PSG College of Technology, Coimbatore

Department of Production Engineering

BE Production Engineering
3rd Semester – AY 2020-2021
19P305 Welding Technology
Arc Welding

Mr.K.Saravanakumar
Assistant Professor (Senior Grade)
Department of Production Engineering
PSG College of Technology
Coimbatore - 641004
Content
Electrodes
Arc welding
Welding equipment
Arc welding circuit
Alternating current
Direct current – DCSP and DCRP
Welding Machines
Duty cycle
Electrodes
Welding safety
Types of arc welding
Arc welding process
ELECTRODES

 1912 experimentation coated electrodes

 1929 coated electrodes are available
 1937 AWS and ASTM Welding electrode wires and coatings
 NEMA – National Electrical Manufacturer’s Association - Colour coding
 Two major
 LIGHTLY DUSTED ELECTRODES
 Semicoated electrodes
Electrodes Classification

 E6010
 E
 60 – 60,000 psi tensile strength
 1 – positions – all, 2 – f and h, 3 - flat
 0 – polarity
 E6011
 E6012
Corrosion resistant electrode
 E308-16, E308-26 E308-25
 E electrode
First three digit
 308 – 18% Cr and 8% nickel
 309 25% Cr & 12% Ni
 310 25% Cr and 20 Ni
 316 18% Cr 12% Ni 2% molybdenium
 317 18% Cr 12% Ni 5% molybdenium
 330 15% Cr and 35% Ni
 347 15-17% Cr
 410 12% Cr
 430 19% Cr 9% Ni
 502 4-6% Cr 0.5% molybdenium
Fourth digit
 1-all positions
Fifth digit
6 – ac or dc
Non Ferrous electrodes
Electrode Composition Base metal Power supply
Copper Phosphorus Electrolytic or AC or Dc-ve
bronze A deoxidized
copper
Copper Phosphorus Electrolytic or AC or Dc-ve
bronze c deoxidized
copper
Aluminum 95% Al and 5% Si All Alloys DC+ve

Alumnium bronze Cu 8% Al and 1% Dissimilar AC or Dc+ve

Fe
Cu 9-10% Al and Similar AC or Dc+ve
3-5% Fe

Cu 12-13% Al and DisSimilar AC or Dc+ve

3-5% Fe
Nickel Greater than 50%
DAV – Drooping arc Voltage
CAV
RAV Y axis – voltage, x axis current
Arc Welding
 The process of fusing two or more pieces of metal
together by using the heat produced from an electric arc
welding machine.
 Otherwise known as SMAW (shielded metal arc welding)
 The electrode produces a gas which shields the arc
from the atmosphere as the electrode melts.
Welding Equipment
✓ Welding hood
✓ Welding gloves
✓ Electrodes
✓ Welding machine
✓ Chipping hammer
✓ Wire brush
Welding Equipment

✓ Welding leads
✓ Electrode holder
✓ Ground clamp
 Arc Welding Circuit

✓ The electricity flows from the

power source, through the
electrode and across the arc,
through the base material to the
work lead and back to the power
source

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Alternating Current Welding

✓ AC (alternating current)
✓ Most common
✓ 180 Ampere or 225 Ampere
between 220-240 volts
✓ Can handle most
agriculture and
construction jobs
✓ Alternating flow of
electrons
Direct Current Welding
✓ DC (direct current)
✓ Can produce direct current of both straight (negative) and
reverse (positive) polarity.
✓ Polarity is the direction in which the current flows across the arc.
✓ Makes a continuous flow of electrons
Straight/Reverse Polarity
✓ Straight Polarity (DC-)
✓ Work is positive and
electrode is negative
✓ Used to weld thinner metals
✓ Shallow penetration
✓ Reverse Polarity (DC+)
✓ Work is negative and
electrode is positive
✓ Used to weld thicker metals
✓ Deeper penetration
Types of Welding Machines

 AC machine
 Only works on alternating
current (+-)
Types of Welding Machines
✓ AC/DC
✓ Can run on three different types of current
✓ Alternating
✓ Direct current + (reverse polarity)
✓ Direct current – (straight polarity)

✓ This machine will have a rectifier switch which will allow it to

switch between the three

✓ Or the leads will need to be placed in certain parts of the

machine.
Types of Welding Machines
✓ AC/DC Machines
✓ Are capable of handling
most agriculture and
construction.
✓ Are the most popular.
✓ Allow the operator to weld
metal of all thickness.
Types of Welding Machines
✓ Machines can either be gasoline
engine driven or they can be
powered be electricity.
 Both the direct current (D.C) and alternating current(A.C)
may be used for arc welding, but the direct current is
preferred for most purposes.

AC Welding
✓ Power source is transformer.
✓ A.c is easily available and does not
produce noise.
✓ It possess high efficiency and
consumes less energy.
DC Welding
✓ Power source is transformer
rectifier unit or dc generator.
✓ It has lower open circuit
voltage,therefore it is safer.
✓ It can be operated in fields where
power supply is not available.
Duty Cycle
✓ Tells the operator how long his machine can operate without causing damage
to the machine.
✓ It is how long a machine can run in ten minute intervals, and is measured by a
percentage.
 If a machine has a duty cycle of 25%, for every ten minutes the machine is
operated you can only weld for 2.5 minutes.
 The remaining 7.5 minutes must be spent letting the machine idle.
Formula for the estimation of duty cycle
other than rated outputs
Example problem 1

Calculate the required duty cycle. For 200 Ampere power source rated at 60%
duty cycle and it is operated at 250 Ampere.
 Given data
 I=200A
 T=60%
 Ia=250A
 Ta=?
Solution
Formula for the estimation others than rated
output currents at a specified duty cycle
Example Problem - 2

 Calculate the maximum output current at a duty cycle of 100% with rated
power source of 200 Ampere at 60% duty cycle.
 Given Data
Ta=100%
I=200A
T=60%
Ia=?
Solution

Given Data
✓ Rated duty cycle 60%
✓ Continuous cycle100%
✓ Rated current 200A

To find Maximum current

Heat Input
 Three important variable in arc welding
 Arc voltage
 Arc current
 Welding speed
Heat input H = Arc voltage * Arc current / Welding speed= V*I/S
H=VI/S
Net Heat input=F1*H
F1 is heat transfer coefficient =0.9
Problem: Calculate the net heat input for a butt welding job performed at an arc voltage
of 30 volts and a current of 150 amps at a welding speed of 300 mm/min. Assume that
the heat transfer efficiency is 0.9.
H=VI/S = (30*150) /(300/60) = 900 Joules / mm
Net Heat input=F1*H =0.9*900 = 810 Joules / mm
Reference

AWS Welding Handbook 9th Edition** – Welding Processes Part 1 Volume 2

Electrodes
✓ All major manufacturers of welding electrodes use the American Welding
Society (AWS) code of specifications.
✓ Each company makes basically the same quality which is established by the
AWS.
Electrodes
Electrodes are classified according to type of coating, composition of
the weld metal and operating characteristics.
The numbering system is started with “E” for electrode and then
followed by a four digit number
Each number in the four number sequence has a specific meaning.
60XX = Tensile Strength in pounds (X 1,000)
60,000 lbs per square inch
XX1X = Welding Position
1 =All 2 = Flat and Horizontal 3 = Flat
XXX1 = Polarity
1,3,4,8=AC or DC Reverse
2 = AC or DC straight
0 = DC Reverse
Electrodes
What is the classification of an E 7018?
E

70

8
Electrode Diameter
✓ Electrodes are also measured by their diameter (the
diameter of the electrode without including the flux.
✓ The diameter is measured in thirty-seconds of an inch.
✓ Always use an electrode ½ the size of you base metal
✓ What does this mean?
Electrodes
When selecting an electrode you need to consider the following:
✓ How thick is your base metal?
✓ What condition is your metal in?
✓ What type of machine do you have access to?
✓ Welding position?
Welding Safety
✓ Electrical shock
✓ Make sure the machine is grounded.
✓ Make sure the cables are not cut or frayed.
✓ Do not stand in wet surfaces.
✓ Wear leather gloves.
✓ Wear rubber-soled shoes
 ARC WELDING
PRODUCTION OF ARC :
➢ An electric arc is formed whenever current is passed between two
metallic electrodes separated by a short distance.
➢ Whenever electrode first touches the plate,a large short circuit flows
and as it withdrawn later,current continues to flow in the form of spark
across the air gap.
➢ Due to this spark,air gets ionized and air becomes conducting and
so,current is able to flow across the gap.
Temperature of arc
welding flame is about
3100°c.
 Types of arc welding
✓ Unshielded arc welding:When a large electrode or filler rod is used for
welding, it is said to be un- shielded arc welding.
✓ Shielded arc welding: When the welding rods coated with fluxing
material are used, then it is called shielded arc welding.
Electrodes
An electrode is a tool used in arc welding to produce electric arc.
Based on their characteristics, arc welding electrodes can be broadly
classified into two types. They are:
Consumable Electrode:
If the melting point of an arc welding electrode is less, it melts and fills
the gap in the workpiece. Such an electrode is called consumable
electrode.
Non-consumable electrode:
If the melting point of the arc welding electrode is high, it does not melt
to fill the gap in the workpiece. Such an electrode is called non-
consumable electrode
Coated electrodes
Coated electrodes are being extensively used for shielded arc welding.
They consist of a metal core wire surrounded by a thick flux coating
applied by extrusion, winding or other processes.

Electrode coating contributes a lot towards improving the quality of the

weld.
The principal advantages of using electrode coating are as under :
1.It stablizes the arc because it contains ionizing agents such as
compounds of sodium and potassium.
2. It fluxes away impurities present on the surface being welded.
3. It forms slag over the weld which
(i) protects it from atmospheric contamination
(ii) makes it cool uniformly thereby reducing the changes of brittleness
and
(iii) provides a smoother surface by reducing ‘ripples’ caused by the
welding operation.
 Arc blow
✓ Arc blow is the, usually unwanted, deflection of the arc during arc
welding.
✓ There are two types of arc blow commonly known in the electric
welding industry: magnetic and thermal.
✓ Magnetic arc blow or "arc wander" : It is the deflection of welding
filler material within an electric arc deposit by a buildup of magnetic
force surrounding the weld pool.
✓ Arc blow tends to occur if the material being welded has residual
magnetism at a certain level, particularly when the weld root is being
made, and the welding current is direct current (DC positive or
negative).
✓ This is due to interaction between the directional magnetic field of the
welding arc and the directional field of the residual magnetism.
✓ Magnetic arc blow is popularly attributed to a change in the direction
of current as it flows into and through the workpiece.
✓ It is experienced most when using currents above 200 A or below 40 A.
✓ Thermal arc blow: It is widely attributed to variations in
resistance within the base metal created by the weld pool as
it is moved across the workpiece.
✓ Thermal arc blow can occur because of:
✓ 1.Improper surface preparation
✓ 2.Improper travel speed
✓ Due to arc blow, heat penetration in the required area is low
which leads to incomplete fusion.Hence it is needed to be
suppressed.
✓ Measures to avoid arc blow:
✓ Arc blow can be avoided by using a.c. rather than d.c.
welding machines because reversing currents in the welding
leads produce magnetic fields which cancel each other out
thereby eliminating the arc blow.
✓ Reducing the rate of travel of the electrode.
✓ Shortening the arc column length etc.
 Carbon arc welding
❖ Carbon arc welding was the first electric welding process.
❖ It’s difference is that it uses non- consumable carbon or
graphic electrodes instead of the consumable flux-coated
electrodes.
❖ Graphite electrodes are harder, more brittle and last longer
than carbon electrodes. They can withstand higher current
densities but their arc column is harder to control.
❖ The main advantage of this process is that the temperature
of the molten pool can be easily controlled by simply
varying the arc length.
❖ Since arc serves only as a heat source, it does not transfer
any metal to help reinforce the weld joint.
❖ The major disadvantage of the carbon-arc process is that
blow holes occur due to magnetic arc blow especially when
welding near edges of the workpiece.
❖ Common types of arc welding used in practice:

❖ Shielded metal arc welding:

❖ Shielded metal arc welding (SMAW), also known as manual metal

arc welding (MMA or MMAW), flux shielded arc welding or
informally as stick welding, is a manual arc welding process that
uses a consumable electrode covered with a flux to lay the weld.
SMAW Advantages
✓ Scrap metal can used make repairs

✓ Repairs can be made quickly before a problem becomes severe

✓ Metal repair and construction can be accomplished more

economically

✓ Arc welders can be used to accomplish jobs like cutting,

piercing, gouging and beveling
❖ Gas Shield Arc Welding:

❖ In this fusion process, welding is done with bare electrodes

but weld zone is shielded from the atmosphere by a gas
which is piped to the arc column. Shielding gases used are
carbon dioxide, argon, helium, hydrogen and oxygen. No
flux is required.
Plasma Arc Welding :
✓ Basic Principle is It consists of a high-current electronic
arc which is forced through a small hole in a water cooled
metallic nozzle.
✓ The plasma gas itself is used to protect the nozzle from
the extreme heat of the arc.
✓ The plasma arc is shielded by inert gases like argon and
helium which are pumped through an extra passageway
within the nozzle of the plasma torch.
✓ As seen, plasma arc consists of electronic arc, plasma gas
and gases used to shield the jet column.
✓ Disadvantages:
✓ Since it uses more electrical equipment, it has higher
electrical hazards.
 Resistance welding
➢ It is fundamentally a heat and squeeze process. The term
‘resistance welding’ denotes a group of processes in which
welding heat is produced by the resistance offered to the
passage of electric current through the two metal pieces
being welded.
➢ These processes differ from the fusion processes in the sense
that no extra metal is added to the joint by means of a filler
wire or electrode.
➢ Advantages: Some of the advantages of resistance welding are
as under :
➢ Heat is localized where required
➢ No filler material is needed.
➢ Requires comparatively lesser skill
➢ Parent metal is not harmed
➢ Only disadvantage is with regard to high initial as well as
maintenance cost.
Arc welding

 How arc weld

https://www.youtube.com/watch?v=CoHVA7nr82A

 Working Principle of arc welding

https://www.youtube.com/watch?v=QZdY3ZRY9RA
References
1. Little R L. “Welding and Welding Technology”, Tata McGraw Hill, New Delhi,
2017.
2. Parmer R S, “Welding Processes and Technology”, Khanna Publishers, New
Delhi, 2015.
3. Larry Jeffus, “Welding Principles and Applications”, Delmar Publishers, New
York, 2017.
4. Howard B Cary and Scott C Hezler, “Modern Welding Technology”, Pearson,
New Delhi, 2005.
Thank You