Welding Processes and Equipment - Power Source

Welding Processes Objective
When this presentation has been completed you

will have a greater understanding of the differences
in processes and their key characteristics and why
we choose one over another.
Welding Processes and Equipment –
Power Source
Sections 11-14
Copyright © TWI Ltd Copyright © TWI Ltd
Power Sources MMA - Principle of Operation
FILM MMA
Electrode angle 75-80°
to the horizontal
Consumable electrode
Filler metal core
Manual Metal Arc Welding Flux coating
Direction of
electrode travel
Solidified slag Arc Gaseous shield
Welding Process Film
Molten weld pool
Parent metal
Weld metal
MMA Welding MMA Basic Equipment
Main features:
 Shielding provided by decomposition of flux.
 Consumable electrode. Control panel Power source
 Manual process. (amps, volts)
Electrode Holding oven

Welder controls: oven
 Arc length.
Electrodes Inverter power
 Angle of electrode.
source
 Speed of travel.
Return lead
 Current setting. Electrode holder
Welding visor
filter glass Power cables
11-1
MMA Welding Variables MMA Welding Parameters
Open circuit voltage (OCV) Current

 Value of potential difference delivered by set  Range set by electrode, diameter, material type
with no load. Must be enough for specific and thickness.
electrode.  Approx 35A per mm diameter.
 Electrodes labelled with min OCV, usually ~80V.  Too low – poor start, lack of fusion, slag
inclusions, humped bead shape.
Voltage  Too high – spatter, excess penetration,
 Measure arc voltage close to arc. undercut, burn-through.
 Variable with change in arc length.
 Too low, electrode stubs into weld pool. Polarity
 Too high, spatter, porosity, excess penetration,  Can be DCEP, DCEN, AC.
undercut, burn-through.  Determined by operation and electrode type.
Constant/Drooping
The Effects of Polarity on Penetration
Current Characteristics
DC + DC - AC
Amperage range
OCV
+/- 5 amps
50-90
70% 30% 50%
- Voltage +
Operational Heat Heat Heat

range 20-40V generated generated generated
30% 70% 50%
Dotted line denotes

- Amperage +
As arc length increases - + penetration depth
voltage increases and
= ion greater density (heavier = increased surface impact).
amperage decreases
= electron generates greater heat.
MMA Welding Parameters MMA – Parameter Setting
Travel speed Left to right

 Controlled by welder.  Good conditions.
 Often measured as run-out length as time to  Current too low.
burn single rod fairly standard at constant
current.  Current too high.
 Too low – wide bead, excess penetration, burn-  Arc length too short.
through.  Arc length too long.
 Too high – narrow bead, lack of penetration,  Travel too slow.
lack of fusion, difficult slag removal.  Travel too fast.
11-2
Operating Factor for MMA Typical Welding Defects
 Welder needs time to change electrodes. Most caused by:

 Also has to de-slag weld bead and grind any  Lack of welder skill.
imperfections.  Incorrect settings of equipment.
 May be required to observe interpass  Incorrect use or treatment of electrodes.
temperatures.
 Inspection will be required. Typical defects:
 On long runs welder has to reposition.  Slag inclusions.
 Arc strikes.
 All reduce time weld metal is deposited.
 Porosity.
 Arc time % to total time is operating factor. For  Undercut.
MMA this is rarely above 30%.  Shape defects (overlap, excessive root
penetration, etc).
Advantages and Disadvantages MMA Welding Consumables
Advantages Disadvantages Plastic foil sealed cardboard box

 Field or shop use.  High welder skill.  Rutile electrodes.
 Range of  High levels of fume.  General purpose basic electrodes.
consumables.  Hydrogen control
 All positions. (flux). Courtesy of Lincoln Electric
Tin can
 Portable.  Stop/start problems.  Cellulosic electrodes.
 Simple equipment.  Low productivity.

Vacuum sealed pack
Courtesy of Lincoln Electric

 Extra low hydrogen
electrodes.
Cellulosic Electrodes Rutile Electrodes
 Use industrially extracted cellulose powder or  High amount of TiO2, (rutile sand or ilmenite).
wood flour in the formula.  Coatings often coloured.
 Characteristic smell when welding.  AWS type E6012 are DC: E6013 run on AC.
 Slag remains thin and friable.  Many designed for flat position.
 Strong arc action and deep penetration.  Fluid slag, smooth bead, easy slag removal.
 AWS E6010 types DC: E6011 run on AC.  Need some moisture to give gas shield.
 Gas shield principally hydrogen.  Not low hydrogen.
 Only used on C- and C-Mn steels.  Available for ferritic and austenitic steels.
 High arc force allows V-D stovepiping.  Fair mechanical properties.
11-3
Rutile High Recovery Electrodes Basic Electrodes
 High amount Fe powder added.  CaCO3 and CaF2 main ingredients.

 More weld metal laid at the same current.  AWS E7015 first modern basic rods. Ran DC.
 Coating much thicker, forms deep cup.  Superseded by E7016 or E7018 – AC and DC.
 End of coating can rest on workpiece.  E7018 has Fe powder to help stabilise arc.
 Slag easy release, sometimes self-releasing.  E7016 good rooting and all-positional.
 Only for flat position.  Both can give good mechanical properties.
 These AWS E7024 have recovery between 150  Often hybrid; small dia. no Fe powder, larger
and 180%. dia. increasing amounts.
 Recovery = Weld metal wt x100/core wire wt.  Used for ferritic, stainless steels, Ni and Cu.
BS EN 2560 MMA Covered Electrodes BS EN 2560 MMA Covered Electrodes
E 50 3 2Ni B 7 2 H10 Electrodes classified as follows:

 E 35 - Minimum yield strength 350 N/mm2
Covered electrode
Tensile strength 440-570 N/mm2
Yield strength N/mm2
 E 38 - Minimum yield strength 380 N/mm2
Toughness
Tensile strength 470-600 N/mm2
Chemical composition  E 42 - Minimum yield strength 420 N/mm2
Flux covering Tensile strength 500-640 N/mm2
Weld metal recovery  E 46 - Minimum yield strength 460 N/mm2
and current type Tensile strength 530-680 N/mm2
Welding position  E 50 - Minimum yield strength 500 N/mm2
Hydrogen content Tensile strength 560-720 N/mm2
AWS A5.1 Alloyed Electrodes MMA Welding Consumables
E 60 1 3 TYPES OF ELECTRODES
(for C, C-Mn Steels)
Covered electrode BS EN 2560 AWS A5.1

Tensile strength (p.s.i)  Cellulosic E XX X C EXX10
EXX11
Welding position
 Rutile E XX X R EXX12
Flux covering EXX13
 Rutile heavy coated E XX X RR EXX24
 Basic E XX X B EXX15
EXX16
EXX18
11-4
Any Questions
?
TIG Welding
TIG Basics Equipment for TIG
Film TIG
Gas nozzle Power control Transformer/
panel Rectifier
Non-consumable tungsten electrode
Power return
cable
Gas shield
Arc Inverter
Filler rod power source
Weld pool Torch
Weld metal assemblies Power
Parent metal control panel
Tungsten
electrodes Power cable
Flow-meter
Arc Starting Polarity
Scratch start DCEN

 Tungsten touched on workpiece.  Most used.
 Short-circuit starts current.  Tungsten cooled by electron emission.
 Arc established as torch lifted.  Workpiece receives more heat.
 Can leave tungsten inclusions.
DCEP
Lift Arc  Will clean oxide from Al and Mg.
 Electronic control very low short-circuit current.  Heat tends to melt tungsten.
 Builds to operational current as torch lifted.  Can be done with water cooled torch.
HF AC
 Superimposition of HF high voltage spark.  Usual way to weld Al and Mg to get cleaning.
11-5
Constant/Drooping Cathodic Cleaning
Current Characteristics Square Wave Maximum
AC
OCV Amperage range
50-90 +/- 5 amps
- Voltage +
Operational
range 20-40V
Cleaning cycle
70 70
- Amperage +
As arc length increases
30 30
voltage increases and
amperage decreases
Square Wave Maximum Penetration
AC
Penetrating Cycle
30 30
+
-
70 70
Polarity
Current DCEN AC DCEP

type/polarity
Heat balance 70% at work 50% at work 30% at work
30% at electrode 50% at electrode 70% at electrode
Weld profile Deep, narrow Medium Shallow, wide
+ Cleaning action Yes – every Yes
Negative cycle Positive cycle No
half cycle
0
Electrode Excellent Good Poor
- capacity (3.2mm/400A) (3.2mm/225A) (6.4mm/120A)
11-6
Manual TIG Ideal for Root Runs
DC Arc AC Arc
GTAW Torch GTAW Torch
Torch types: Tungsten

electrode
Torch cap / tungsten Electrode
housing collet Collet
holder
Torch
body Ceramic
 Gas cooled: Cheap, simple, large size, short life nozzle
for component parts.
 Water cooled: Recommended over 150A, On/off
expensive, complex, longer life of parts. switch
11-7
TIG Welding Sequence Purpose of These Functions
3 4 5
1
2 4 2
1 5
1. Purges the line, protect weld area, improve ionization.

1. Slope
2.
3.
4.
5. Postwelding
Pre
Main gas
welding
up
down
supply
current
gas
current
current
to
supply
protect 2. Prevent thermal shock to tungsten electrode.
Timeline
molten pool
prevents burn
upon
craterthrough,
cooling
cracks 3. Main welding current.
tungsten inclusions 4. Prevents thermal shock and crater cracking.
5. Protects weld and tungsten electrode from contamination.
Shielding Gas Selection Gas Lens
Argon (Ar) He/Ar mixes Stainless steel

 Suitable for welding  Suitable for welding wire sieve
C-steel, stainless C-steel, stainless
Thread for gas
steel, Al and Mg. steel, Cu, Al and Mg.
ceramic
 Lower cost, lower  High cost, high flow
flow rates. rates. Thread for
torch body
 More suitable for  More suitable for
thinner materials thicker materials and
and positional materials of high  Reduces eddies in gas flow.
welding. thermal conductivity.  Extends length of laminar flow
prevents contamination.
 Highly recommended for reactive
metals (eg Ti, Al).
Commercially Available
Special Shielding Methods
Trailing Shields
Torch trailing shield Welding in protective tent
11-8
Pipe Backing Gas Dams Purging Methods
 There are many ways to purge a pipe or void,

the easiest being to displace all the air with
inert gas by pumping it in and capping the end
of the pipe allowing the heavier inert gas to
push the oxygen up through the top of the
butt.
 Soluble dams and tapes can also be used as
well as the chain and bung method.
 Calibrated purge monitors should record the
oxygen content in the pipe and confirm that
welding can commence.
Tungsten Types Electrode Tip for DCEN
Pure W – green band Penetration

increase
Cheap, but short life. Poor arc start.
electrode diameter
W +ThO2 – yellow (1%), red (2%)

2-2.5 times
 High current carrying but slightly radioactive. Increase

W + CeO2 – grey (Europe), orange (USA) Vertex
Good for low current DC work.

angle
W + La2O3 – black
 Increasing use to replace thoriated. Decrease
W + ZrO2 – white (Europe), brown (USA)
 Used for AC. Bead width
Electrode tip for low increase Electrode tip for high
current welding current welding
Electrode Tip for AC Autogenous Welding and Fillers
 TIG can be used autogenously.

 Can mechanise and use more than one head.
 Can add filler from reel for mechanised.
 Manual filler – 1m rods in 5kg pack.
 Stamped for identity:
Electrode tip ground Electrode tip ground

and then conditioned
11-9
Orbital TIG Orbital TIG
Click for Orbital TIG video….
Orbital TIG Potential Defects
Click to play Tungsten inclusions

 Thermal shock splinters W.
 Touch start fuses spots to workpiece.
 Spitting and melting can throw pieces into pool.
 Very visible on radiograph but not critical defect.
Solidification cracking
 Some compositions inherently crack sensitive.
 Impurities often make eutectics.
 Fillers designed with elements to react with
impurities, eg Mn used to give high MPt MnS.
Potential Defects Advantages of TIG
Oxide inclusions  No spatter, high cleanliness.

 Oxides contribute to lack of fusion.  Good welder easily produces quality welds.
 No fluxing to absorb oxides.  Good for penetration beads in all positions.
 Need to keep good gas cover to avoid oxidation  Wide range metals, including dissimilar.
of reactive metals.  Good protection for reactive.
 Very good for joining thin materials.
 Very low levels of diffusible hydrogen.
11-10
Disadvantages of TIG
 Low deposition rates.



Higher dexterity and co-ordination.
Less economical for thicker sections.
Any Questions
?
 Not good in draughty conditions.
 Low tolerance of contaminants.
 Tungsten inclusions can occur.
MIG/MAG Welding
 Also known as Gas Metal Arc Welding.

 Uses continuous wire electrode.
 Weld pool protected by shielding gas.
 Classified as semi-automatic – may be fully
MIG/MAG Welding automated.
 Wire can be bare or coated solid wire, flux or
metal cored hollow wire.
MIG/MAG - Principle of Operation Process Characteristics
 DCEP from CV power source.

Gas nozzle  Wire 0.6 to 1.6mm diameter. Gas shielded.
Consumable  Wire fed through conduit. Melt rate maintains
flux/metal cored wire constant arc length/arc voltage.
electrode
Contact Tube
 WFS directly related to burn-off rate.
Gas shield
Weld Pool Arc  Burn-off rate directly related to current.
Slag  Semi-automatic – set controls arc length.
Parent Metal Weld Metal
 Can be mechanised and automated.
11-11
MIG/MAG Equipment Wire Feeding
External wire Transformer

feed unit / Rectifier
Internal wire
feed system Power cable &
hose
assembly
Power control
panel
Liner for wire
Separate wire feeder Wire feeder in set
15kg wire spool
Welding gun
Power return assembly
cable
Feeder Drive Rolls Types of Wire Drive System
Internal wire drive system Plain top roller
Two roll Four roll
Half grooved Wire guide

bottom roller
Roll Grooves Liners for MIG/MAG
 Often have plain top roll.

 Bottom, and sometimes top, roll grooved.
 V shape for steel.
 U shape for softer wire, eg Al.
 Knurled for positive feed.
 Care needed on tightness of rolls.
 Too light – rolls skid, wire stalls.
Too tight – rolls deform wire, wire can jam.

Close wound Teflon liner
 If wire stops arc burns back to contact tube. stainless
steel wire
11-12
The Relationship Between
Torch Components
Amps and Volts
Welding gun assembly Welding gun body
(less nozzle) Voltage Dial on
On/Off switch weld machine
Spatter Hose
- Voltage +
protection port
Arc
Length
Nozzles or Spot welding
- Amperage +
shrouds spacer
Gas diffuser Contact tips
Self-Adjusting Arc Self-Adjusting Arc
Arc and wire feed Arc length increased Wire feed rate is Arc and wire feed Arc length is decreased Arc length returns to
rate in equilibrium. momentarily, burn constant so original arc rate in equilibrium. momentarily, burn off original condition.
off reduces. length is re established. increases.
Example: Self-Adjusting Arc Welding Parameters
Wire feed speed:

 Increasing wfs automatically gives more current.
Wire feed at Voltage:
constant speed
 Controls arc length and bead width.
CTWD is increased
which momentarily Current:
increases arc length
 Wire feed sets, Mainly affects penetration.
As wire feed is Inductance:
constant, the original
arc length is re  In dip, controls rise in current. Lowers spatter. Gives
established. hotter or colder welding.
More info on several websites, eg:
www.millerwelds.com/resources/articles/MIG-
GMAW-welding-basics
11-13
The Effect of Increasing Arc Voltage Shielding Gas
Argon:
 OK for all metals weldable by MIG.
 Supports spray transfer, not good for dip.
 Low penetration.
Carbon dioxide:
 Use on ferritic steel.
Arc Length @ Arc Length @  Supports dip and globular, not spray.
28 V – 250A 34 V – 230A
Ar based mixtures:
 Add He, O2, CO2 to increase penetration.
 >20Ar + He, >80Ar + O2, CO2 can spray and
dip.
MIG and MAG Shielding Gases Metal Transfer Modes
Metal Inert Gas (MIG) Depending on shielding gas and voltage, metal
 Usually Ar shielding. crosses from wire to work in:
 Can be Ar + He mixture – gives hotter action.  Spray mode – wire tapers to a point and very
fine droplets stream across from the tip.
 Used for non-ferrous alloys, eg Al, Ni.
 Globular mode – large droplets form and drop
Metal Active Gas (MAG) under action of gravity and arc force.
 Has oxidising gas shield.  Short-circuiting (dip) mode – wire touches pool
 Can be 100% CO2 for ferritic steels. surface before arc re-ignition.
 Often Ar + 12 to 20% CO2 for both dip and  Pulsed mode – current and voltage cycled
spray. between no transfer and spray mode.
 Ar + O2 for stainless steel.
Use of Transfer Modes Droplet Growth and Detachment
Spray Transfer: V > 26; i > 220  Current heating wire causes melting and
 Thicker material, flat welding, high deposition. droplet formation.
Globular Transfer: between dip and spray  Droplet held by surface tension and viscosity.
 Mechanised MAG process using CO2.  Droplet detachment by electromagnetic forces
Dip Transfer: V < 24; i < 200 (Lorentz and arc forces), gravity.
 Thin material positional welding.  Electromagnetic forces proportional to current
– hence dip at low current.
Pulse Transfer: spray + no transfer cycle
 Frequency range 50-300 pulses/second.
 Positional welding and root runs.
These values will depend on gas mixture.
11-14
Dip Transfer Dip Transfer
 Droplet stays attached and touches pool causing

short-circuit.
 Current rises very quickly giving energy to
pinch-off droplet violently.
 Akin to blowing a fuse – causes spatter.
 Droplet detaches, arc re-establishes and current
falls.
 Cycle occurs up to 200 times per second.
The Effect of Inductance Practical Effect of Inductance
Controls the rate of current rise Maximum inductance Minimum inductance

 Reduced spatter.  Colder arc used for wide
Current (A)
 Hotter arc more gaps.
Short circuit Excessive current,
current high spatter penetration.  Convex weld, more
 Fluid weld pool flatter, spatter.
No inductance
smoother weld.  Good pool control.
 Good for thicker materials  Recommended on thin
and stainless steels. materials.
Desired current for good

stability, low spatter
Time (sec)
Dip Transfer Attributes Globular Transfer
Advantages  Transfer by gravity or short

 Low energy allows welding in all positions. circuit.
 Good for root runs in single-sided welds.  Requires CO2 shielding.
 Good for welding thin material.  Drops larger than electrode
hence severe spatter.
Disadvantages  Can use low voltage and bury
arc to reduce spatter.
 Prone to lack of fusion.
 High current and voltage, so
 May not be allowed for high-integrity
applications. high distortion.
 Tends to give spatter.
11-15
Gas Metal Arc Welding Spray Transfer
Spray transfer  Continuous transfer

When current and voltage are raised together higher energy of metal.
is available for fusion (typically > ~ 25 volts & ~ 250 amps).  High voltage long
This causes a fine droplets of weld metal to be sprayed from arc.
the tip of the wire into the weld pool.  High heat input.
Transfer-mode advantages  Fluid weld pool.
 High energy gives good fusion.  High deposition.
 High rates of weld metal deposition are given.  No spatter.
 These characteristics make it suitable for welding thicker
joints.
 Transfer-mode disadvantages.
 It cannot be used for positional welding.
Dip, Globular and Spray Transfer Spray Transfer
 Tapered tip as anode

climbs wire.
 Small droplets with free
flight from pinch effect.
Dip, Globular and Spray Film  Requires Ar-rich gas.
 High current and
voltage, high distortion.
 Large pool, not
positional.
 Used for thick material
and flat/horizontal weld.
Pulsed Transfer Pulsed Transfer Attributes
Advantages
 Good fusion.
 Small weld pool allows all-position welding.
Disadvantages
 More complex and expensive power source.
 Difficult to set parameters.
Amps
Back Peak current  But synergic easy to set, manufacturer

Current provides programmes to suit wire type, dia.
and type of gas.
Time
11-16
Pulse Transfer The Effect of Increasing CTWD
The self adjusting arc

quickly re adjusts to
Pulse Transfer Film
establish equilibrium.
AMPS 190 AMPS 170

VOLTS 23 VOLTS 23
Although the arc length remains the same, the current will decrease
due to the increased resistance of lengthening the CTWD.
The Effect of Decreasing CTWD Contact Tip to Nozzle Distance
Metal transfer mode Contact tip to nozzle

Dip +/- 2mm
The self adjusting arc Spray 4-8mm inside
quickly re adjusts to Spray (Al) 6-10mm inside
establish equilibrium.
Contact tip Electrode

Contact tip
Electrode recessed extension
AMPS 170 AMPS 190 extension
(0-3.2mm)
extension (3-5mm) 19-25mm
6-13mm
VOLTS 23 VOLTS 23
Although the arc length remains the same, the current will increase
due to the decreased resistance of shortening the CTWD. Set up for Dip transfer Set up for Spray transfer
Filler Wire Potential Defects
 Similar composition to base material.  Most defects caused by lack of welder skill, or
 Solid, flux cored or metal cored. incorrect settings of equipment.
 FCW run in spray, gives good fusion. FCW  Worn contact tip causes poor power pick up
allows all-positional welding, slag formation. and this causes wire to stub into work.
 Metal cored wires similar to solid wires, but  Silica inclusions build in steels if poor inter-run
better deposition rate. cleaning.
 Some FCW are self-shielded.  Lack of fusion (primarily with dip transfer).
 Porosity (from loss of gas shield on site etc).
 Cracking, centerline pipes, crater pipes on
deep narrow welds.
11-17
MIG/MAG Attributes
Advantages Disadvantages
 High productivity.
 Easily automated.
 Lack of fusion (dip).
 Small range of Any Questions
?
 All positional (dip consumables.
and pulse).  Protection on site.
 Material thickness  Complex equipment.
range.  Not so portable.
 Continuous
electrode.
Gas Shielded Principle of Operation
Flux Core Welding
Self-Shielded Principle of Operation Benefit of Flux
 Flux assists in producing gas cover, more

tolerant to draughts than solid wire.
 Flux creates slag that protects hot metal.
 Slag holds bead when positional welding.
 Flux alloying can improve weld metal
properties.
 Reduced cross-section carrying current gives
increased burn-off at any current, higher
resistance.
11-18
FCAW - Differences from MIG/MAG Self-Shielded Welding Gun
 Usually operate DCEP

but some self-shielded Close wound stainless steel
Handle
24V insulated
spring wire liner (inside switch lead
wires run DCEN. welding gun cable)
 Some hardfacing wires Conductor
are larger diameter – tube
need big power source.
 Don't work in dip. Welding
Trigger
gun cable
 Need knurled feed rolls.
 Self-shielded wires use Thread protector
Hand shield
a different torch.
Contact tip
Courtesy of Lincoln Electric
Backhand (Drag) Technique Forehand (Push) Technique
Advantages Disadvantages Advantages Disadvantages

 Preferred for flat or  Produces higher weld  Preferred method for  Produces low weld
horizontal with profile. vertical up or profile, with coarser
FCAW.  Difficult to follow overhead with ripples.
 Slower travel. weld joint. FCAW.  Fast travel gives low
 Deeper penetration.  Can lead to burn-  Arc gives preheat penetration.
through on thin effect.  Amount of spatter
 Weld hot longer so
gasses removed. sheet.  Easy to follow weld can increase.
joint and control
penetration.
FCAW Advantages Deposition Rate for C-Steel
 Less sensitive to lack of fusion.

 Smaller included angle compared to MMA.
 High productivity, up to 10kg per hour.
 All positional.
 Smooth bead surface, less danger of undercut.
 Basic types produce excellent toughness.
 Good control of weld pool in positional welding
especially with rutile wires.
 Ease of varying alloying constituents gives
wide range of consumables.
 Some can run without shielding gas.
11-19
FCAW Disadvantages
 Limited to steels and Ni-base alloys.

 Slag covering must be removed.
 FCAW wire is more expensive per kg than solid
wires (except some high alloy steels) but note
may be more cost effective. Submerged Arc Welding
 Gas shielded wires may be affected by winds
and draughts like MIG.
 More fume than MIG/MAG.
SAW Principle of Operation SAW FILM
Flux recovery Contact tube
Consumable Weld pool

electrode
Flux feed SAW Film
Weld metal Arc Parent metal
Slag
Process Characteristics Process Characteristics
 Arc between bare wire and parent plate.  Flux fed from hopper in continuous mound
 Arc, electrode end and the molten pool along line of intended weld.
submerged in powdered flux.  Mound is deep to submerge arc. No spatter,
 Flux makes gas and slag in lower layers under weld shielded from atmosphere, no UV light.
heat of arc giving protection.  Un melted flux reclaimed for further use.
 Wire fed by voltage-controlled motor driven  Only for flat and horizontal-vertical positions
rollers to ensure constant arc length. in most cases.
11-20
SAW Basic Equipment Types of Equipment
Transformer/
Power return Rectifier
cable
Power control Welding carriage Hand-held gun
panel control unit
Tractor
Welding carriage
Granulated Electrode wire

flux reel
Granulated
flux
Column and boom Gantry
SAW Equipment Tractor Units
Wire reel  For straight or gently

curved joints.
Slides  Ride tracks alongside
Flux
joint or directly on
hopper workpiece.
Wire feed  Can have guide
Feed roll motor wheels to track.
assembly  Good portability, Courtesy of ESAB AB
used where piece

Torch
assembly cannot be moved.
Tracking
Contact tip
system Courtesy of ESAB AB
Column and Boom Gantry
 Linear travel only.  2D linear movement

 Can move in 3 axes. only.
 Workpiece must be  For large production.
brought to weld  May have more than
station. one head.
 Mostly used in
workshop.
Courtesy of ESAB AB
11-21
Power Sources Constant Voltage Power Supply
Power sources can be:  Most commonly used.

 Transformers for AC.  Can be mechanised or automatic welding.
 Transformer-rectifiers for DC.  Self-regulating arc so simple WFS control.
 WFS controls current, power supply controls
Static characteristic can be: voltage.
 Constant Voltage (flat) – most popular.  DC limited to 1000A by severe arc blow.
 Constant Current (drooping) – used for high
current.
Constant Current Power Wire
 Preferred >1000A.  Usually 2 to 6mm diameter.

 Can be mechanised or automatic welding.  Copper coated to avoid rusting.
 Not self-regulating arc so must have voltage-  25 or 30kg coils.
sensing WFS control.  Can be supplied in bulk 300 to 2000kg.
 More expensive.
 Voltage from WFS control, power source
controls current.
 Not for high-speed welding of thin steel.
Fused Fluxes Bonded or Agglomerated Flux
 Original Unionmelt design – manganese,  Powdered minerals pelletised with silicate.

aluminium and calcium silicates.  Baked to high temperature but hygroscopic.
 Non-hygroscopic, no need to bake.  Flexible composition, can alloy, make basic.
 Good for recycling, composition doesn’t vary.  Can add de oxidants for good properties.
 Some can accept up to 2000A.  Composition can vary as particle breakdown.
 Very limited alloying and property control.  Needs to be filtered when recycling.
 Cannot make basic fused flux.  Can add Mn and Si flux.
11-22
SAW Operating Variables Starting/Finishing the Weld
 Welding current.
 Current type and polarity.
 Welding voltage.
 Travel speed.
 Electrode size.
 Electrode extension why?
 Width and depth of the layer of flux. Extension bars Run off plate Extension bars
simulating
identical joint
preparation
Any Questions
?
Copyright © TWI Ltd
11-23

Welding Processes and Equipment - Power Source

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Welding Processes and Equipment - Power Source

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Welding Processes Objective

When this presentation has been completed you

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Power Sources MMA - Principle of Operation

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MMA Welding MMA Basic Equipment

Electrode Holding oven

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Open circuit voltage (OCV) Current

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Operational Heat Heat Heat

30% 70% 50%

Dotted line denotes

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MMA Welding Parameters MMA – Parameter Setting

Travel speed Left to right

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 Welder needs time to change electrodes. Most caused by:

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Advantages and Disadvantages MMA Welding Consumables

Advantages Disadvantages Plastic foil sealed cardboard box

 Simple equipment.  Low productivity.

Courtesy of Lincoln Electric

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Cellulosic Electrodes Rutile Electrodes

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 High amount Fe powder added.  CaCO3 and CaF2 main ingredients.

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BS EN 2560 MMA Covered Electrodes BS EN 2560 MMA Covered Electrodes

E 50 3 2Ni B 7 2 H10 Electrodes classified as follows:

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AWS A5.1 Alloyed Electrodes MMA Welding Consumables

Covered electrode BS EN 2560 AWS A5.1

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TIG Basics Equipment for TIG

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Arc Starting Polarity

Scratch start DCEN

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Square Wave Maximum Penetration

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Current DCEN AC DCEP

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GTAW Torch GTAW Torch

Torch types: Tungsten

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1. Purges the line, protect weld area, improve ionization.

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Shielding Gas Selection Gas Lens

Argon (Ar) He/Ar mixes Stainless steel

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Torch trailing shield Welding in protective tent

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 There are many ways to purge a pipe or void,

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Tungsten Types Electrode Tip for DCEN

Pure W – green band Penetration

W +ThO2 – yellow (1%), red (2%)

 High current carrying but slightly radioactive. Increase