FACULTY OF MECHANICAL ENGINEERING

WELDING AND JOINING TECHNOLOGY

BMM4793

ASSIGNMENT 1

LECTURER : ASSOC. PROF DR. MAHADZIR BIN ISHAK @

MUHAMMAD
SECTION : 01
GROUP MEMBER :
LEE HEYY DEE MA16046
MOHD ZAKI ARIFIN BIN ABDUL RAHIM MA16045
MUHAMMAD NUR ARIFF HAKIMI BIN MOHD JAAFAR MA15001
ULFAH HANI BINTI BURHAN HB16003
LIYANA NABILAH BINTI AHMAD NASUHARDI HB16011
QUESTION 1

Discuss the advantage and disadvantage of constant current and constant voltage
characteristics. List welding processes involve in constant current and constant voltage.

Constant Current Current Voltage

Advantage ▪ Output of the welding is the ▪ Semi - automatic process

most stable output. where the wire feed speed is
▪ Preferred output of welding automatically controlled at
due to it is an associated constant speed.
level of automation welding
process.
Disadvantage ▪ It is the manual welding ▪ Still need to know all the
process which required welding variable such as to
welder with skills. hold the welding gun in hand
▪ Need to be able to control all and required to control the
the welding variables by angle, travelling speed and
hand. other variables.
Welding ▪ TIG (Tungsten Inert Gas) / ▪ GMAW (Gas Metal Arc
processes GTAW- (Gas Tungsten Arc Welding)
involved Welding) ▪ MAG (Metal Active Gas
▪ Manual Metal Arc Welding / Welding)/ (MIG- Metal Inert
SMAW (Shield Metal Arc Gas Welding)
Welding) ▪ FCAW (Flux- Cored Arc
▪ Plasma Arc Welding Welding)
▪ SAW (Submerged Arc ▪ SAW (Submerged Arc
Welding) Welding)
QUESTION 2

How magnetic pinch occurred and how it effects to the welding qualities? How the mechanism
of magnetic pinch happened?

A pinch is the pressure of an electrically directing fiber by attractive powers. The circular
segment in all conductors conveying current is encompassed by an attractive field. The bend
in welding is commonly worked under a high current condition and the attractive field made
by the current affects the welding circular segment.

Figure 1: Electromagnetic force Figure 2: Magnetic field

Magnetic pinch effect

An electric flow going through a fluid or vaporous channel makes its cross segment to recoil
because of the electro-attractive powers. This is called as Magnetic Pinch Effect.

The electro-magnetic force or Lorentz force is expressed as follows,

F=J×B

J = Current density

B = Magnetic flux density

 Figure 3: Electro-magnetic force in a columnar conductor

In a specific condition, the squeeze impact is applied to control the metal exchange mode in
circular segment welding, as the liquid metal on the tip of wire cathode is squeezed off.

Arc force ／Magnetic pinch effect

The attractive squeeze impact causes a pivotal power under the condition that the present way
is extending, as appeared in the figure. The hub power: Fm is around communicated as pursues,
Ia, Ra and Rb. In welding bend, the present way is extending from anode to work-piece, this
power is called as Arc Force.

la = Current

Ra = Upper of current path

Rb = Lower of current path

In welding circular arc, the present way is growing from cathode to work-piece, this power is
called as Arc Force.

Figure 4: Axial force caused by magnetic pinch effect.

Metal transfer in MAG/ Magnetic pinch effect

The electro-attractive power has a significant job on the metal exchange in MAG welding. The
figure demonstrates the impact of electro-attractive power on the metal exchange. The E-M
power: Fem is given around by Eq(1).

I = Curent

μ= Permeability

R = Wire-diameter

Ra = Diameter of current zone top of molten

As per Eq.(1), the power isn't little and the heading of the power relies upon the anode-size in
MAG bend.

Figure 5: Current path in various transfer modes

QUESTION 3

In DCSP, when high speed electrons strike the workpiece and its kinetic energy is changed
over into thermal energy, which results in higher generation of heat closer to workpiece. This
causes fast and complete melting of base metal and making it have better penetration. While in
DCRP the base plate is made of negative terminal, so higher heat is created. Because of small
amount of heat, it may cause lack of penetration and incomplete fusion. While AC offers
moderate degree of infiltration.

DCEN DCEP

Metals are related with the positive terminal Electrode is connected with the positive
and electrode is connected with the negative terminal and metals are connected with the
terminal of the power source. negative terminal of the power source.

Electrons release from the landfill of the Electrons release from the base metal surface
electrode and strike the metal surface under and strike the electrode tip.
enough potential difference.

Heat is generated almost 2/3 of the total arc Heat is produced 2/3 of the total arc at
near plate and rest is produced at electrode electrode landfill and the others is produced
tip. near plate.

With straight polarity suitable fusion of the Incomplete fusion of metal may be
base metal can be reached simply as more encountered due to less heat generation near
heat is produced at the area of base metals. base metal. This may lead to lack of
So, it removes lack of penetration defects and penetration defects and lack of fusion.
lack of fusion.
Question 4

Explain about constant power and constant voltage power source characteristic.

Constant power power source characteristic

Manual Metal Arc Welding (MMA), Tungsten Inert Gas (TIG) and submerged arc
power sources are therefore designed with what is known as a loose output or constant current
static characteristic, Metal Inert Gas (MIG)/Metal Active Gas (MAG) and Flux-Core Arc
Welding (FCAW) power sources with a flat or continuous voltage static characteristic. On most
power sources the angle of the characteristic can be changed either to flatten or make steeper
the curves shown in figure above.

Figure above shows drooping or constant current power source static characteristics,
such as would be used for the MMA or TIG process, superimposed on the arc characteristic
curves. When manual welding is taking place the arc length is constantly changing as the
welder cannot maintain a constant arc length. With a constant current power source as the arc
length variations due to welder’s operation of the welding torch there is only a small
modification in the welding current – the sharper the curve the smaller the change in current so
there will be no current flows and a steady welding condition is achieved. Since it is mainly
the welding current that determines such structures as the penetration and electrode feeding
this means that the arc length is less critical, making the welder’s task easier in achieving sound
defect free welds. Typically, a plus minus 5-volt change would result in around a plus minus 8
ampere change at 150 amperes welding current.

In some situations – for example when welding in the overhead location or when the
welder is faced with variable root gaps - it is an advantage if the welder has rather more control
over deposition rates by enabling the welder to fluctuate the rate by changing the arc length. In
such a situation a flatter power source characteristic will be of advantage.

Submerged arc welding also uses a drooping characteristic power source where the
welding current and the electrode feed amount are matched to the rate at which the wire is
melted and moved across the arc and into the weld pool – the “burn-off rate”. This matching
of parameters is carried out by a monitoring system which uses the arc voltage to control the
electrode feed speed – if the arc length/voltage rises the wire feed speed is increased to restore
balance.
Constant voltage power source characteristic

With Metal Inert Gas (MIG)/Metal Active Gas (MAG) and Flux-Core Arc Welding
(FCAW) power sources the welding current is controlled by the wire feed speed, the welding
current determining the rate at which the welding wire is melted and moved across the arc and
into the weld pool – the “burn-off” rate. Therefore, as the current decreases the burn-off rate
also falls, less wire is melted and the wire tip approaches the weld pool. In doing so, the voltage
decreases, the welding current and hence the burn-off rate increase. Since the wire feed speed
is constant there is an extra of burn-off over wire feed such that the chosen arc length, voltage
and current remain re-established. The opposite also occurs – a shortening of the arc causes a
reduction in voltage, the current increases, the burn-off rate increases, causing the arc to
lengthen, the voltage to rise and the welding current to fall until the pre-set welding conditions
are re-established. Again, a typical character for the change in welding current for a constant
voltage power source would be in the area of plus minus 40 amperes for a modification in arc
length of plus minus 5 volts. This feature gives us what is known as a “self-adjusting arc”
where changes in arc length, voltage and current are automatically returned to the required
values, producing stable welding conditions. This makes the welder’s task slightly easier when
compared with MMA or TIG welding. Although in principle it may be possible to use a
constant voltage characteristic power source for MMA welding it is far more difficult for the
welder to judge burn-off rate than arc length so arc instability results and the technique is not
effective.