Eng.

Khalid Mohamed Hafez

Osaka Uni., Japan

ARC WELDING:
1

Definition: A process whereby upon the application of intense heat, metal at the
joint between two parts is melted and caused to intermix. Upon cooling &
solidification, a metallurgical bond results.
Heat: Developed between the work and an electrode, manually or mechanically
moved along the joint.
Electrode: May be non-consumable carbon or tungsten rod or may be consumable
specially prepared rod or wire that conducts the current, sustains the arc, & supplies
filler metal to joint.
Welding Current: AC or DC power source, connected by a work cable to
workpiece & by an electrode cable. Temp of arc at end of electrode between 9,000
& 10,000 F or 5,000 to 6,000 C. Pool of molten metal at end of rod called crater.
This crater is caused by the force of the arc causing the molten metal to flow back
into the weld bead.
Arc Shielding: Needed to prevent high temp. molten puddle of metal from
reacting with and absorbing nitrogen and oxygen into the liquid metal. Bond
would be very porous and brittle. Shielding accomplished by coating on electrode,
granular flux, wire with flux core inside, special attachment to force shielding gas
over molten metal.

SELECTING A WELDING PROCESS

Primary Consideration:
- Ability of process to give the required quality at lowest cost.
- Job:
-Defines the metals to be joined
-Number of pieces to be welded
-Total length of welds
-type of joints
-Preparation of joints
-Quality of weld required
-Assembly-positioning requirements
4 Step Procedure (Semi-mechanization)
1. Joint to be welded is analyzed in terms of requirements.
-Economy
-Fast-Fill (High deposition rate)
-Fast-Freeze (joint is out-of-position)
-Fast-Follow (High arc speed w/very small welds)
-Penetration (Depth of penetration into base metal)
2. Matching Joint Requirements with Processes.
-Read manufacturers literature - Gives information on the ability of various
processes to deliver joint requirements. Once capabilities of processes known,
can then be matched joint requirements and tentative processes can then be
made.
3

3. Make Check List.

-Volume of Production - Must be adequate to justify the cost of the process.
-Weld Specifications - What are weld properties specified by the code.
-Operator Skill - Replacing manual equipment with automated process may
require training program.
-Auxiliary Equipment - Process may require special power sources.
-Accessory Equipment - chipping hammers, deslaging tools, flux lay-down
and pickup equipment, exhaust systems.
-Base-Metal Condition - Rust, oil, fit-up of joint, weldability of steel
-Arc Visibility - Need for open-arc process or covered.
-Fixture Requirements - Adaptability of process to fixturing & welding
positioners.
-Production Bottlenecks - i.e. process reduces unit fabrication cost but creates
material holding.
4. Review of Application buy Manufacturers Representative
-Manufacturer of equipment knows its capabilities best. Will be able to clear
up any questions, supply up-to-date information, point out pitfalls, etc.
SMAW PROCESS
-Most widely used of all the arc welding processes
-Commonly called stick welding or manual welding.
-Arc welding to common person usually means SMAW
-Characteristics
-Versatile
-Flexible
-Simplicity in equipment
-used by small welding shop, home mechanic, farmer, but also extensive
application in industrial fabrication, structural steel erection, weldment
manufacture
Process Description:
Individual touches tip of electrode against work, withdraws electrode to establish
arc. Heat of arc melts base metal in immediate area, the electrodes metal core,
and any metal particles in electrodes covering. Heat also melts, vaporizes, or
breaks down chemically nonmetallic substances in covering for arc shielding,
metal-protection, or metal-conditioning purposes. Mixing of molten base metal
4

and filler metal from electrode produces coalescence required to effect joining.
Disadvantages:
-Rod becomes shorter & periodically needs replacing
-Slows production rate be decreasing the operating factor (% time welder welding)
-Limitation placed on current that can be used (High amperages can not be used Current limited by resistance heating of electrode. Temperature must not exceed
Break Down temp of covering.
Advantages:
-Used with many electrode types & sizes
-Used in all positions
-Used on great variety of materials
-Flexibility in operator control makes it the most versatile of all
welding processes
-Low cost of equipment
Principles of Operation:
-Arc struck between work & tip of electrode; Heat of arc melts electrode & surface
of work near arc; Tiny globules molten metal form on tip of electrode, transfer
through arc in molten weld pool or puddle on work surface.
-Transfer through arc stream brought about by electrical & magnetic forces.
-Movement of arc along work produces progressive melting & mixing of molten
metal, followed by solidification, & joint.
-Shielding ingredients functions:
-Shield arc & molten metal from atmosphere; prevents formation of oxides &
Nitrides in weld puddle
-Scavengers & deoxidizers refine the weld metal
-Produce slag blanket over molten puddle & newly solidified weld to further
prevent oxide and nitride absorption
-Provides the ionization needed for AC welding.
-Stabilizes arc
-Fluxing action to clean metal
Power Source:
5

-Requirements:
-Currents 10 to 600 amp
-Open circuit voltage - 85 volts
-Welding Voltages 17 - 45 volts
-Source may be AC, DC motor generator or combination AC/DC, Gasoline
engine driven generator, or inverter
-Variable voltage power source