Fusion Welding Processes

Fusion welding processes can be grouped according to the source of the heat, for
example, electric arc, gas, electrical resistance and high energy.

These processes include:

Arc Welding Processes - with the most common processes being:

Arc welding is a type of welding process using an electric arc to create heat to melt and
join metals. A power supply creates an electric arc between a consumable or non-
consumable electrode and the base material using either direct (DC) or alternating (AC)
currents.

Arc welding is a fusion welding process used to join metals. An electric arc from an AC
or DC power supply creates an intense heat of around 6500°F which melts the metal at
the join between two work pieces.

The arc can be either manually or mechanically guided along the line of the join, while
the electrode either simply carries the current or conducts the current and melts into the
weld pool at the same time to supply filler metal to the join.

Because the metals react chemically to oxygen and nitrogen in the air when heated to
high temperatures by the arc, a protective shielding gas or slag is used to minimise the
contact of the molten metal with the air. Once cooled, the molten metals solidify to form
a metallurgical bond.

Types of Arc Welding process

This process can be categorised into two different types; consumable and non-
consumable electrode methods.
Consumable Electrode Methods
• Metal Inert Gas Welding (MIG) and Metal Active Gas Welding (MAG)

• Shielded Metal Arc Welding (SMAW)

• Flux Cored Arc Welding (FCAW)

• Submerged Arc Welding (SAW)

• Electro-Slag Welding (ESW)

• Arc Stud Welding (SW)

Non-consumable Electrode Methods

• Tungsten Inert Gas Welding (TIG)

• Plasma Arc Welding (PAW)

Shielded Metal Arc Welding (SMAW)

SMAW is also known as manual metal arc welding (MMA or MMAW), flux shielded arc
welding or stick welding. Suitable for welding ferrous and non-ferrous materials in all
positions. It uses a metallic consumable electrode of a proper composition for
generating arc between itself and the parent work piece. The molten electrode metal fills
the weld gap and joins the work pieces.

This is the most popular welding process capable to produce a great variety of welds.

The electrodes are coated with a shielding flux of a suitable composition. The flux melts
together with the electrode metallic core, forming a gas and a slag, shielding the arc and
the weld pool. The flux cleans the metal surface, supplies some alloying elements to the
weld, protects the molten metal from oxidation and stabilizes the arc.
The slag is removed after Solidification.
Advantages of Shielded Metal Arc Welding
▪ Simple, portable and inexpensive equipment;
▪ Wide variety of metals, welding positions and electrodes are applicable;
▪ Suitable for outdoor applications.

Disadvantages of Shielded Metal Arc Welding

▪ The process is discontinuous due to limited length of the electrodes;
▪ Weld may contain slag inclusions;
▪ Fumes make difficult the process control.

Metal Inert Gas Welding (MIG) and Metal Active Gas

Welding (MAG)
MIG & MAG are also known as Gas Metal Arc Welding (GMAW). MIG and MAG
welding are the most common arc welding processes, in which an electric arc forms
between a consumable wire electrode and the work piece leading them to melt and join.
Both use a shielding gas to protect the weld from airborne contaminants, or oxidation in
the case of MIG welding.

Metal Inert Gas (MIG) and Metal Active Gas (MAG) welding are gas metal arc welding
(GMAW) processes that use heat created from a DC electric arc between a consumable
metal electrode and a workpiece which melt together to create a weld pool that fuses to
form a join.

MIG and MAG welding are known as gas metal arc welding (GMAW) processes
MIG/MAG is similar to MMA in that heat for welding is produced by forming an arc
between a consumable metal electrode and the workpiece; the electrode melts to form
the weld bead. The main difference is that the metal electrode is a small diameter wire
fed through the contact tip from a wire feeding spool gun, while a shielding gas is fed
through the welding torch. As the wire is continuously fed, the manual process is
sometimes referred to as semi-automatic welding. MIG and MAG welding both use gas
bottles to provide the shielding gas and compatible filler materials. For example, to weld
aluminium, an aluminium wire should be used, whereas steel MIG welding would
require an appropriate steel filler wire.

Difference Between MIG and MAG

MIG (Metal Inert Gas) welding is a welding process in which an electric arc forms
between a consumable wire electrode and the work piece. This process uses inert
gases or gas mixtures as the shielding gas. Argon and helium are typically used for the
MIG welding of non-ferrous metals such as aluminium.

MAG (Metal Active Gas) welding is an arc welding process where an electric arc is
created between a consumable wire electrode and the material to be joined. MAG
welding uses active shielding gases, primarily for the welding of steels. These shielding
gases are mixtures of carbon dioxide, argon and oxygen.

Examples of these active gases include CO2 ,Ar + 2 to 5% O2 , Ar + 5 to 25% CO2 and
Ar + 10% CO2 + 5% O2.

The only difference between MIG and MAG is the type of shielding gas used.

The make-up of the shielding gas is important as it has a significant effect on the
stability of the arc, the metal transfer and the degree of spatter. The shielding gas also
impacts the behaviour of the weld pool, with particular regard to the penetration and
mechanical properties of the welded joint.

Tungsten Inert Gas Welding (TIG)

It is also known as Gas Tungsten Arc Welding (GTAW). This arc process uses a non-
consumable tungsten electrode to create the arc between the electrode and the base
plate. An inert shielding gas is used to protect from oxidation or other atmospheric
contamination. This process can be used autogenously on thin parts, but will require the
addition of a wire, rod, or consumable to be added for thicker parts.

Electrodes

Electrodes for DC welding are normally pure tungsten with 1 to 4% thoria to improve arc
ignition. Alternative additives are lanthanum oxide and cerium oxide which are claimed
to give superior performance (arc starting and lower electrode consumption). It is
important to select the correct electrode diameter and tip angle for the level of welding
current. As a rule, the lower the current the smaller the electrode diameter and tip angle.
In AC welding, as the electrode will be operating at a much higher temperature,
tungsten with a zirconia addition is used to reduce electrode erosion. It should be noted
that because of the large amount of heat generated at the electrode, it is difficult to
maintain a pointed tip and the end of the electrode assumes a spherical or 'ball' profile.

Shielding gas
Shielding gas is selected according to the material being welded. The following
guidelines may help:

• Argon - the most commonly-used shielding gas which can be used for welding a
wide range of materials including steels, stainless steel, aluminium and titanium.
• Argon + 2 to 5% H2 - the addition of hydrogen to argon will make the gas slightly
reducing, assisting the production of cleaner-looking welds without surface
oxidation. As the arc is hotter and more constricted, it permits higher welding
speeds. Disadvantages include risk of hydrogen cracking in carbon steels and
weld metal porosity in aluminium alloys.
• Helium and helium/argon mixtures - adding helium to argon will raise the
temperature of the arc. This promotes higher welding speeds and deeper weld
penetration. Disadvantages of using helium or a helium/argon mixture is the high
cost of gas and difficulty in starting the arc.

Applications

TIG welding is applied in all industrial sectors but is especially suitable for high quality
welding. In manual welding, the relatively small arc is ideal for thin sheet material or
controlled penetration (in the root run of pipe welds). Because deposition rate can be
quite low (using a separate filler rod) MMA or MIG may be preferable for thicker material
and for fill passes in thick-wall pipe welds.

Plasma Arc Welding (PAW)

This process uses an electric arc created between an electrode and the torch nozzle.
The electric arc ionizes the gas (usually argon) in the chamber creating what is
called’plasma.' It is then forced through a fine bore copper nozzle that constricts the arc
and directs it to the workpiece, allowing the plasma arc to be separated from the
shielding gas (which is usually made from a mixture of argon and hydrogen).

Three operating modes can be produced by varying the bore diameter and plasma gas
flow rate -

Microplasma welding (0.1 - 15A)

Microplasma is used for welding thin sheets (down to 0.1mm thickness), and wire and
mesh sections. The needle-like, stiff arc minimises arc wander and distortion.

Medium current welding (15 - 200A)

When used in the melt mode, this is an alternative to conventional TIG. The advantages
are deeper penetration (from higher plasma gas flow), greater tolerance to surface
contamination including coatings (the electrode is within the body of the torch) and
better tolerance to variations in electrode to workpiece distance, without significant
change in heat input.

Keyhole welding (over 100A)

By increasing welding current and plasma gas flow, a very powerful plasma beam is
created which can achieve full penetration in a material, as in laser or electron beam
welding. During welding, a keyhole is formed which progressively cuts through the metal
with the molten weld pool flowing behind to form the weld bead under surface tension
forces. This process can be used to weld thicker material (up to 10mm of stainless
steel) in a single pass.

The plasma arc is normally operated with a DC, constant current (drooping)
characteristic power source. Because its unique operating features are derived from the
special torch arrangement and separate plasma and shielding gas flows, a plasma
control console can be added on to a conventional TIG power source. Purpose-built
plasma systems are also available.

Although the arc is initiated using HF, it is first formed between the electrode and
plasma nozzle. This 'pilot' arc is held within the body of the torch until required for
welding then it is transferred to the workpiece. The pilot arc system ensures reliable arc
starting and, as the pilot arc is maintained between welds, it obviates the need for HF
re-ignition which may cause electrical interference.

The electrode used for the plasma process is tungsten-2% thoria, and the plasma
nozzle is copper. The plasma nozzle bore diameter is critical and too small a bore
diameter for the current level and plasma gas flow rate will lead to excessive nozzle
erosion or even melting.

Normal gas combinations are argon for the plasma gas, with argon or argon plus 2 to
5% hydrogen for the shielding gas. Helium can be used for plasma gas but because it is
hotter this reduces the current rating of the nozzle. Helium's lower mass can also make
the keyhole mode more difficult. Helium argon mixtures are used as a shielding gas for
materials such as copper.

Submerged Arc Welding (SAW).

Submerged-arc welding (SAW) is a common arc welding process that involves the
formation of an arc between a continuously fed electrode and the workpiece. A blanket
of powdered flux generates a protective gas shield and a slag (and may also be used to
add alloying elements to the weld pool) which protects the weld zone.

This frequently-used arc welding process uses a continuously-fed consumable

electrode and a blanket of fusible flux which becomes conductive when molten and
provides a current path between the workpiece and the electrode. The flux also
prevents spatter and sparks while suppressing ultraviolet radiation and fumes.

A shielding gas is not required. The arc is submerged beneath the flux blanket and is
not normally visible during welding.

This is a well established and extremely versatile method of welding.

The electrode may be a solid or cored wire or a strip made from sheet or sintered
material. The flux may be made by either fusing constituents to form a glassy slag
(which is then crushed to form a powder) or by agglomerating the constituents using a
binder and a corning process. The chemical nature and size distribution of the flux
assists arc stability and determines the mechanical properties of the weld metal and the
shape of the bead.

SAW is usually operated as a mechanised process. Welding current (typically between

300 and 1000 amperes), arc voltage and travel speed all affect bead shape, depth of
penetration and chemical composition of the deposited weld metal. Since the operator
cannot observe the weld pool, great reliance must be placed on parameter setting and
positioning of the filler wire.

Although SAW is normally operated with a single wire using either AC or DC current,
there are a number of variants including the use of two or more wires, adding chopped
wire to the joint prior to welding, and the use of metal powder additions. Additional
productivity may be gained by feeding a small diameter non-conducting wire into
leading edge of the weld pool. This can increase deposition rates by up to 20%. These
variants are used in specific situations to improve productivity through increasing
deposition rates and/or travel speed. Replacing the wire with a 0.5mm thick strip,
typically 60mm wide, enables the process to be used for surfacing components.

SAW is ideally suited to the longitudinal and circumferential butt welds required for the
manufacture of line pipe and pressure vessels. Welding is normally carried out in the flat
(BS EN ISO 6947 PA) position because of the high fluidity of the weld pool and molten
slag and the need to maintain a flux layer. Fillet joints may also be produced, welding in
either the flat or horizontal-vertical (PB) positions.
Applications

SAW is ideally suited for longitudinal and circumferential butt and fillet welds. However,
because of high fluidity of the weld pool, molten slag and loose flux layer, welding is
generally carried out on butt joints in the flat position and fillet joints in both the flat and
horizontal-vertical positions. For circumferential joints, the workpiece is rotated under a
fixed welding head with welding taking place in the flat position. Depending on material
thickness, either single-pass, two-pass or multipass weld procedures can be carried out.
There is virtually no restriction on the material thickness, provided a suitable joint
preparation is adopted. Most commonly welded materials are carbon-manganese
steels, low alloy steels and stainless steels, although the process is capable of welding
some non-ferrous materials with judicious choice of electrode filler wire and flux
combinations.