Syandde Welding System Workbook (se82+) Orbital Welding Training Program wor swagetok comSyoodhde Welding System SWS Orbital Welding Training Program A training program designed for users and sales representatives of the Swagelok® Welding System (SWS). It has been developed from information trade publications, reference materials, welding experience and the SWS user’s manual. DATE OF PROGRAM: Address: City/State/Zip: Phone (Office): Phone (Home):Table of Contents Introduction .. Program Objectives ...... c : ‘Scope .. Historical Overview of the Welding Process Review and Quiz Gas Tungsten Arc Welding (Gtaw - Principles of Operation : Components Process Advantages Process Limitations Potential Problems Process Variables ‘Are Current Are Voltage Travel Speed Orbital Welding Power Supplies . Direct Current Electrode Negative (DCEN) Pulsed de Welding Pulsed de Current Characteristics ‘Arc Initiation Methods 13 33 34 35Tungsten Electrodes .. Classification of Electrodes Electrode Sizes and Current Capacities Electrode Tip Configurations Grinding Electrode Contamination Replacing Electrodes . Shielding Gases ........ Types of Shielding Gases IGOR. eee Helium. eee ‘Argon-Hydrogen Mixtures... ..... : Selection of Shielding Gases Gas Flow Rates Purge (Backing) Gas .. Seconds per Turnover Volume Charts Fractional Tubing... Metric Tubing Materials Carbon and Alloy Steels Nickel Alloys 7 Refractory and Reactive Metals Stainless Steels High/Low Sultur Stainless Stee! Welding High Suifur Stainless Steel Welding Low Sulfur Materials Welding Mixed Sulfur Materials Guidelines for Welding Mi Review and Quiz 1d Sulfur Materials. Joint Design . Welding Techniques .. Definitions : = Single Level Single Pass ‘Single Level Multiple Pass Choosing Between Single Level Techniques Multiple Level Single Pass Single Level Single Pass Process Example Single Level Multiple Pass Process Example Multiple Level Single Pass Process Example 54 5-10 5:10 515 85Swagelok Welding System (sws) 0 Overview . Power Supplies Weld Heads Finture Blocks and Side Plates Collets . ‘SWS Welding Capabilities Materials Accessories ‘Additional Equipment Requirements SWS Setup SWS User's Manual Satety Precautions Cooling .. Humidity Welding Fumes . Ozone . Inert Shielding Gases ‘Arc Radiant Eneray Gas Cylinders and Gas Regulators Electrical Shock Statements Caution! WARNING! Symbols : Unpacking the SWS Components Power Supply Setup Electrical Requirements Weld Head installation Electrode Installation ....... Shielding/Purge Gas System Weld Head Shielding Gas Flow Rates Foqure Blocks ....... 10-2 10-2 10-2 10-2 10-2 10-2 10-3 10-3 10-3 103 103 10-4 10-4 10-4 10-4 10-4 10-4 105 107 10-7 108 10-10 10-10Operational Concepts ..........-.+ Digital Switch Controlled Systems (D100B) Operating Controis ‘SWS Modes of Operation ... Micro Processor Controlled Systems (M100) Operating Controls ‘SWS Modes of Operation Weld Procedure Guideline WPG Process Example .......... Determine the Work Specicatons Understanding Travel Speed and Weld Time ‘Setting Single or Multi-Level Program Parameters Step Programs Multi-Level ‘Socket Welds . Example Weld Procedure Guideline Worksheet Weld Procedure Guideline Worksheet US Customary Standard (Inches) ‘Weld Procedure Guideline Worksheet - Metric Standard . ‘Automatic Socket Weld Procedure Guideline Worksheet US Customary Standard (Inches) Micto Weld Head - Tube Welding M-series Series 5 Weld Head - Tube Welding M-series Seties 10 Weld Head - Tube Welding M-series ‘Series 20 Weld Head - Tube Welding M-series .. ‘Series 20 Weld Head - Pipe Welding M-series, \Wicro Weld Head - Tube Welding M-Series Series 5 Weld Head - Tube Welding M-series .. Series 10 Weld Head - Tube Welding M-series ‘Series 20 Weld Head - Tube Welding M-series ‘Micro Weld Head - Tube Welding D-series Sories 5 Weld Head - Tube Welding D-series .. Series 10 Weld Head - Tube Welding D-series Series 20 Weld Head - Tube Welding D-series Series 20 Weld Head - Pipe Welding D-series ‘Micto Weld Head - Tube Welding D-series Series 5 Weld Head - Tube Welding D-series Series 10 Weld Head - Tube Welding D-series Series 20 Weld Head - Tube Welding D-series Weld Flow Diagram 11-3 113 W38 11-3 11-4 11-4 1-6 119 11-9 11-40 11-12 W414 11-23, 11-24 11-25 11-27 11-29 11-31 11-33 11-34 11-35, 11-36 11-37 W228 11-39 11-40 1-41 11-42 11-43 11-44 11-45, 11-46 W447 11-48 11-49 11-60 11-51Hands-on Exercises .. Keys to Consistent Welds Weld Joint Preparation Improper Preparation Methods .... ‘dea! Preparation Method Effects of Burrs on Wall Thickness . Fixturing Internal Pressure Weld Joint Method Purge line Method Tube Welding Exercises Evaluation of Weld Quatity Weld Discontinuties and Defects . Review of Parameters for Weld Compensation Setting up a QC Department Maintenance . Weld Head and Fixture Maintenance Troubleshooting Introduction SWS Repair Procedure Repair and Replacement instructions Appendix A, Glossary . 12-3 123 123 126 127 127 12.8 12-9 12-9 124 125 12-18 12-22 1222 12-23 133, 198 143, 143 143 14-4 AtHighlights: Scope ........ Historical Overview of the Welding Process . Program Objectives When you finish this lesson, you should: 1 understand basic welding principles specific to the Swagelok® Welding System (SWS). J know the proper setup and operation of the SWS. 1 know how to troubleshoot basic welding problems 1 perform a first class demonstration of the SWS {188 Spl Campa a sere I samen ormages Conan M4Introduction SWS Orbital Welding Training Workbook (©1889 Swagelok Company a gs esero3 ‘Fabasy 2000SWS Orbital Welding Training Workbook Introduction Introduction Scope This program is designed to provide comprehensive training in the techniques of orbital welding for all SWS user Historical Overview of the Welding Process Welding has been in existence since the Bronze and Iron Age, 2000 to 3000 years ago. Forging, or hammering, was the first form of welding. ‘There have been many welding processes cevefoped since forging. ‘The most significant advances in welding began with two discoveries: + acetylene ‘© using carbon rods and a battery to create an electric are Sir Humphrey Davy first discovered an electric are could be created and maintained, and give off considerable heat. This discovery took place in Engiand in 1801. The first attempts to use this intense heat of the arc were made in 1881 by Augusti de Meriteus to weld lead storage battery plates. Electric are welding as we know it today began with the development oO of the covered electrode in the early 1900s. Welding applications grew A covered electrode is rapidly after the 1920s and accelerated at the onset of World War I in ‘referred to as “stick welding.” the early 1940s. and was further refined by Meredith and others, The welding process advanced rapidly during World War Hf due to aerospace and Inert gas welding is shipbuilding industry requirements. ‘sometimes referred to as a | “TIG" of “Heli-Arc welding. Inert gas welding was developed in 1926 by Hobart and Devers ‘2/88 Swageiok Company al ges eserves Sxgeok Company. 13Introduction SWS Orbital Welding Training Workbook 14 ‘Today, there are six main welding process categ resistance welding gas welding brazing solid-state welding other processes are welding There are many sub-categories within the six main welding processes. Figure 1-1 (Welding Handbook, Volume I., 8th Edition, American Welding Society) highlights four common arc welding processes, including gas tungsten arc welding (GTAW), the process used by the SWS. GTAW is the process described in this training program. Figure 1-1 Welding Processes Review and Quiz (©1890 Swegelok Company, al gs reserved ‘Peery 2000Highlights: Principles of Operation Process Advantages Process Limitations ...... Potential Problems . Process Variables Orbital Welding ... 24 27 Objectives When you finish this lesson, you should: 1 understand the GTAW process. know the functions of GTAW components. 1 understand the process limitations and advantages. 1 know the process variables, "BoB Suan Coney as eave a4Gas Tungsten Arc Welding 22 SWS Orbital Welding Training Workbook 121888 Swagoik Campany, a gs sored February 2000SWS Orbital Welding Training Workbook Gas Tungsten Arc Welding Gas Tungsten Arc Welding (GTAW) GTAW is a process that operates by establishing an arc between a nonconsumable tungsten electrode and the work (weld puddle). See Figure 2-1. Both the electrode and weld puddle are surrounded by a shielding gas, Filler metal can be used in GTAW, but is not a requirement, GTAW provides advantages in a wide range of industries, from high-tech processes (requiring high quality) to the autogenous, manual welding needs of sheet metal manufactusing. Autogenous welding is a process that does not sequire filler. The key advantage of GTAW is its precise control of heat input. This fact makes GTAW the preferred process for joining thin gage metals and for welding in close proximity to heat-sensitive components. GTAW is used in welding most metals and many types of joint geometries in tubing and pipe. It is particularly suited for welding sections less than 0.375 in. (9,5 mm) thick. For autogenous welds, 0.188 in. (4,8 mm) thick sections are considered maximum. Direction of Travel BL welding Toren Tungsten Electrode Filler Reo Figure 2-1 GTAW Process ‘PigSeSuapebk Company a ges resoves 23Gas Tungsten Arc Welding ‘SWS Orbital Welding Training Workbook Principles of Operation GTAW uses a non-consumable tungsten (or tungsten alloy) electrode held in a torch or other holding device. Shielding gas is fed through the torch to protect the electrode, molten weld puddle, and solidifying weld metal from atmospheric contamination. An electric arc is established between the tip of the electrode and the work through the conductive, ionized shielding gas. The heat produced by the arc melts the base metal. Afier the weld puddle is established, the electrode moves along the joint and progressively melts and joins the adjoining surfaces. Filler wire, if used, is generally added to the leading edge of the weld puddle to fill the joint, as shown in Figure 2-1, Components The four components commonly used in GTAW are (Figure 2-2): + Welding power supply ‘The power supply converts the incoming high voltage, low current ac power to low voltage, high current de power. + Shielding gas ‘The shielding gas protects the electrode and the molten weld metal from atmospheric contamination. + Torch (orbital weld head) The torch holds the electrode and is attached to the weld power supply by a conductive cable. * Electrode ‘The electrode conducts the arc from the torch to the work piece. ‘These four basic components are considered necessary, but other components such as wire feeders, programmable controllers, and turntables can also be used in GTAW. a 2224s = Sage Conary. Argan eemenesSWS Orbital Welding Training Workbook Gas Tungsten Arc Welding Vv Welding Power Supply ‘AC Power in fi ‘Shielding Gas in Figure 2-2 Common GTAW Welding Components Process Advantages ‘The GTAW process has several advantages: produces consistent, high-quality welds provides excellent control of heat input is capable of welding a wide variety of different metals, welds with or without filler material can produce 4 high volume of autogenous welds at a low cost eliminates spatter {8 Suaplok Company al ats reseed 25Gas Tungsten Aro Welding SWS Osbital Welding Tealning Workbook Process Limitations The GTAW process has some limitations: «has low deposition rates compared to other processes + requires more operator dexterity and coordination when manual welding + is less economical when welding thick materials than consumable electrode arc welding processes + is difficult to maintain proper shiel drafty environments ng of the weld zone in Potential Problems Potential problems of GTAW include: «tungsten inclusions (weld defects) ‘* weld metal contamination due to improper shielding + low tolerance for contaminants,SWS Orbital Welding Training Workbook Gas Tungsten Arc Welding Process Variables ‘The major process variables in GTAW are arc current, arc voltage, and travel speed, Arc Current Arc current is the current measured between the tungsten electrode and the work. Generally, the arc current level controls weld penetration Arc Voltage Arc voltage is the voltage measured between the tungsten electrode and the work. Arc voltage is affected by: © arc length (distance between the electrode and the work) © type and purity of shielding gas ‘+ shape of the tungsten electrode tip © arc current. Arc length is important because it affects the width of the weld puddle. Because weld puddle width is proportional to are length, it is desirable to have an arc length as short as possible. Travel Speed Travel speed is the speed at which the electrode moves over the Work while welding, Travel speed affects both the width and the penetration of the weld. It affects width more than penetration. increasing travel speed decreases the width of the weld. Generally, travel speed is fixed in mechanized welding. Other variables, such as current, are varied to maintain control of the weld. Seg eee _ _Gas Tungsten Arc Welding 28 SWS Orbital Welding Training Workbook Orbital Welding ‘Welding with equipment that performs the welding operation without adjustment of the controls by a welding operator is called automatic welding. In this type of welding process, the equipment may load and unload the work pieces. Orbital welding is an automated process in which an electrode is accurately rotated in an orbit around a part joint on a rotor using gear trains and a motor (see Figure 2-3). Weld Head Tungaten ne 0 Shiekang Gee = ™, LF is Leg Figure 2-3 GTAW Orbital Process Manual welding, although performed by highly skilled and experienced welders, may produce inconsistent results. Orbital welding systems require less operator training, produce consistent high-quality welds. is typically autogenous and is in high demand in many industries. 1008 val ©1969 SwageiokComoany a ps sendSWS Orbital Welding Training Workbook Gas Tungsten Arc Welding GTAW orbital welding systems perform a set of operations in a controlled ‘manner where variables are maintained at preset levels regardless of changing weld quality. The welding system automatically starts and completes the weld, stepping from one variable setting to the next at either a predetermined time or location along a weld joint. Part tolerances must be closely controlled, and fixturing must be strong and accurate since the welding system cannot compensate for part movement, 121898 Swagelak Company, ats esened Febuary 200Gas Tungsten Arc Welding SWS Orbital Welding Training Workbook 210Highlights: Constant Current Power Supplies .... 3-3 Direct Current Electrode Negative .... 3-3 Pulsed de Welding......-..... Arc Initiation Methods . Objectives When you finish this lesson, you should: 1 know the types of power supplies used in GTAW. 1 understand DCEN and its advantages. + understand pulsed de welding and its variables. 1 know how to calculate average welding current. 1 understand how the arc is initiated. 1288 Supe Company. at ase eared otPower Supplies SWS Orbital Welding Training Workbook (©1880 Swagolok Company, a gs reserved abc 2000‘SWS Orbital Welding Training Workbook Power Supplies Power Supplies ‘The goal of machine or automatic welding is to produce accurate and repeatable weld current levels during each weld cycle. To accomplish this, GTAW power supplies use a constant current design. A constant current power supply maintains a desired output current level, regardless of load conditions. In addition, design advances have improved the performance of constant current power supplies and have made them popular for both shop and field GTAW applications. A constant voltage power supply is used for GMAW (“mig”) welding. This course does not cover constant voltage power supplies. An electronically controlled inverter power supply is also capable of rapid dynamic response. Rapid dynamic response means the supply can change its output current levels quickly and accurately. This characteristic makes the design ideal for pulsed welding applications. Refer to Pulsed de Welding on page 3-4. Generally, inverter power supplies are the most versatile because they are usually lighter and more compact than other power supply designs of an equivalent current rating. Direct Current Electrode Negative (DCEN) Direct Current Electrode Negative (DCEN), also referred to as “straight polarity,” is the term used to describe one possible electrical configuration of a welding system. Describing a welding power supply as a DCEN type means that the output is direct current (dc), and the electrode is the negative terminal. Given that the electrode is the negative terminal (or cathode), the work piece becomes the positive terminal (anode). During welding, the arc is established, and electrons flow from the electrode to the work piece. ‘The advantage of DCEN is that it deposits approximately 70 % of the generated heat into the work piece and 30 % into the electrode. Because DCEN delivers the greatest amount of heat to the work piece for a given welding current, it provides deeper weld penetration than direct current electrode positive (DCEP or “reversed polarity”). Therefore, DCEN is the ‘most common configuration used in GTTAW and can be used with a variety of shielding gases. 2. gg Conn ara sons a