Professional Documents
Culture Documents
HAZARDS PRECAUTIONS
Live Dried insulated gloves have to be used while broken and
conductors used gloves should not be used.
Electrical parts should not be touched.
Do not use cables without enough current capacity or the
ones which are not intact on the surface or inside
conductors shown already.
The cable joints must be tightly clamped and insulated.
All powers have to be cut off completely when equipment is
not in use.
Hazardous Ensure you have enough ventilation and air breathing
fumes and apparatus.
gases Do not weld in locations near chlorinated hydrocarbons
vapors coming from degreasing, cleaning and spraying
operations. The heat and rays of the arc can react with
solvent vapors to form phosgene (a highly toxic gas) and
other irritating products.
SMAW components
o In Gas Metal Arc Welding, DC reverse polarity is most commonly used. This
means the welding wire has positive polarity and the parent material has
negative polarity.
2) Wire feeder
o In general, air cooling torch is used for currents lower than 300A.
o The contact tube used for this should have a size that matches the
diameter of the wire to be used. If a tube bigger than the diameter of wire
is used, it will turn on an electric current and result in unstable arc.
GMAW process is unique in that there are several modes of transferring the filler
metal from the wire to the weld.
Mode of metal transfer is a mechanism by which molten filler metal is transferred
across the arc to the base metal.
Selection of the mode of metal transfer used depends on: Welding power
source, the wire electrode size, type and thickness of the material, type of the
shielding gas used.
a) Spray Transfer
Hundreds of droplets of the metal are transferred from the end of the electrode
in the form of a fine spray. It is used for welding thicker plates in the flat,
horizontal/ vertical positions.
Spray transfer requires the use of higher welding current and arc voltages.
The true spray can be obtained when the shielding gas is argon or
argon/oxygen mixture.
b) Globular Transfer
This is generally used on thin materials and at very low currents range.
In globular heat transfer, the arc melts the end of the electrode, forming a
molten ball which becomes so large and It falls across the arc landing onto the
molten weld pool. This can be achieved when using Carbondioxide.
c) Pulsed Transfer
This process produces dual pulsed currents. One pulse of high current is for axial
spray transfer mode and the other pulse of current should not transfer any weld
metal. The pulsing of the current levels permits the use of high amperage
transfer mode and the low amperage so that the total heat input to the weld is
low.
The high current of the spray produces good penetration and fusion, and the
low current allows the weld pool to cool.
This method reduces spatter and gives greater control of heat input to the work
piece.
d) In Short Circuit (Dip) Transfer
Generally used in low currents allowing the liquid metal at the electrode tip to
be transferred by direct contact with the molten weld pool. This process requires
a very short arc length so as to create a short circuit. This process produces a
weld pool that solidifies quickly hence allowing welding of thinner sheets, motor
vehicle body repair and sheet metal construction.
Welding equipment is more complex, more costly and less portable than
that for Stick Welding
The required welding torch makes reaching into constricted areas difficult,
and the need for good gas shielding necessitates the torch being
relatively close to the weld area
Relatively high levels of radiated heat and light may cause operator
discomfort and initial resistance to the process
Burn through is a common issue when welding extremely thin materials
(<1/16”)
This process does not perform well where base metal contamination is a
problem. The base metal must be clean and rust free