Professional Documents
Culture Documents
Manual Metal Arc Welding
Manual Metal Arc Welding
WELDING
MMA welding
Main features:
Shielding provided by decomposition of flux
covering
Electrode consumable
Manual process
Welder controls:
Arc length
Angle of electrode
Speed of travel
Amperage settings
Arc characteristics
Welding involves striking an arc
between the electrode and the
workpiece, with the heat of the arc
melting the electrode (i.e. the filler
material), and with the coating
melting to form a protective slag
Uses
This has many operational uses such
as repair work to constructional
steel. It is ideal for outdoor uses as
the gasses needed to form the shield
are not blown away.
Rectifier:
Changes A.C. to D.C., can be mechanically or
statically achieved.
Inverter:
An inverter changes D.C. to A.C. at a higher
frequency.
AC or DC machine
Electrode
Electrode holder
Cables, cable connectors
Cable lug
Chipping hammer
Earthlings clamps
Wire brush
Helmet
Safety goggles
Hand gloves
Aprons, sleeves.
Conductor
In welding an electrical conductor is a metal trough which
electricity will easily flow. Copper is the most used conductor.
Voltage
This is the unit of electrical pressure. The voltage at the terminals
of an AC welding mashine is never more than 80 volts for safty
reasons. This electrical pressure (of force) is responsabile for the
current flow in a welding circuit.
Amperage
This is the measurement of the electron flow, or current, trough an
electrical conductor. Amperage is mesured in amps. An amp is a
unit quantity of electricity passing trough a given pointper second.
This is similar to the rate water flows trough a pipeline.
Voltage
The arc voltage in the MMA process ismeasured as
close. It isvariable with a change in arc lengththe arc
as possible.
O.C.V.
The open circuit voltage is the voltage required
toinitiate, orre-ignite the electrical arc and will change
with the type ofelectrode being used e.g 70-90 volts
Current
The current used will be determined by the choice
ofelectrode, electrode diameter and material type and
thickness. Current has the most effect on penetration.
Polarity
Polarity is generally determined by operation and
electrode type e.g DC +ve, DC ve or AC
MMA weldingparameters
Welding current
Too low
Welding
current
poor starting
slag inclusions
weld bead contour too high
lack oflack offusion/penetration
Too high
spatterspatt
er
excess
penetration
undercut
burn-through
MMA weldingparameters
Arc length = arc voltage
Too low
arc can be extinguished
stubbing
Arc voltage
Too high
spatter
porosity
excess penetration
under cut
burn-through
Type of current:
voltage drop in welding cables is lower with
AC
inductive looses can appear with AC if cables
arecoiled
cheaper power source for AC
no problems with arc blow with AC
DC provides a more stable and easyto strike
arc,especially with low current
better mechanical properties
DC provides a smoother metal transfer
MMA - Troubleshooting
Advantages:
Field or shop use
Range of consumables
All positions
Portable
Simple equipment
Disadvantages:
High welder skill required
High levels of fume
Hydrogen control (flux)
Stop/start problems
Comparatively uneconomic when compared with
some other processes i.e MAG, SAW and FCAW
Hazards
Fumes
Fumes can result from:
the production of oxides and nitrous gases from in complete
combustion or oxidation of nitrogen from the atmosphere
the surface coatings on steel such as galvanising, cadmium or
chrome plating and paints and solvents such as red oxide
parts/degreasing solvents
elements within the parent metal
electrode flux coatings.
Safty
Welding should be carried out in well ventilated areas. If an
extraction system is not available, an approved respirator should be
used to filter out the fumes.
Dangerous fumes
Gases, dusts and vapours are given off during welding. They
can cause:
gassing or asphyxiation because the oxygen has been used
up in the work area (common in confined spaces)
build up of poisonous metals in the body, such as lead,
cadmium, zinc, beryllium or mercury
respiratory ailments from wheeziness to serious lung
disorders.
Heat
Heat may be generated by various means. In manual metal
arc welding it is generated by the passage of an electric
current across an arc gap.
The electric arc (about 6000C) generates the heat to melt
and fuse the metal surfaces. Heat is transferred in two ways,
by conduction and by radiation.
Protective clothing
Protective clothing will help
to protect from heat,
hot metal and harmful rays.
Safty
Wear safety glasses at all times.