Professional Documents
Culture Documents
Engineering Faculty
Dept. Of Mechanical Engineering
Welding Technology
2021-2022 Fall
Additional Slides- After the midterm exam
Contents:
SMAW
SAW
GTAW (TIG)
GMAW (MIG-MAG)
FCAW
PAW
• Instructor
– Prof. Dr. Emel TABAN
Weld penetration
SMAW Advantages
• Easily
implemented
• Inexpensive
• Flexible
• Not as sensitive to
part fit-up
variances
Underwater welding with SMAW
Limitations
• Low deposition
rates
• Low productivity
• Requires high level
of manual welder
skills
• Welding fume
Quality Issues
• Discontinuities associated
with manual welding
process that utilize flux
for pool shielding
– Slag inclusions
– Lack of fusion
• Other possible effects on
quality are porosity, and
hydrogen cracking
Lack-of-fusion defects
in two-sided SMA weld
20
Volume [dm3]
1
50 Frequency [H z] 100 k
– Electrodes of this type cellulosic material in the form of wood flour or reprocessed low
alloy electrodes have up to 30 percent paper.
– These gases tend to produce a digging arc that provides deep penetration.
– The weld deposit is somewhat rough, and the spatter is at a higher level than other
electrodes.
– It is normally used with direct current with the electrode positive (reverse polarity).
– Typical application is for the pipeline welding
– Electrodes with this coating have a quiet arc, an easily controlled slag, and a low level
of spatter.
– the penetration will be less than with the cellulose electrode.
– The weld metal properties will be slightly lower than the cellulosic types.
– For the rutile type, the weld deposit will have a smooth surface
– Typical application is for structural components
• There are many types of coatings other than those mentioned here, most of
which are usually combinations of these types.
• Not all the types of electrodes are available for every material, both ferrous and
non-ferrous
Iron powder
Cellulose
The electrodes containing iron power in the coating have the highest deposition rates.
In the United States, the percentage of iron power in a coating is in the 10 to 50 percent range.
This is based on the amount of iron power in the coating versus the coating weight. This is
shown in the formula:
300
250
200
Corrente [A]
Cellulose-sodium (EXX10)
Cellulose-potassium (EXX11)
Rutile-sodium (EXX12)
Rutile-potassium (EXX13)
Rutile-iron powder (EXXX4)
Low hydrogen-sodium (EXXX5)
Low hydrogen-potassium (EXXX6)
Low hydrogen-potassium-iron
powder (EXXX7).
Low hydrogen-iron powder (EXXX8)
Low hydrogen-high iron
powder (EXX28)
Iron oxide-sodium (EXX20)
Rutile-iron powder (EXXX4)
E7018
• “E” indicates “stick” electrode
• 70 indicates nominal 70 ksi tensile
strength
• 1 indicates use for welding in all positions
• 8 indicates low hydrogen coating
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Prof.Dr. Emel Taban
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Prof.Dr. Emel Taban
Submerged Arc Welding (SAW)
Characteristics
• Developed in 1950’s
• Uses bare wire filler metal and granular flux
• Equipment costs moderately high
• Very high deposition rates and travel speeds possible
• Limited to horizontal position
• Generally not used in the field
• Fume generation relatively low
Advantages
Limitations
• Slag removal required
• Flux is subject to contamination
and porosity
• Normally not suitable for thin
material
• Restricted to the flat position for
grooves - flat and horizontal for
fillets
• Flux handling equipment
required
• The power source for submerged arc welding must be rated for a 100
percent duty cycle, with size from 300 amperes to 1500 amperes
• Direct current power is used for semiautomatic applications, but
alternating current power is used primarily with the machine or the
automatic method.
• For semiautomatic application, a welding gun and cable assembly are
used to carry the electrode and current and to provide the flux at the
arc.
• For automatic welding, the torch is attached to
• the . the wire feed motor and includes current pickup tips for
transmitting the welding current to the electrode wire. The flux hopper
is normally attached to torch, and may have magnetically operated
valves which can be opened or closed by the control system.
Corrente [A]
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Prof.Dr. Emel Taban
Other welding variables
• Depth of the flux layer
– If it is too thin, there will be too much
arcing through the flux or arc flash.
Resulting in porosity.
– If the flux depth is too heavy, the
weld may be narrow and humped.
• Wire diameter
– Smaller diameters will result in
higher deposition rate and
penetration
F7A2-EM12K
• F indicates flux
– 70-95 ksi UTS, 58 ksi minimum yield strength, 22% elongation
– A - as welded; P - postweld heat treated
– 2 - minimum impact properties of 20 ft-lbs @ 20°F
• E indicates electrode (EC - composite electrode)
– M - medium manganese per AWS Specifications
– 12 - 0.12% nominal carbon content in electrode
– K - produced from a heat of aluminum killed steel
43
Welding Technology 2021-2022
Prof.Dr. Emel Taban
Flux – wire combination: AWS A 5.17M
44
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Prof.Dr. Emel Taban
Joint preparation: High current welding
Adaptative control
Characteristics
Advantages
• High quality
• Precise control of arc
and fusion
characteristics
• Intricate geometries
weldable
• Easily mechanized
• Used with or without
filler material GTAW of Stainless Steel Bellows
Disadvantages
Deformation reduction
Reduction of grain size increasing Welding seam very smooth
Reduction of and regular
heat affected zone
Welding torch
Flowmeter Shielding gas supply
Teflon seal
Gas lens
Tungsten electrode clamp
Ceramic orifice
Refractory
orifice
Tungsten electrode
I2
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Prof.Dr. Emel Taban
Pulsed current
Pulsed current has some advantages in comparison the standard
TIG:
1) Good penetration with less heat input reduction of hot cracks;
2) Less distortion;
3) Good control of the pool when welding out of position;
4) Ease of welding thin materials;
5) Ease of welding materials of dissimilar thickness levels;
6) depth/width ratio till 2 to 1 in the welding of stainless steels
reduction of hot cracks;
7) sagging (seam concavity) reduction because high currents and the
short time of the pulsed mode gives the possibility to the weld pool of
rapidly cooling;
8) short heat affected zone;
9) gas inclusions reduction because the pulsed arc shakes the weld
pool and permits the gas discharge.
B a c k g ro u n d a m p e ra g e
T im e [se c ]
Peak Amperage —This value is usually set somewhat higher than it would be set for a non-pulsed GTAW
weld.
Background Amperage —This of course would be set lower than peak amperage.
Pulses Per Second —Is the number of times per second that the weld current achieves peak amperage.
% On Time —Is the pulse peak duration as a percentage of total time. It controls how long the peak
amperage level is maintained before it drops to the background value.
Material
DC AC
EN EP
Aluminium (t 2.5 [mm]) 2 2 1
Aluminium (t>2.5 [mm])
and aluminium alloys
2 3 1
Magnesium and
magnesium alloys
3 2 1
1=Best results;
Carbon steels and
low alloyed steels
1 3 3 2=Acceptable results;
Stainless steels 1 3 3 3=Not recommended
Copper 1 3 3
Bronze 1 3 2
Copper-aluminium alloys 2 3 1
Silicon-Bronze 1 3 3
Nickel and nickel alloys 1 3 2
Titanium 1 3 2
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Prof.Dr. Emel Taban
Current intensity: EN 26848
EN 26848 W T 10
W is the first letter of the main element (Wolframium); T is the first letter of the
added oxide (in this case thorium); 10 is the average percentage of oxide
content divided 10.
Therefore:EN 26848 W T 10 means an tungsten electrode with 1% of thorium.
The added oxides are usually finely dispersed in the tungsten matrix, but there some
electrodes defined “composites” that are constituted by a pure tungsten core covered with
oxides. These electrodes have the disadvantage that they can’t be tapered because in this
case they loss the oxide present on the surface.
All the electrodes, in function of the type of added oxide and of the added quantity have
an identification coloured ring on their extremity (see the following picture). The
“composites” electrodes have a second pink coloured ring.
Composition
Code Colour
Oxides [%] Impurities [%] Tungsten [%]
WP / 0,20 99,8 Green
WT4 0,35 to 0,55 of ThO2 0,20 remainder Blue
WT10 0,80 to 1,20 of ThO2 0,20 remainder Yellow
WT20 1,70 to 2,20 of ThO2 0,20 remainder Red
WT30 2,80 to 3,20 of ThO2 0,20 remainder Violet
WT40 3,80 to 4,20 of ThO2 0,20 remainder Orange
WZ3 0,15 to 0,50 of ZrO2 0,20 remainder Brown
WZ8 0,70 to 0,90 of ZrO2 0,20 remainder White
WL10 0,90 to 1,20 of LaO2 0,20 remainder Black
WC20 1,80 to 2,20 of CeO
Welding
2 0,20 2021-2022remainder
Technology Grey 86
Prof.Dr. Emel Taban
Electrodes codification (AWS 5.12)
The non consumable electrodes are also classified by an American Standard
AWS 5.12 as indicated below:
Composition
Code Colour
Oxides [%] Oxides type Tungsten [%]
EWP / / 99,5 min. Green
EWCe-2 1,80 to 2,20 CeO2 97,3 min. Orange
EWLa-1.5 1,30 to 1,70 LaO2 97,8 min. Gold
EWLa-2 1,50 to 2,00 LaO2 97,5 min. Blue
EWTh-1 0,80 to 1,20 ThO2 98,3 min. Yellow
EWTh-2 1,70 to 2,20 ThO2 97,3 min. Red
EWZr-1 0,15 to 0,40 ZrO2 98,3 min. Brown
EWG 1,70 to 2,20 Rare earth 94,5 min. Grey 87
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Prof.Dr. Emel Taban
Electrodes codification (AWS 5.12)
The lanthanated tungsten electrodes are ecological because the thorium oxide
has been substituted by non radioactive Lanthanum oxide.
The most used electrodes are EWLa-1 (1[%] Lanthanum, Black), EWLa-1.5
(1.5 [%] Lanthanum, Gold) and EWLa-2 (2 [%] Lanthanum, Blue).
The addition of 1 [%] or 2 [%] of Lanthanum oxide increases the maximum
current capacity of these electrodes of 50 [%] in comparison with the pure
tungsten with same electrode’s diameter using AC current.
The increase of lanthanum oxide percentage in the electrode increases also
the cost.
These electrodes have excellent arc starting, low-burn-off rate, arc stability,
and excellent re-ignition characteristics. The 1.5 [%] content appears to most
closely match the conductivity properties of 2 [%] thoriated tungsten.
Compared to cerium and thorium the Lanthanum electrodes had less tip wear
at given current levels.
For Inverter Squarewave use the electrode shape is very nearly the same as
for DC electrode negative welding. This improves the ability to focus the arc
along with an even greater localisation of the heat into the work. In this case is
not recommended the use of pure tungsten.
For AC Sine Wave use the electrodes should have a hemispheric or balled
end formed.
The diameter of the end should not exceed the diameter of the electrode by
more than 1.5 times. As an example, a 1,6 [mm] electrode should only form a
2.4 diameter end maximum. If it becomes larger than this because of
excessive current, there is the possibility of it dropping off to contaminate the
weld. If the end is excessively large the arc tends to wander around on the
large surface of the electrode tip. The arc becomes very hard to control as it
wanders from side to side.
If welding conditions are correct, a visual observation of the electrode should
reveal a ball end of uniform shape and proper size.
Regarding the penetration a pointed end of electrode produces a more focused arc
and a deep and narrow penetration.
A balled end electrodes produces, on the contrary, a wide and shallow penetration.
Tolerance
0,5÷1,0÷1,6÷2,0÷2,5
0.05
3,2÷4,0÷5,0÷6,3÷8,0 Tolerance
10,0 0.10
Gas nozzles or cups as they are better known, are made of various types of heat
resistant materials in different shapes, diameters and lengths.
The nozzles are either screwed into the torch head or pushed in place.
Nozzles can be made of ceramic, metal, metal-jacketed ceramic, glass, or other
materials. Ceramic is the most popular, but are easily broken and must be replaced often.
Nozzles used for automatic applications and high amperage situations often use a water-
cooled metal design.
Gas nozzles or cups must be large enough to provide adequate shielding gas coverage
to the weld pool and surrounding area. A nozzle of a given size will allow only a given
amount of gas to flow before the flow becomes turbulent. When this occurs the
effectiveness of the shielding is reduced, and nozzle size must be increased to restore an
effective non-turbulent flow of gas.
For welding of particular materials like titanium the gas purity shall be greater
than 99,995 [%].
When choosing a shielding gas, a fact that must be considered is the
ionisation potential of the gas. Ionisation potential is measured in volts and is
the point where the welding arc will be established between the electrode and
the work piece through the shielding gas. In other words, it is the voltage
necessary to electrically charge the gas so that it will conduct electricity. The
ionisation potential of argon is 1.5 lower than helium. Therefore, arc voltage
produced with argon would be lower than that produced by helium; therefore
we have a more stable arc, and easier arc start and re-ignition.
Argon, since has an atomic weight greater than Helium, provides excellent
cleaning action even at low amperages.
Argon is insoluble in the fused seam and for this reason is very low the risk to
have inclusions of this gas in the weld.
EN 1089-3
Gas cylinder colour
• The best position of the torch and filler metal is shown in the following
picture:
Filler metal
75°
Torch
15°
Piece
Torch direction 117
Welding Technology 2021-2022
Prof.Dr. Emel Taban
Special applications (tube to tube-sheet welding)
TIG torch
Circumferential
weld
Tube
Process Characteristics
Composition
Electrode 6 = high silicon
Solid Electrode
Rod (can be used
with GMAW) Minimum ultimate tensile
strength of the weld metal
Shielding Gas
• Shielding gas can
affect
– Weld bead shape
– Arc heat, stability,
Ar Ar-He He CO2 and starting
– Surface tension
– Drop size
– Puddle flow
– Spatter
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Prof.Dr. Emel Taban
Gas Metal Arc Welding
GMAW Advantages
• Deposition rates
higher than SMAW
• Productivity higher
than SMAW with
no slag removal
and continuous
welding
• Easily automated
Quality Issues
Limitations
• Equipment is more expensive and
complex than SMAW
• Process variants/metal transfer
mechanisms make the process
more complex and restricts the
process “window”
• Restricted access
– GMAW gun is larger than
SMAW holder
– Out-of-position issues
• Welding fume
Characteristics
Electrode
Type Gas, Usability
Minimum UTS and Performance
70,000 psi
Flux Cored /Tubular
Position Electrode
Advantages
• High deposition rates
• Deeper penetration than
SMAW
• High-quality
• Less pre-cleaning than
GMAW
• Slag covering helps with
larger out-of-position
welds
• Self-shielded FCAW is
draft tolerant.
Limitations
• Slag must be removed
• More smoke and fumes
than GMAW and SAW
• Spatter
• FCAW wire is more
expensive
• Equipment is more
expensive and complex
than for SMAW
SHIELDING GAS
CONSTRICTING NOZZLE
ORIFICE DIAMETER
TORCH STANDOFF WORK
ORIFICE GAS
SHIELDING
GAS
WORK
TRANSFERRED NONTRANSFERRED
• Advantages • Industries
– Better penetration than – Medical (pacemakers)
GTAW and GMAW – Aerospace
– 100% root penetration by – Electronics
formation of “keyhole” – Precision manufacturing
– Easily automated • Applications
– Bellows and seals
– Good out-of-position
– Motors and transformers
– Low fume generation
– Tube mills
• Disadvantages
– Cladding, wire mesh, process
– Equipment cost piping
– Familiarity with – Space shuttle tanks
technology