WELDI

NGI
NSPECTOR
Ar
esponsi
bleper
soni
nvol
vedi
nthedet
ermi
nat
ionofwel
dqual
i
tyaccor
dingt
otheappl
i
cabl
e
codesorspeci
fi
cat
ion,oper
ati
ngi
ndi
ff
erentci
rcumst
ancesdependi
ngonpr
imar
il
ytowhom
t
heyar
ewor
king.Heshoul
dhav
egoodknowl
edge,at
ti
tude,ski
l
landhabi
tst
oper
for
mthe
wel
dingi
nspect
ion.

Responsi
bil
it
ies
1. Responsi
blef
orgener
alwel
dqual
i
tyateachf
abr
icat
ionst
eps

2.performi
ngandev
aluat
ing,
wit
nessi
ngt
heNDEandDEt
hati
snecessar
y

3.compl
etef
ami
l
iar
it
ywi
thr
equi
rementofj
obsorpr
oject
swher
ehei
swor
king

4.Fai
r,i
mpar
ti
al,
consi
stentdeci
sionmaki
ngbasedont
hef
act
s,condi
ti
onofwel
d,

accept
ancecr
it
eri
aspeci
fi
edont
hespeci
fi
cat
ionorcodes.

5.performi
ngwel
dingi
nspect
ionwi
thr
espectt
othesaf
etyst
andar
ds

6.Abi
l
ityt
ounder
standandr
esponsi
blet
oappl
ythev
ari
ouswel
dingdocument
sdescr
ibi
ng

t
her
equi
rement
s

7.revi
ewi
ngoft
henecessar
ywel
dingdocument
sbef
oret
hewor
kst
ars.

8.generati
ngcl
eardocument
sandi
nter
pret
ingv
ari
ousi
nspect
ionandwel
dingdocument
s,

whi
char
ebear
ingwher
e,whenandhowt
hei
nspect
ionhasbeenper
for
med.

9.gai
ningknowl
edgeonv
ari
ouswel
dingpr
ocess.

10. i
tist
hemaj
orr
esponsi
bil
i
tyt
ounder
standt
hepr
obl
em ofwel
derhef
acesdur
ing

wel
ding.

11. moni
tor
ingofcr
it
ical
wel
dingv
ari
abl
esandt
hedef
ectofwel
ding.

12. adv
isi
ngt
hewel
derdur
ingcr
it
ical
sit
uat
ionandal
way
stosol
vet
hei
rpr
obl
ems

encount
eri
ngdur
ingwel
ding.

13. wel
dvi
sual
inspect
ionandawar
enessofal
ter
nat
emet
hodst
oenhancet
hev
isual

i
nspect
ion

14. pr
ovi
dingt
rai
ningt
othesubor
dinat
es

15. communi
cat
ingwi
tht
hewel
der
,fabr
icat
or,
wel
dingsuper
visor
,engi
neer
,and

managementt
eam r
egar
dingt
hewel
dandwel
dingqual
i
ty.

16. conf
ir
mingt
hewel
dingpr
ocess,
procedur
eandot
herdat
ausedf
orwel
dingar
ethe

speci
fi
ed.
Wel
dingpr
ocess

SMAW – SHIELDMETALARCWELDING
GMAW – GASMETALARCWELDI NG(MIG/MAG)
FCAW – FLUXCOREDARCWELDI NG
GTAW – GASTUNGSTENARCWELDI NG
SAW – SUBMERGEDARCWELDI NG
PAW – PLASMAARCWELDI NG
EGW – ELECTROGASWELDI NG
ESW – ELECTROSLAGWELDING
OFW – OXYFUELGASWELDI NG
EBW – ELECTRONBEAM WELDING
LBW – LASERBEAM WELDING
ERW - ELECTRICALRESI
STANTWELDING.

WELDI
NG:
Local
i
zedj
oini
ngofmat
eri
alswi
thorwi
thoutpr
essur
eorf
il
lermet
al.

SMAW :Shi
eldmet
alar
cwel
ding.
Methodofjoi
ningofmetalwi
thanEl
ect
ri
calAr
ccr
eat
edbet
weent
hecov
eredf
il
lermet
al,
cal
l
edaselect
rodeandt
hebasemetal
.

Thi
si sa const
antcurr
entweldi
ng method.The wel
ding arci
spr
oduced bet
ween t
he
el
ectr
odeandthebasemetal
duetothef
lowofelect
ri
ccurrent
.

Ar
cpr
ovi
dest
heheatener
gyt
omel
tthebasemet
al,
fil
l
ermet
alandt
hecov
eredf
lux.

Ashor tarcwi
llpr
ovi
debetterwel
dingabi
l
ityandLongarcwil
lreducetheheati
nwel
dpool
.
Excessiv
elongarcwi
llr
educethearcst
abi
li
tyandshi
eldi
nggasstabil
i
ty.

Themai
nel
ementoft
heSMAW pr
ocessi
stheel
ect
rodeonl
y.

Theel
ect
rodei
sabar
emet
alwi
recov
eredwi
thgr
anul
arf
luxt
hrought
hebondi
ngagent
s.

Theconv
ert
edf
luxwhi
chcov
ersandsol
i
dif
iesont
hewel
dmet
ali
scal
l
edassl
ag.

Thefl
ux/sl
agsol
i
dif
iesaf
tert
hesol
i
dif
icat
ionoft
hewel
dmet
al,
that
’swhyt
hesl
agf
loat
son
thewel
dmetal
.

Whent
hesl
agt
rappedi
nthewel
dmet
ali
tbecomesasadef
ectandcal
l
edassl
agi
ncl
usi
on.

Lowcarbonri
mmedst
eelwi
rei
susedascor
ewi
ret
opr
oduceal
lel
ect
rodet
owel
dal
ltheCS
andLowall
oyCS.

Al
l
oyi
ngoft
heel
ect
rodei
sbei
ngdonet
hrought
hecoat
ing,
asi
tiseconomi
cal
.

Theel
ect
rodesar
ecl
assi
fi
edswi
tht
hef
luxonl
y.
Funct
ionsoft
hef
luxcoat
ing:

Shi
eldi
ng,
All
oyi
ng,
Deoxi
dizi
ng,
Ioni
zi
ng,
andI
nsul
ati
ng.

Shi
eldi
ng:
for
mingt
hegaseousshi
eldf
ort
hemol
tenmet
al.
Al
l
oyi
ng:
thr
oughmi
xi
ngt
heal
l
oyi
ngel
ement
swi
thf
luxt
hewel
dmet
albecomesasal
l
oyed.
Deox
idi
zi
ng:
remov
ingt
heoxy
genandot
herat
mospher
icgasesbyf
luxi
ngact
ion.
I
oni
zi
ng:
incr
easi
ngt
hear
cst
abi
l
itybyv
ary
ingt
heel
ect
ri
cal
char
act
eri
sti
c
I
nsul
ati
ng:t
oal
i
mit
edext
entt
hesol
i
dif
icat
ionofwel
dmet
ali
sbei
ngsl
ow downedbyt
he
sol
i
dif
iedsl
ag.

SMAW El
ect
rodei
dent
if
icat
ion

E–XXXX
E-El
ect
rode
XX–Tensi
leSt
rengt
hinKsi(
Klbs/
Sqi
n)

X–Posi
ti
onoft
hewel
ding.

X–Fl
uxchar
act
eri
sti
c.
Thefl
uxcharact
eri
sti
cswi
ll
determi
net
heoper
ati
ng,
cur
rentandpol
ari
tychar
act
eri
sti
cs.
The3rddi
git(
posi
ti
onofwel
ding)–

1–El
ect
rodesui
tabl
eforal
lposi
ti
on

2–Mol t
enmet
ali
sver
yfl
uidandsui
tabl
eonl
yforf
lat
posi
ti
on

3–Nol
ongeri
nuse.

4–El
ect
rodesui
tabl
efordownhi
l
lpr
ogr
essi
on.

4thdi
git
s(f
luxchar
act
eri
sti
cs)

5,
6,8–Lowhydr
ogenel
ect
rodesandt
hemoi
stur
econt
entshal
lbe
l
esst
han2%.Goodwel di
ngpr
operti
es,
deposi
ti
onr
ate.Easyt
oal
l
oy.
Moi
stur
econt
rol
requi
rementi
shigh.

10,11–Cel
l
ulosecoat
edsui
tabl
eforRootwel
dingandDownhi
l
l
pr
ogr
essi
on.Doesnotr
equi
redheat
ing.Bet
terabi
l
ityt
openet
rat
e.

2,
3,4–Rut
il
ecoat
edel
ect
rode.Wel
der
sfr
iendl
yel
ect
rode.Sui
tabl
e
f
ort
ackwel
dingandcommer
cial
wel
dings.
r
d t
h
3 &4 di
git
stoget
her:

20–Ir
onoxi
de+sodium coated(cel
l
ulose)
24–Ruti
l
eir
onpowder
27–Ir
onoxi
deironpowder
28–LowhydrogenI
ronpowder.

Toident
if
ytheal
l
oyi
ngofel
ect
rodes,
thesuf
fi
x–1mayf
oll
owwi
tht
heEXXXXnumber
.
E-
7018–1.

Pr
oper
tydet
ail
sofel
ect
rodes.

SNO ELECTRO F.
NO CURRENT ARC PENETRAT FLUX %IRON
DE I
ON POWD
ER
1 E-
XX20 1 AC/DCEP MEDI
UM MEDIUM FeO2+Na 0
2 EXX24 1 AC/DC MEDI
UM MEDIUM Rut
il
eI r
onpwdr 50
3 EXX27 1 AC/DC MEDI
UM MEDIUM FeO2+I ronpwdr 50
4 EXX28 1 AC/DCEP MEDI
UM MEDIUM LH2Ironpwdr 50
5 EXXX2 2 AC/DCEN MEDI
UM MEDIUM Rut
il
eNa 10
6 EXXX3 2 AC/DC MEDI
UM MEDIUM Rut
il
eK 10
7 EXXX4 2 AC/DC MEDI
UM MEDIUM Rut
il
eI r
onPwdr 10
8 EXXX0 3 DCEP DI
GGI
NG DEEP Cel
l
uloseNa 0
9 EXXX1 3 AC/DCEP DI
GGI
NG DEEP Cel
l
uloseK 0
10 EXXX5 4 DCEP MEDI
UM MEDIUM LH2Na 0
11 EXXX6 4 AC/DC MEDI
UM MEDIUM LH2K 0
12 EXXX8 4 AC/DCEP MEDI
UM MEDIUM LH2IronPwdr 25–45

Themajoral
loy
ingel
ementsthr
ought hef
luxcoat
ingshal
li
ndi
cat
edaf
tert
heel
ect
rode
cl
assi
fi
cati
onwithanumberoralphanumeri
c.

Themajoral
l
oyi
ngel
ement
sar
eMo, Cr,Ni,Mn,
V.t
hesear
ecl
assi
fi
edsi
ntoA1,
B1t
oB4,
C1
toC3,
D1,D2andW.(
W –Weat
hershiel
ding)

S.
No. Suf
fi
xNo Mn Ni Cr Mo V
1 A1 0.
5
2 B1 0.
5 0.
5
3 B2 1.
25 0.
5
4 B3 2.
25 1
5 B4 2 0.
5
6 C1 2.
5
7 C2 3.
5
8 C3 1
9 D1 1 0.
3
10 D2 1.
25 0.
3
11 W 1 0.
5 0.
3 0.
2 0.
1
Adv
ant
ageandDi
sadv
ant
ageofSMAW.

S.
no ADVANTAGE DISADVANTAGE
1 Usedinmostoft heindustri
es Exoti
calloyscannotwel d
2 Si
mpl eandl essexpensive Lessspeedandl owproducti
vi
ty
3 Wellsuit
ablef orremotelocati
on Manual operat
ionrequir
ementi smor e
4 Easyhandlingduet ocompactabi l
i
ty Slagremov al&repai
rduet oslagincl
usion
5 Moreav ai
labil
ityofal
loyi
ng Elect
rodehandlingforLowH2el ect
rode.
el
ectrodes
6 Bett
erqualityinwelding Repai
rchancesduetoimpr
operhandl
i
ngof
l
owH2el ect
rode.
7 Lessweldi
ngvari
abl
es Occur
renceofporosi
ty
8 Reducedmaint
enance

Of
tendef
ect
sinSMAW.

1. SlagInclusion:Duetotheimpr opercl
eaningorduet othesol
idifi
cati
ont
imingt
he
moltenf l
uxt r
appedintheweldmet al.
2. Porosit
y: Theporousholesduet oMoisture/entr
apmentofat mospheri
cgases/
condemnat i
onofweldregion.
3. ArcBlow: Thespli
tspil
lofwel di
ngmet alduri
ngweldingduetothemagneticef
fect
onthef erromagneti
cmat eri
als.
4. Undercut s:Thedefectwhichacquiresduet otheexcessi
vecurrent.

GasTungst
enAr
cWel
dingPr
ocess.(
GTAW)
.

Ot
herwi
secal
l
edasTI
G(Tungst
enI
ner
tGasWel
ding)

LikeSMAW pr ocesst hi
salsoaConst antCurrentProcess.Inthisprocesst he
electr
odeusedi snotconsumeddur ingwel di
ng.Fordeposi t
ionofwel dmet al
additi
onalfi
l
lerwi r
eisbeingused.Thear ciscreatedbet weent heelectrode
andbasemet alandaddi t
ionalfi
l
lermet alisfedi nbetweenasr equired.In
GTAW t hewel dingcanbedonewi thAC /DC ( EP,EN).How ev erahi gh
frequencyuniti
sr equir
edtocontroltheelectri
calfrequency.Wheni nuseof
theDCEPcur rentthemaximum heatwi l
lbeont hetungstenelectr
odehence
i
nGTAW pr ocesst heDCENi sprefer
red.

Toinit
iatethearcthet ungsteni
sall
oyedwit
hsomeot herel
ementsandi ti
s
cl
assifi
edint o5t ypesandcodedwi thdi
ff
erentcol
ors.TheyarePureW,
Ceri
atedW, Lanthanat
edW, Thor
iat
edW andZincr
onat
edW.Pur etungst
enis
usedint healuminum wel di
ngasitfor
msroundedendont hetipwhichwill
notdamaget hetungsten.

EWP - Puretungsten green

EWCe2 - 1.
8-2%Cer i
um Orange
EWLa-
1 - 1%Lant hanum Bl
ack
EWLa-
1.5 - 1.
5%Lant hanum Gold
EWLa-
2 - 2%Lant hanum Bl
ue
EWTh-
1 - 1%Thor ium Yell
ow
EWTh-
2 - 2%Thor ium Red
EWZr - Zi
rconium Brown.
Adv
ant
ages

Hi
ghqual
i
ty,
cleanwel
dingmet
hod

Suit
abl
eforal
lmetal
sandal
loyev
enifassi
gnedf
il
lermet
alnotavai
l
ableal
so
thepor
ti
onofbasemetal
shall
beshear
edandbeusedasafil
lermet
al.

Excell
entmethodf ort
hinsheetaswel
l
,thewel
dingcanbedoneupt
oa
minimum t
hicknessof0.
005in.

Suit
ablef
orfi
eldandshopwel
ding.I
nfi
eldmechani
calwi
ndshi
eldr
equi
resi
f
thewindvel
oci
tyexceedst
hel
i
mi t
s.

Wel
der/oper
atorcanv
iewt
hewel
dpuddl
edur
ingwel
ding.

Env
ironmentf
ri
endl
ymet
hod.

Di
sadv
ant
ages

Eventhoughi
tishi
ghqual
i
tymet
hod,of
tendef
ectf
oundi
stheTungst
en
I
nclusi
on.

Hi
gherskil
lrequi
red,t
hewel
derhast ousehi
sbot
hhandt
ocont
rolt
he
wel
dingt
orchandtofeedt
hef
il
lermet
al.

Ext
remecleani
ngofbaseandf
il
lermet
alisr
equi
red.
Condemnati
onint
hepurgi
nggascausethepor
osit
yinwel
d.

Causesf
orTungst
enI
ncl
usi
on.:

DuetoDCEPpol ar
it
y
Wornoutt i
ps
Impropergri
ndingofti
p
Lesserski
llofwelder
Shorterar
clength
Contaminatedgas

GASMETALARCWELDI
NG(
GMAW)ot
herwi
seMI
G/MAG

MI
G–Met
all
i
cIner
tGasWel
ding.

MAG–Met
all
i
cAct
iveGasWel
ding.

Pr ocess:Thi sisaConst antVol

tagePr ocess.Itisasemiaut omat i
cprocess.
Thef il
lerwi r
eitselfactsasel ectr
ode.Thef il
l
erwireisinthef orm ofcoiled
spoolcur rentispassedt hroughthefil
lerwire.Inspi
teofthepoweruni tl
ikein
SMAW /GTAW addi t
ionalwi r
efeedinguniti sfi
xedont hemachi ne.Thef i
ll
er
wiref eedt hroughther ol l
ersofthewi ref eedingmechanism t ot heLINER
(hoset ypearrangement) .Endoft hecont acttubeisbeenfixed.Thecont act
tubewi l
lpasst hecur r
entt othef i
ll
ermet al
.Thust hefi
ll
ermet albecomes
elect
rode.Whent hefil
lermetalcontactwi thbasemet alt
hearcisproduced
andwel dingiscar ri
edout .Asthespeedofwi refeed(WFS-WireFeedSpeed)
willbe adjusted t he elect
ri
calpar amet ers wi
llaut
omat i
cal
l
ychanged as
requi
red.Themodeofwel dmet altransferisveryi
mpor t
anti
nthismethod.
Therearef ourtypesofmet altr
ansfers.
1.spr ayt y
pe
2.di ptransferorshor tci
rcuitmet hod
3.gl obulartransfer
4.pul sedar cmet hod.

Spraytype:Thewel dmetalfr
om thefi
ll
erwir
eisdeposi
tedintheparent
metalintheform ofspr
aytoobtai
ngoodpenetr
ati
on.Themaindr
awbacki s
highheatinputandhighspat
terandpoorf
ini
shi
ng.Thi
smethodisusedonly
forheavystr
uctur
al.

Diptr
ansf
er:usedmainl
yfort hi
nsect
ions.Whentheel
ect
rodewi
llcomein
cont
actwit
htheparentmetalattheweldthef
il
lerwi
remel
tsanddeposi
ted.
Ther
ewill
notbeanyarcgapproduced.