DJJ 10033-Chapter 7.3

DJJ 10033
WORKSHOP TECHNOLOGY
CHAPTER 7:
Welding
Prepared by:
Mohd Zulfadli bin Ahmad
Learning Outcome
Upon completion of this chapter, students should be

able to:-
 Explain Gas Metal Arc Welding (GMAW)

 Explain Gas Tungsten Arc Welding (GTAW)
 Distinguish defect & distortion in Welding
Learning Outcome

able to:-

Gas Metal Arc Welding (GMAW)
• An arc welding process that uses an arc between

a continuous filler metal electrode and the weld
pool to produce a fusion (melting) together of the
base metal
• The process is used with a shielding gas
supplied from an external source without
pressure.
ALSO KNOWN AS:

• Wire Feed
• MIG = Metal Inert Gas
– Inert Gas= Inactive gas that does not combine
chemically with base or filler metal
• MAG= Metal Active Gas
– Active Gas= Gas will combine chemically with
base or filler metal
GMAW Safety
• Cover all skin to prevent Radiation burns

• Cover hair to prevent sparks setting hair on fire
• Wear ear plugs to protect from noise and
burning ear drums with sparks
• Use a 14 shade welding helmet to protect eyes
• Wear safety glasses at all times
• Make sure pants pockets are empty
GMAW Equipment
• Power Supply
– Direct Current Electrode Positive (DCEP)
• (Electrons flow from – to +)
• Wire Feeder
– Electrical mechanical device that feed required
amount of filler material at a constant rate of speed
GMAW Equipment
• Welding filler electrode

❑ Small diameter consumable electrode that is
supplied to the welding gun by the roller drive
system
• Shielding Gas
❑ Gas used to protect the molten metal from
atmospheric contamination
75%Argon (inert gas) & 25% Carbon Dioxide most common gas
used for GMAW
Principle of GMAW Process

GMAW Set Up
• Plug ground wire into (Neg) Terminal
• Plug Wire Feeder into (Pos) Terminal
• Select CV-Wire mode
• Hot start is not used
• Set Arc Control to “-5”
– -10= soft arc (for use with inert gases)
– +10= crisp arc (for use with CO2)
Min. Arc Control Max Arc Control

• Soft Arc • Crisp Arc
• Thicker Materials • Thin Materials
• Deeper Penetration • Arc Stability On Open Gaps
• More Fluid Weld Pool • Convex Weld Bead
• Flatter / Smoother Weld • Increased Spatter
• Reduce Spatter • Colder Arc
• Stainless Steels • Improved Weld Pool Control
GMAW Set Up
• Set Volts
– See Chart for proper setting
• Set Wire Speed
– Increase wire speed = Increase amps
– Decrease wire speed = Decrease amps
• Set gas flow
– Pull trigger to get gas flowing then adjust regulator
RUNNING A BEAD
❑ Hold tip 1/16” to 1/8” from work piece
❑ Angle of tip should be 10-15°
❑ Can push or pull bead
• Pull (preferred)
• More stable arc
• Less Spatter
• Deeper penetration
• Push
• More spatter
• Less penetration
• Good cleaning action
BEAD FORMATION
GMAW Process Parameters

Steel Material .035” wire Short-Arc Mode
Thickness Gas Amps Wire Volts
75%AR- Speed
25%CO2
1/8” 18-19 140-150 280-300 23-24
3/16” 18-19 160-170 320-340 24-25
1/4” 21-22 180-190 360-380 24-25
5/16” 21-22 200-210 400-420 25-26
3/8” 23-24 220-250 420-520 26-27
ADVANTAGE DISADVANTAGE
Not required the high degree of Welding equipment is more complex &
operator skill more costly
Continuous welding at higher speeds Mechanical properties of the joint may

and in all position be affected due to high cooling rate
Thick & thin, both type of workpieces

Difficult to weld in small corners
can weld effectively
Process can be easily mechanized Process variable are more
No flux: more visibility, cleanliness

Learning Outcome

able to:-

Gas Tungsten Arc Welding (GTAW)
► What is GTAW?
▪ Gas Tungsten Arc Welding
► Alsoreferred to as TIG
▪ Tungsten Inert Gas
► In TIG welding, a tungsten electrode heats the
metal you are welding and gas (most typically
Argon) protects the weld from airborne
contaminants
► TIG welding uses a non-consumable tungsten

► Filler metal, when required, is added by hand
► Shielding gas protects the weld and tungsten
SAFETY PRECAUTION
❑Electric shock can kill.
– Always wear dry insulating gloves
– Insulate yourself from work and ground
– Do not touch live electrical parts
– Keep all panels and covers securely in place
❑Fumes and gases can be hazardous to your

health.
– Keep your head out of the fumes
– Ventilate area, or use breathing device
SAFETY PRECAUTION
✓ Welding can cause fire or explosion.
– Do not weld near flammable material
– Watch for fire; keep extinguisher nearby
– Do not locate unit over combustible surfaces
– Do not weld on closed containers
✓ Arc rays can burn eyes and skin; Noise can

damage hearing.
– Wear welding helmet with correct shade of filter
– Wear correct eye, ear, and body protection
SAFETY PRECAUTION
• Hot parts can cause injury.
– Allow cooling period before touching welded metal
– Wear protective gloves and clothing
• Magnetic fields from high currents can affect

pacemaker operation.
• Flying metal can injure eyes.
– Welding, chipping, wire brushing, and grinding cause
sparks and flying metal; wear approved safety glasses
with side shields
EQUIPMENT
❑ Welding power source
❑ Tungsten electrode
❑ Filler metal
❑ Welding torch
❑ High frequency unit suppressor & cable
❑ Inert gas cylinder
❑ Pressure regulator
❑ Cooling water supply
❑ Water & gas solenoid valve
EQUIPMENT
EQUIPMENT
EQUIPMENT
Technique for basic (GTAW)
Arc Length
• Arc length normally one electrode diameter, when
AC welding with a balled end electrode
• When DC welding with a pointed electrode, arc
length may be much less than electrode diameter
Gas Cup Size

• Inside diameter of gas
cup should be at least
three times the
tungsten diameter to
provide adequate
shielding gas coverage
• Picture on right shows
example of gas cup
size and torch position
1-Workpiece, 2-Work clamp, 3-Torch, 4-Filler rod,
5-Gas cup, 6-Tungsten electrode
Electrode Extension
• Refers to distance the tungsten extends out
beyond the gas cup
• May vary from flush with the gas cup to no more
than the inside diameter of the gas cup
• Longer the extension, the more likely it may
contact something by accident
• General rule would be to start with an extension of
one electrode diameter
Manual Torch Movement

Butt Weld and

Stringer Bead
• Be sure to center weld
pool on adjoining
edges
• When finishing a butt
weld, torch angle may
be decreased to aid in
filling the crater
Torch and rod position for welding the butt weld and stringer
bead
Lap Joint
• Pool is formed so that the
edge of the overlapping
piece and the flat surface
of the second piece flow
together
• Torch angle is important
because the edge will
become molten before the
flat surface
• Enough filler metal must
be added to fill the joint as
illustrated on the right
Torch and rod position for welding the lap joint
T-Joint
• Edge will heat up and melt
sooner
• Torch angle illustrated will
direct more heat onto the
flat surface
• Electrode may need to be
extended further beyond
the cup in order to hold a
short arc
Torch and rod position for welding the T-joint
Corner Joint
• Both edges of the
adjoining pieces
should be melted and
the pool kept on the
joint centerline
• Sufficient filler metal is
necessary to create a
convex bead as shown
Torch and rod position for welding the corner joint
(GTAW) Shield Gases
• Argon
• Helium
• Argon/Helium Mixtures
(GTAW) Shield Gases
Argon Helium
► Good arc starting ► Faster travel speeds
► Good cleaning action ► Increased penetration
► Good arc stability ► Difficult arc starting
► Focused arc cone ► Less cleaning action
► Lower arc voltages ► Less low amp stability
► 10-30 CFH flow rates ► Flared arc cone
► Higher arc voltages
► Higher flow rates (2x)
► Higher cost than argon
(GTAW) Shield Gases
Argon/Helium Mixtures
► Improved travel speeds over pure argon
► Improved penetration over pure argon
► Cleaning properties closer to pure argon
► Improved arc starting over pure helium
► Improved arc stability over pure helium
► Arc cone shape more focused than pure helium
► Arc voltages between pure argon and pure helium
► Higher flow rates than pure argon
► Costs higher than pure argon
(GTAW) Parameter
Aluminum weld parameters

Tungsten Electrode Selection
Guide to selecting a tungsten electrode based on amperage range

POLARITIES
❑ DCSP (Direct Current Straight Polarity)
✓ Tungsten electrode (-ve), work (+ve) used for mild steel,
stainless steel, copper & titanium.
❑ DCRP (Direct Current Reverse Polarity)

✓ Tungsten electrode (+ve), work (-ve) used for welding
aluminium and heavy oxidized aluminium castings.
❑ ACHF (Alternating Current High Frequency)

✓ it is used for Al and Mg. High frequency also helps in
oxide cleaning action.
ADVANTAGE DISADVANTAGE
Welds more metals and metal alloys

Lower filler metal deposition rates
than any other process
Good hand-eye coordination a

High quality and precision
required skill
No sparks or spatter Brighter UV rays than other processes
Slower travel speeds than other

No flux or slag
processes
Equipment costs tend to be higher
No smoke or fumes
than other processes
Learning Outcome

able to:-

Defect & Distortion in Welding
WELD DEFECT
WELD DEFECT
According to the American Society of Mechanical Engineers

(ASME) welding defect causes are broken down into the
following percentages:
41% poor process conditions,
32% operator error,
12% wrong technique,
10% incorrect consumables, and
5% bad weld grooves.
WELD DEFECT
Crater crack
 Crater cracks occur when a crater is not filled before the arc is
broken
 This causes the outer edges of the crater to cool more quickly than
the crater, which creates sufficient stresses to form a crack
WELD DEFECT
Hat crack
 Hat cracks get their name from the shape of the cross-section of the
weld, because the weld flares out at the face of the weld
 The crack starts at the fusion line and extends up through the weld.
WELD DEFECT
Hot cracking
 Hot cracking, also known as solidification cracking, can occur with
all metals, and happens in the fusion zone of a weld
 To diminish the probability of this type of cracking, excess material
restraint should be avoided, and a proper filler material should be
utilized
WELD DEFECT
Underbead crack
 An underbead crack, also known as a heat-affected zone (HAZ)
crack,is a crack that forms a short distance away from the fusion
line; it occurs in low alloy and high alloy steel
 The other factor that affects this type of crack is internal stresses
resulting from: unequal contraction between the base metal and the
weld metal.
WIRE BURNBACK
Possible Causes Corrective Actions
* Drive Rolls in Poor Condition *Tighten, Clean, or Replace
Drive Rolls
* Excessive Welding Voltage * Reduce Voltage
* Insufficient Electrical Stickout * Increase Contact Tip to Work

Piece Distance
* Contact Tip in Poor Condition * Clean or Replace Contact tip
* Spatter on Contact Tip * Remove Spatter

BURNTHROUGH

* Excessive Amperage *Reduce Amperage
* Improper Travel Angle * Use a Push Angle
*Travel Speed Too Low * Increase Travel

Speed
* Insufficient Electrical Stickout * Increase Contact
Tip to Work Distance
INCOMPLETE PENETRATION

* Insufficient Amperage *Increase Amperage
* Improper Travel Angle * Use Less of a Drag angle
* Excessive Electrical Stickout * Decrease Contact Tip to

Work Piece Distance
* Weld Joint Too Narrow * Increase the Opening of
the Weld Joint
INCOMPLETE PENETRATION

* Insufficient Amperage *Increase Amperage
* Improper Travel Angle * Use Less of a Drag angle
* Excessive Electrical Stickout * Decrease Contact Tip to

Work Piece Distance
* Weld Joint Too Narrow * Increase the Opening of
the Weld Joint
DISTORTION
Distortion can pose a major problem, since the final product is not
the desired shape. The following pictures describe various types of
welding distortion
 Transverse shrinkage
◦ Shrinkage stresses leading
to a shortening of the
member across the toes of
the welded joint
DISTORTION
 Angular distortion
◦ Weld zone transverse
shrinkage stresses not in the
plane of the neutral axis
leading to rotation of one
member with respect to an
adjacent member.
DISTORTION
 Longitudinal shrinkage
◦ Shrinkage stresses leading
to a shortening of the
member along the principal
axis of the welded joint.
DISTORTION
Fillet distortion
Neutral axis distortion

DISTORTION
Proper Edge Preparation and Fit-up
 By making certain the edges are properly beveled and spacing is
adequate, you can restrict the effects of distortion.
 Additionally, you should use tack welds, especially on long joints. Tack
welds should be spaced at least 12 inches apart and run approximately
twice as long as the thickness of the weld
DISTORTION
Control the Heat Input

 The faster a weld is made, the less heat is absorbed by the base metal
 An intermittent weld (sometimes called a skip weld) is often used instead
of one continuous weld.
 When you are using an intermittent weld, a short weld is made at the
beginning of the joint. Next, you skip to the center of the seam and weld a
few inches.
 Then, you weld at the other end of the joint. Finally, you return to the end
of the first weld and repeat the cycle until the weld is finished.
DISTORTION
Preheat the Metal
 To control the forces of expansion and contraction, you preheat the
entire structure before welding.
 After the welding is complete, you allow the structure to cool slowly.
Limit the Number of Weld Passes

 You can keep distortion to a minimum by using as few weld passes as
possible.
 You should limit the number of weld passes to the number necessary
to meet the requirements of the job.
DISTORTION
Use Jigs and Fixtures
 Since holding the metal in a fixed position prevents excessive movements,
the use of jigs and fixtures can help prevent distortion.
 A jig or fixture is simply a device used to hold the metal rigidly in position
during the welding operation.
Allow for Distortion

 To reduce distortion, you angle the parts to be welded slightly in the
opposite direction in which the contraction takes place.
 When the metal cools, contraction forces pull the pieces back into
position.
DISTORTION
END OF LESSON ….. DJJ1043

DJJ 10033-Chapter 7.3

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DJJ 10033

Upon completion of this chapter, students should be

 Explain Gas Metal Arc Welding (GMAW)

Upon completion of this chapter, students should be

 Explain Gas Metal Arc Welding (GMAW)

• An arc welding process that uses an arc between

ALSO KNOWN AS:

• Cover all skin to prevent Radiation burns

• Welding filler electrode

Principle of GMAW Process

Min. Arc Control Max Arc Control

GMAW Process Parameters

Continuous welding at higher speeds Mechanical properties of the joint may

Thick & thin, both type of workpieces

Process can be easily mechanized Process variable are more

No flux: more visibility, cleanliness

Upon completion of this chapter, students should be

 Explain Gas Metal Arc Welding (GMAW)

► TIG welding uses a non-consumable tungsten

❑Fumes and gases can be hazardous to your

✓ Arc rays can burn eyes and skin; Noise can

• Magnetic fields from high currents can affect

Gas Cup Size

Manual Torch Movement

Butt Weld and

Aluminum weld parameters

Guide to selecting a tungsten electrode based on amperage range

❑ DCRP (Direct Current Reverse Polarity)

❑ ACHF (Alternating Current High Frequency)

Welds more metals and metal alloys

Good hand-eye coordination a

No sparks or spatter Brighter UV rays than other processes

Slower travel speeds than other

Upon completion of this chapter, students should be

 Explain Gas Metal Arc Welding (GMAW)

According to the American Society of Mechanical Engineers

* Insufficient Electrical Stickout * Increase Contact Tip to Work

* Spatter on Contact Tip * Remove Spatter

Possible Causes Corrective Actions

* Improper Travel Angle * Use a Push Angle

*Travel Speed Too Low * Increase Travel

Possible Causes Corrective Actions

* Improper Travel Angle * Use Less of a Drag angle

* Excessive Electrical Stickout * Decrease Contact Tip to

Possible Causes Corrective Actions

* Improper Travel Angle * Use Less of a Drag angle

* Excessive Electrical Stickout * Decrease Contact Tip to

Neutral axis distortion

Control the Heat Input

Limit the Number of Weld Passes

Allow for Distortion

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