BASIC WELDING

COMMON WELDING PROCESSES

WELDING TERMINOLOGY
WELD SYMBOLS / JOINT
CONFIGURATION
WELDER RELATED
WELDING SAFETY

BASIC WELDING
Common Welding Processes
Listed below are some of the more
common welding processes used :
SMAW -Shielded Metal Arc Welding
(stick)
GMAW -Gas Metal Arc Welding (mig)
GTAW -Gas Tungsten Arc Welding (tig)
SAW
-Submerged Arc Welding

BASIC WELDING
Common Welding Processes
SMAW- Shielded Metal Arc Welding uses the heat
of an electric arc between a covered metal
electrode and the work (pipe, plate, etc). Shielding
comes from the decomposition of the electrode
flux coating. Filler is supplied by the electrode
core wire and covering (iron powder and alloys).
This process is usually done manually. The basic
equipment is a power source, an electrode holder,
a work clamp and the electrode. Electrodes
operate variously on alternating current, direct
current electrode positive (reverse polarity) or
direct current electrode negative (straight
polarity).

BASIC WELDING
Common Welding Processes
SMAW welding metallurgy
Weld is strengthened by adding alloying elements
and by incorporating iron powder in the electrode
covering(flux). Some ingredients in the covering may
attract and hold moisture (a source of hydrogen)
which causes cracking in certain welds. A group of
electrodes specifically formulated to result in weld
deposits having very low levels of hydrogen are
referred to as Low Hydrogen electrodes. These
have identification numbers ending in 5,6 or 8. Once
removed from containers they require electrically
heated storage in a vented oven capable of holding
the electrodes between 250 350 deg F. (Low
hydrogen electrodes should be stored in their
original containers until ready for use)

BASIC WELDING
Common Welding Processes
SMAW ELECTRODE IDENTIFICATION SYSTEM

POSITION

E X X X X
STRENGTH

COATING / OPERATING
CHARACTERISTICS

Strength- Tensile strength (I.E. 70, or 60) 70,000 psi / 60,000 psi
Position: 1= all positions. 2= flat and horizontal fillet position only
Example: E-7018, E-6010

BASIC WELDING
Common Welding Processes
SMAW limiting factors
All of the welding manipulations are
controlled by the welder, such as electrode
inclination, arc length and travel speed. The
welder must set the proper current and
select polarity if direct current.
Discontinuities
Almost any discontinuity can be produced,
but the most common is porosity, and slag
inclusions.

BASIC WELDING
Common Welding Processes
GMAW- Gas Metal Arc Welding, sometimes call
Mig uses the heat of an electric arc between a
continuous bare wire filler metal electrode and
the work. Shielding is obtained entirely from an
externally supplied inert gas (argon or helium) or
reactive gases (C02 o 02) or a combination
thereof. This process can be semi-automatic or
automatic. GMAW process deposits the weld
metal in the joint by one of the following modes:
spray transfer, globular transfer and short
circuiting transfer.

BASIC WELDING
Common Welding Processes
GMAW MODES:
Spray Transfer Spray transfer occurs with high
current and voltage combinations. Spray transfer
mode best defines the arc and the pool for the
welder. Due to high heat capacity this mode is
best suited for flat and horizontal welding.
Globular Transfer Occurs at low currents
compared to spray transfer. Low current at the tip
produces large irregular drops without much
direction which results in increased amounts of
spatter compared to spray mode.

BASIC WELDING
Common Welding Processes
GMAW MODES
Short Circuiting Transfer (GMAW-S) The
short circuiting mode is a rather cold
process and its misapplication may result
in incomplete fusion. It is mainly used for
very light gauge sheet metal welding.
Most refineries and petrochemical plants
do not allow the short circuiting mode of
transfer in their welding specifications to
weld on pressure retaining equipment.

BASIC WELDING
Common Welding Processes
GMAW Welding Chemistry
Shielded gases protect gas metal arc welds from
the atmosphere. Fluxes are not used in this
process. All deoxidizers and alloying elements are
incorporated into the electrode wire.
Limiting Factors
The semi-automatic features of gas metal arc
welding simplify the training of the welder and
should make work more consistent, however the
short circuiting mode may lead to incomplete
fusion.

BASIC WELDING
Common Welding Processes
GMAW ELECTRODE IDENTIFICATION CHART

STRENGTH

CHEMICAL
COMPOSITION

ERXXS-X
ELECTRODE ROD

SOLID
WIRE

BASIC WELDING
Common Welding Processes
Discontinuities
GMAW may result in any of the common
discontinuities with the exception of slag
inclusions.
Porosity which is caused by gas trapped in the
weld, is often the discontinuity found in this
process.
Incomplete fusion is possible especially in welds
made in the short circuiting transfer mode.

BASIC WELDING
Common Welding Processes
GTAW Gas Tungsten Arc Welding (TIG) uses
an electric arc between a non consumable
electrode (tungsten) and the work. Shielding is
obtained from an inert gas or inert gas
mixture. Filler metal is added as needed.
Welds may be made with or without filler
metal as required.
The most significant feature in GTAW is that
the electrode (tungsten) used is not intended
to be consumed. Only the filler metal is
consumed

BASIC WELDING
Common Welding Processes
Welding Chemistry
The tungsten electrode contributes neither
deoxidation nor fluxing, so it is fortunate
that the melting is essentially slow and that
most of the gases can escape from the weld
pool before it freezes. The filler rod contains
the needed deoxidizers. The slow heating
and lower temperatures combined with
slower cooling rates in GTAW will result in
improved weld metal and heat affected
zone mechanical properties.

BASIC WELDING
Common Welding Processes
Limiting Factors
The outstanding factor of GTAW is the
exceptional cleanliness that can be
obtained in the weld, producing crack free
welds in alloys that are difficult to weld in
other process. However the limiting factor
is the high skill level necessary to produce
high quality welds is acquired by long
experience in manipulating the electrode
and feeding the filler wire when used.

BASIC WELDING
Common Welding Processes
Discontinuities
All of the common types of discontinuities
are possible with the exception of slag
inclusions. Porosity is a common
discontinuity due to the processes low
tolerance for contamination. Tungsten
inclusions may also result from accidental
touching (dipping ) of tungsten into the
molten weld pool.

WELDING TERMINOLOGY
LISTED BELOW IS SOME COMMON WELDING TERMS:
AIR ARC(ARC GOUGE) The process of removing metal by
means of a carbon arc rod (electrode) connected to a welding
machine and air
BACKWELD The process of completely welding the one side
of a component, and then back grinding or back gouging the
other side and applying a weld from that side
BACKING WELD The process of applying a weld pass to the
back side of the weld to provide a backing. And then
completely welding out the opposite side
BACKING PLATE OR STRAP The installation of a plate, strip
of plate, usually of the same material as base metal to the
back side of the weldment to aid in welding up large root
openings in a weldment

WELDING TERMINOLOGY
Cap- The finished portion of the weld (last pass)
Consumable insert A type of spacer that is
installed in the root spacing of a pipe or plate to
keep the specified root opening and is made of the
same material as the base metal. This insert acts as
the filler metal for the root and is melted
(consumed) with the welding process normally with
GTAW.
Discontinuity an imperfection in the weld
Defect a discontinuity of sufficient size, length,
type that will render that particular object unsuitable
for intended service base on a criteria in an
applicable code

WELDING TERMINOLOGY
Destructive testing- a sampling of the weld that is
actually taken from the weldment and is subjected
to a bend, tension, or other form of test that
usually destroys the test coupon.
Essential variables- are those which a change, is
considered to affect the mechanical properties of
the weldment and shall require requalification of
the WPS
Filler metal- The consumable electrode that is used
in most welding processes to fill the weld groove
Flux- The coating on welding electrodes that when
decomposes during welding forming a shielding
gas around the weld.

WELDING TERMINOLOGY
Heat Affected Zone (HAZ)- The portion of the
base metal that has not been melted, but whose
mechanical properties or microstructure have
been altered by the heat of welding and cutting
Preheat- the process of applying heat to a
weldment before welding. This process reduces
the thermal gradients within a weldment and
slows down the cooling rates, resulting in a more
ductile structure with lower residual stress.
Preheat also aids in removing moisture and helps
remove hydrogen.

WELDING TERMINOLOGY
Post Weld Heat (PWHT)- also known as stress
relieving in carbon and low alloy steels. The
metals temperature is raised to just below the
lower transformation temperature and held for a
prescribed time and allowed to cool at a
controlled rate. This process is done to help
eliminate the residual stress in metals and to
reduce the hardness of the weld and adjacent
HAZ after welding to back within acceptable
limits, thereby reducing the possibility of cracking
Porosity- a discontinuity in a weld when gas is
trapped in the solidifying metal which is caused
by gas released in the welding process or gas
released from chemical reactions occurring during
the welding process.
Repair any rework on a completed weld that
requires re-welding to correct a fault discovered
by visual or non-destructive testing and is beyond
the standard limits of acceptability

WELDING TERMINOLOGY
Root Bead- The first or stringer bead that
initially joins two sections of pipe, plate or fitting
Welding Procedure Specification (WPS)- a
written procedure (recipe) prepared to provide
direction for making production welds to a code
requirement. It is supported by a PQR
(procedure qualification record) which is a
record of actual variables used in the welding of
the test coupon.
Procedure Qualification Record (PQR)
documentation of what occurred during welding
the test coupon and the test results of the
coupon

JOINT CONFIGURATION
Butt Weld

1= Groove Face
2= Root Opening
3= Groove Angle
4= Root Face
5=Plate thickness
6=Bevel Angle
1

4
5
2

JOINT CONFIGURATION
Root Opening A separation at the joint root
between the two work pieces
Root Face The portion of the groove face
adjacent to the joint root
Groove Face The surface of a joint member
included in the groove
Groove Angle The total included angle of the
groove between the two work places
Bevel Angle The angle formed between the
prepared edge of a member and a plane
perpendicular to the surface of the member
Groove weld size The joint penetration of a
groove weld
Plate thickness The thickness of the base
metals to be welded

JOINT CONFIGURATION
Parts of a butt weld

Toe of Weld
both side

Weld Face

Weld Root

Face or Weld
Reinforcement

JOINT CONFIGURATION
Parts of a butt weld
Weld Metal

Cap
Groove Faces

Base
Metal
Heat Affected
Zone (HAZ)

Root

WELDING SYMBOL
Finish symbol

Groove angle

Contour symbol
Groove weld size

Tail
omitted
when
reference
not used

F
B

Depth of
bevel

Root opening
Length of weld

O
S

The weld symbol

both sides or one
side

(E)

Pitch (center to center )

Other side
Arrow side

L-P

Weld all around

symbol

I
D

(N)

Reference line

E
S
Number of spot,
seam or plug welds

Arrow connecting
reference line to arrow
side member of joint or
arrow side of joint

WELDING SYMBOL
75 deg. groove angle

Examples: Single V Butt Weld

1/8

75 deg
75 deg

1/8

1/8 root
opening

WELDING SYMBOL

Staggered intermittent fillet weld

3

(3/8)

3-10

(3/8)

3-10

10
3/8

Fillet weld side view

WELDING SYMBOL
Single V Groove

Double V Groove

Single Bevel Groove

Double Bevel Groove

WELDER RELATED
A Welder Performance Qualification test is given to
determine the ability of the welder or welding
operator to make sound welds.
When a welder has not welded with a process for
a period of 6 months or more his qualification
shall expire, unless within the six month period
prior to his expiration date, the welder has welded
using a manual or semiautomatic welding process
for that process for which he was qualified.
(Recommend to use a welder continuity sheet)
Or when there is specific reason to question his
ability to make sound welds.

WELDER RELATED
Welder test positions for pipe
1G- Pipe is horizontal and rotated ,
welding flat on
or near top of pipe
2G- Pipe or tube is vertical and not rotated
during welding, welding is horizontal
5G- Pipe or tube is horizontal fixed, and
not
rotatated, weld is vertical,
flat and overhead
6G- Pipe is inclined fixed at a 45 deg angle
and
not rotated during welding

WELDER RELATED
Welder test positions for plate
1G- Plate is horizontal weld position is flat
2G- Plate is vertical axis of weld is
horizontal
weld position is horizontal
3G- Plate is vertical and axis of weld is
vertical weld position is vertical
4G- Plate is horizontal weld position is
overhead

WELDER RELATED
Common Discontinuities
IP- or inadequate penetration without hi-low is
defined as the incomplete filling of the weld root.
Inadequate penetration due to hi-low is the
condition that exists when one edge of the root is
exposed or un-bonded because the adjacent pipe or
fitting are misaligned.
Hi-Low- is the mismatch of either the root or the OD
surface of the pipe, plate or fittings
Slag Inclusion- is a non metallic solid entrapped in
the weld metal or between the weld metal and
parent metal
Burn Thru- is defined as a portion of the root bead
where excessive penetration has caused the weld
puddle to be blown into the pipe

WELDER RELATED
Common Discontinuities cont.
Concave Root a root bead that is properly fused
to and completely penetrates the sides of the
pipe or plate wall thickness along both sides but
whose center is somewhat below the the inside
surface of the ID wall
Porosity- can be cluster, wormhole etc. Porosity is
entrapped gas pockets inside the weld
Undercut- A discontinuity at the edge or toe of
the welds where a groove is created by welding
too hot or traveling too fast during welding.

WELDER RELATED
Tungsten inclusion- is cause when the welder
accidentally dips his tungsten electrode into the
weld puddle, and the tip of the tungsten electrode
breaks off and is left un-fused in the weld metal.
Incomplete fusion- due to cold lap is defined as
an imperfection between two adjacent weld
beads or between the weld metal and base metal
that is not open to the surface (condition where
the two passes or base metal and weld metal are
not fused together)

WELDING SAFETY
SAFETY IS AN IMPORTANT CONSIDERATION IN ALL
WELDING, CUTTING AND RELATED WORK
THE MOST IMPORTANT COMPONENT OF AN EFFECTIVE
WELDING SAFETY PROGRAM IS LEADERSHIP SUPPORT AND
DIRECTION. MANAGEMENT MUST CLEARLY STATE OBJECTIVES
AND SHOW ITS COMMITMENT TO WELDING SAFETY
Management must be certain that only approved welding,
cutting, equipment are used. Such equipment includes
torches, regulators, welding machines, electrode holders,
and personal protective devices.
Proper use and maintenance of the equipment must be
taught
Personnel in areas next to welding and cutting must also be
protected from radiant energy and hot spatter

WELDING SAFETY
Where arc welding or cutting is regularly performed next to
painted walls, the walls should be painted with a finish having a
low reflectivity of ultraviolet rays
Open flame, electric arcs are a ready source of ignition. The
best protection against fire is to do welding and cutting in
specially designated areas or enclosures made of non
combustible materials
Welding helmets containing the appropriate filter plates must
be used by welders and nearby personnel when viewing an arc.
Sturdy shoes, boots and heavy clothing should be worn to
protect the body from flying sparks, spatter and radiation
burns. (cuff less pants and covered pockets are recommend
Durable leather gloves or other suitable material should be
worn
Sparks or hot spatter in the ears can be serious, properly
fitted , flame resistant earplugs should be worn whenever such
risk is present
Ear plugs should be worn when performing air arc gouging

WELDING SAFETY
Personnel should be protected from fumes and
gases performed during welding, cutting etc.
Protection from this exposure is usually
accomplished by adequate ventilation
Where exposure would exceed permissible
limits, with available ventilation, suitable
respiratory protection must be worn
Last, do not forget x-ray (gamma ray) radiation
safety. Obey all x-ray barrier signs. Do not go
into these areas when radiography is taking
place (normally magenta and yellow tape)
REMEMBER, WELDING SAFETY IS A VERY
IMPORTANT PART OF WELDING

WELDING WRAP UP
This presentation was only a brief overview
of welding, and was intended to only give a
general understanding and familiarization
of some of the more common processes,
safety concerns and terms.
If you have any questions I will try to
answer them now, if I cannot I will research
and look up. I can be reached at ext. 4083

Thank you for your attendance