is plastically displaced from the faying surfaces.

5.4 What is the fundamental difference between brazing and soldering. 2 marks

Brazing - the filler metal melting temperature is higher than 450C
Soldering - the filler metal melting temperature is lower than 450C

5.5 Explain the principles of Explosive Welding. 3 marks

Explosive welding is a solid state welding process (that is, no fusion or liquid state) that uses a
progressive explosive detonation to force two metals to impact together at high speed and pressure
to form a metallurgical bond.

The explosive force brings the two metals progressively together at the collision front while expelling
a jet of metal that forms just ahead. The jet cleans the surfaces from oxides and contaminants.

5.6 Explain with the aid of a sketch, the hot plate welding process used for weldable plastics. 5 marks

The technique involves heating the ends of the parts to be joined against an electrically heated
platen until they are sufficiently molten. The heater plate is then removed and the parts pressed
together. A cooling cycle follows, allowing the weld to develop strength. The platens are normally
stainless steel or aluminium coated with PTFE to prevent the molten polymer sticking to them.
Holding fixtures are required to hold the parts in alignment for welding. To make the weld, the joining
surfaces are brought into contact with the heated platen and held with sufficient pressure to allow
the surfaces to melt. Once the surfaces are melted, the holding pressure is released, the platen
removed and the two surfaces pushed together to form the joint. Pressure is maintained until the
molten material has solidified.
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ABN 69 003 696 526

















5.7 Explain with the aid of a sketch, the principle of carbon arc air gouging. 5 marks

Travel.
Electrode at 35-70
to work surface.
Air jet under electrode
Electrode clamp with air holes.
DCEP or AC
Copper coated electrode.
Stickout ~150mm max.
Molten material
Torch

An arc is struck between a consumable carbon-graphite electrode and this produces a molten pool on the
workpiece. The molten metal is then blown away by jets of compressed air, the forward movement of the
electrode producing a cut or groove in the metal.





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ABN 69 003 696 526
QUESTION 6

The following questions have multiple-choice answers and are worth 2 marks each.
Only one answer is correct. Tick only one. If more than one box is ticked, no marks will be awarded.

6.1 The development of the GMAW/MAG welding processes has been mainly due to?

a. Improvement of productivity and ease of mechanisation.
b. Applicability to welding of stainless steels.
c. Use of inert gases.
d. Improvement of mechanical strength of weld.

6.2 Which welding process you recommend for Cr-Mo steel pipes, 20 mm diameter and 2 mm wall
thickness:

a. Manual Metal Arc Welding (MMAW)
b. Gas Tungsten Arc Welding (GTAW)
c. Plasma Keyhole Welding
d. Submerged Arc Welding (SAW)

6.3 Which of the following welding processes is only suitable for automation?

a. Manual Metal Arc Welding (MMAW)
b. Submerged Arc Welding (SAW)
c. Electron beam welding (EBW)
d. Gas Tungsten Arc Welding (GTAW)

6.4 In arc welding processes, penetration is mostly affected by?

a. Preheat
b. Voltage
c. Arc length
d. Current

6.5 The welding power source must:

a. Decrease the voltage of the power supply and increase the current.
b. Maintain the parameters of the power supply.
c. Increase the efficiency of the primary consumption.
d. Decrease the power supply current.

6.6 Which of the following power source types produces direct current?

a. A rectifier
b. A diesel generator
c. An inverter
d. All of the above

6.7 What is the difference between MIG and MAG Welding?

a. The base material
b. The type of shielding gas used
c. The wire electrode
d. The power source

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ABN 69 003 696 526
6.8 When welding austenitic stainless steels, backing gas is often used to prevent oxidation of the
surface of the material thereby reducing the corrosion resistance. Which of the following types is not
used as backing gas for stainless steel?

a. Argon
b. Argon and CO
2
mixture
c. Helium
d. Nitrogen and hydrogen mixture, eg. 90/10

6.9 What determines the selection of a wire feed roller for GMAW/MAG?

a. The type (chemical composition) of the wire
b. Wire feed rate
c. The pre-bending of the wire
d. Diameter of the roller

6.10 Which MMAW electrodes produce the deepest penetration in the base metal?

a. Acid coated electrodes
b. Rutile coated electrodes
c. Basic coated electrodes
d. Cellulose coated electrodes

6.11 In MMAW with covered electrodes when the arc length increases,

a. Current increases.
b. Penetration increases.
c. Arc voltage increases.
d. Spattering decreases.

6.12 In submerged arc welding:

a. Only alternating current is used
b. Only direct current is used.
c. The polarity has no importance.
d. Alternating and/or direct current can be used.

6.13 Which of the following statements are not correct for the requirements of Laser Beam Welding,
LBW?

a. Very accurate fit-up is necessary
b. Filler metal is always used
c. Mirrors or optic fibres are used to focus the laser beam
d. The process calls requires automation
6.14 Which joining methods can be used for surfacing:

a. TIG-Hotwire
b. Acetylene/Oxygen process
c. Thermal spraying
d. Answers a), b) and c) are correct.

6.15 What are the four main process parameters of the resistance spot welding process?

a. Material, thickness, current type and pressure
b. Current, pressure, time, electrode type and size
c. Time, pressure, material type, electrode size and type
d. Polarity, pressure, material type, coating type