Welding

1/9/2020 By Mac Irvine

MIG/GMAW Welding:
Things that control weld quality

Power settings: Making an acceptable weld requires balancing the voltage and
amperage

If one i set too high/low then poor penetration can result.

Wire Speed (faster wire= higher amperage)

Voltage (thicker the metal higher the voltage)

PSI 25-30(regulator), Fully turn on gas,

Travel speed:
Arc needs to be kept right in front of the weld pool

Too fast you can overrun the ability of the arc to melt the base metal which results
in poor fusion

Too slow and the weld pool gets too large and the heat is directed into the weld
pool instead of the base metal resulting in poor fusion
Electrode extension:
This is the distance from the contact tube to the arc measured along the wire

Adj. in the distance cause a change in the wire resistance and weld bead

Since GMAW in constant voltage, the amperage adjusts

Gun tip closer means more amps and more heat

Gun tip further from the weld metal equals less amps and less heat
4 types of welding
G= Groove, F= Fillet, B=Bead, P= Plug/spot
4 Positions
Flat(1), Vertical(3), Horizontal(2), Overhead(4)

Flag Down, weld arrow side

Flag Up ,weld opposite side

SMAW (shielded metal arc welding)
Advantages: Easily implemented, inexpensive, flexible, not as sensitive to part
fit-up variances

Can be used on carbon steels, copper, nickel, cast irons, relatively easy to use,
less sensitive to drafts ,dirty parts
Limitations
Low deposition rates, low productivity, operator dependent.

Heat too high for lead,zinc, other alloys

SMAW DCEN (Direct current electrode negative)
Current flows through the electrode cable to the electrode holder through the
electrode amd across the arc.

On the work side of the arc the current flows through the base material to the work
clamp and back to the welding machine.