Fusion Welding Processes Welding Processes

Arc Welding

• MDP 252
Electric Arc Welding -- Welding Processes

Definition of Arc WeldingProcesses

❑ Arc welding processes use an electric arc as a
heat source to melt metal.
❑ The arc is struck between
an electrode and the workpiece
to be joined.
❑ The electrode can consist of
consumable wire or rod, or may be a non-
consumable tungsten electrode.
❑ The process can be manual, mechanized, or
automated.
❑ The electrode can move along the work or
remain stationary while
the workpiece itself is moved.
❑ A flux or shielding gas is employed to protect
the molten metal from atmosphere.
Electric Arc Welding -- Welding Processes

Electric Arc Welding

Fusion Welding Processes Welding Processes

Consumable Electrode
SMAW – Shielded Metal Arc Welding
GMAW – Gas Metal Arc Welding

SAW – Submerged Arc Welding

Non-Consumable Electrode
GTAW – Gas Tungsten Arc Welding
PAW – Plasma Arc Welding

High Energy Beam

Electron Beam Welding
Laser Beam Welding
SMAW – Shielded Metal Arc Welding Welding Processes

• Consumable electrode
• Flux coated rod
• Flux produces protective gas around weld pool
• Slag keeps oxygen off weld bead during cooling

• General purpose welding—widely used

Power... Current I (50 - 300 amps)
• Thicknesses 1/8” – 3/4” Voltage V (15 - 45 volts)
• Portable
Power = VI  10 kW
Electric Arc Welding -- Polarity Welding Processes

Shielded Metal Arc Welding

SMAW
Electric Arc Welding -- Welding Processes

SMAW Process

Identify all the above segments for the SMAW process,

describe the function of each segment, and determine if any
safety aspects exist.
 SMAW Process
Let’s take a little closer look at the SMAW
process… Electrode
1 1
Travel direction

ShieldingGas
4

Slag
6 Slag
6
Weld Puddle 3
3 Weld Puddle 2 Arc
2 Arc

5 Solidified Weld Metal

5 Solidified WeldMetal
Electric Arc Welding -- Welding Processes

SMAW Key Parts

• Electrode Holder: Also known as the “stinger” Handle-
like tool that holds the electrode while welding.
– Never hold this part with your bare hand while welding.
• Ground Connection: Also known as the “workpiece
connection clamp” that connects to the work to
complete the electrical circuit
• Power Source: Where the welder plugs into
• Amperage Scale: Determines the amount of “heat” or
power the welder will operate at.
• Polarity Switch: Setting that determines how the
electrons will flow during the welding process.
Electric Arc Welding -- Welding Processes

SMAW Welding Circuit

• Current flows through the electrode cable, to the electrode
holder, through the electrode, and across the arc
• On the work side of the arc, the current flows through the
base material to the work clamp and back to the welding
machine
Electric Arc Welding -- Welding Processes

The Electrode
What is it?
• Is a consumable - it gets melted during the welding process
• Is composed of two parts
– Core Rod (Metal Filler)
▪ Carries welding current
▪ Becomes part of the weld
– Flux Coating
▪ Produces a shielding gas
▪ Can provide additional filler
▪ Forms a slag
Electric Arc Welding -- Welding Processes

AWS Classification
of SMAW Electrodes
E70XX
Electrode
Tensile in Ksi
Welding Position:
1 = All Position, 2 = Flat & Horizontal
Type of Current and Coating
Electric Arc Welding -- Welding Processes
Electrode
Classification
•Electrodes are classified
by a numbering system
•E6013
oE = Electrode
o60 or first two
numbers = Tensile
strength (thousands
of pounds
o1 or third number
= Welding position
o3 or fourth number Pictured above are E-7018 electrodes. Identify
= Welding current what the tensile strength is for this electrode.
type and depth of
weld penetration.
Electric Arc Welding -- Welding Processes
Electrode
Classification
Third Digit
•Third Digit
E_ _ 1 _ = Usable in
all directions
E_ _ 2 _ = Usable in
flat and horizontal
positions only
E_ _ 4 _ = Usable
for vertical down Pictured above are E-6011 electrodes. Identify
only what each digit resembles up to the third digit.
Electrode
Classification
Fourth Digit
•Fourth Digit
E_ _ _ 0 = DC reverse polarity
only
E_ _ _ 1 = AC and DC reverse
polarity
E_ _ _ 2 = AC and DC straight
polarity
E_ _ _ 3 = AC and DC
E_ _ _ 4 = AC and DC
E_ _ _ 5 = DC reverse polarity
E_ _ _ 6 = AC and DC reverse Pictured above are E-6013 electrodes. Identify
polarity what each digit resembles.
E_ _ _ 8 = AC and DC reverse
polarity
DCEN/DCSP and DCEP/DCRP
Direct Current Straight Polarity (DCSP) or Direct Current Electrode Negative (DCEN):

It occurs when the electrode is connected with the negative terminal of the power
source and base metals are connected with the positive terminal.

DCSP polarity, an electron avalanche is liberated from the electrode and flows
towards the base plates.

Due to sufficient potential difference, electrons are accelerated between the

electrode and base metals, finally striking the base metal surface at a very high
velocity. Upon striking, the kinetic energy of the electrons is converted into
thermal energy and thus immense heat is generated in the vicinity of the base
plate surface. As a thumb rule, it is considered that about 66% of the total arc heat
is generated on the base metal surface, while the rest of the heat is generated at
the electrode surface.

This helps in the quick melting of the base plates and thus deeper penetration can
be achieved easily. However, the filler metal deposition rate reduces due to less
heat near electrodes, especially in consumable electrode-based welding.

Also, the cleaning of the surface is less.

Direct Current Reverse Polarity (DCRP) or Direct Current Electrode Positive
(DCEP):

Here the base metals are connected with the negative terminal of the
power source, while the electrode is connected with the positive terminal.

Thus electrons are emitted from the base plates and flow towards the
electrode. Accordingly, the majority of the arc heat is generated at the
electrode surface, while less heat is generated on the base metal’s surface.
This leads to a higher filler deposition rate (with consumable electrodes).

Insufficient fusion of the base metal may be noticed due to lack of heat.
However, when the avalanche of electrons is liberated from the base plate,
the dirt and oxide layers on the base metals get ruptured.

This phenomenon is also termed an arc-cleaning action. This is beneficial

as it inherently removes contaminated particles from the faying surfaces
and thus helps in achieving defect-free weld beads.
Electric Arc Welding -- Polarity Welding Processes

The Arc
•An arc occurs when the electrode comes
in contact with the work-piece and
completes the circuit … like turning on a
light!

•The electric arc is established in the space

between the end of the electrode and the
work

•The arc reaches temperatures of 10,000°F

which melts the electrode and base
material

•Don’t look at the arc without proper eye

protection.

•Wear proper body protection. The UV

rays will cause bodily harm.
Arc burning off the electrode
Electric Arc Welding -- Polarity Welding Processes

Weld Puddle
•As the core rod, flux
coating, and work pieces
heat up and melt, they
form a pool of molten
material called a weld
puddle
•The weld puddle is
what a welder watches
and manipulates while
welding
•Don’t touch the hot
puddle!!! The metal is
hot!!!
Electric Arc Welding -- Polarity Welding Processes

Shielding Gas
•A shielding gas is Shielding Gas
formed when the flux
coating melts.
•This protects the weld
puddle from the
atmosphere preventing
contamination during
the molten state
•Don’t touch the
metal!!! The metal is
hot!!!
•Shielding gas can cause
bodily harm. Be sure The shielding gas protects the molten puddle
proper ventilation is from the atmosphere while stabilizing the arc
being used.
Electric Arc Welding -- Polarity Welding Processes
Solidified
Weldment
•As the molten weld
puddle solidifies, it
forms a joint or
connection between
two pieces of base
material
•When done properly on
steel, it results in a weld
stronger than the
surrounding base metal
•Don’t touch the
metal!!! The metal is
hot!!!
 Warnings
• Welding can be safe when proper measures
are taken to protect yourself and others from
potential hazards.
• Understand and follow all warning labels
found on equipment and with all
consumables.
 Potential Hazards
• Protect yourself and others from potential hazards
including:

– Fumes and Gases

– Electric Shock
– Arc Rays
– Fire and Explosion Hazards
– Noise
– Hot objects
– Welding Sparks
 Fumes and
Gases
•Welding fumes can be harmful
to the welder causing
implications such as:
oIrritation of the
respiratory tract
oMetal fume fever
oSlightly increase the risk
of lung cancer
•Use enough ventilation,
exhaust at the arc, or both, to
keep fumes and gases from
your breathing zone and the
general area
•Use a respirator if needed or
required by the process.
•The ventilation system must be
on while welding at all times.
 Electrical
Shock
•Electric shock can kill
•Do not touch live electrical
parts
Primary Voltage –208 -
240, 416 - 480 volt
input power
Secondary Voltage – 6
to 100 volts for welding
•Insulate yourself from work
and ground
•Follow all warnings on
welding equipment
•Wear insulated clothing
•Always shut off machinery
when done and roll the
cords up neatly
•Do not make repairs
yourself, alert your
instructor immediately!
U.V. Rays
•Welding will produce ultraviolet rays
that are harmful to the human eye and
skin. Proper protection is needed to
avoid bodily harm.
•Arc rays are ten times brighter than
the sun and can injure eyes and burn
skin
•Precaution must be taken to protect
your eyes and skin from UV radiation.
The welding arc is brighter than the
sun
• Wear correct eye and body protection
o10 shade helmet
oSafety Glasses under the
helmet
oGloves
oArm and Body Protection
➢ Jacket
➢ Shoulder Covers
➢ Coveralls
 Fire Hazards and Material Safety
• Welding sparks can cause fires and explosions
• Sparks and spatter from the welding arc can spray up
to 35 feet from your work
• Flammable materials should be removed from the
welding area or shielded from sparks and spatter
• Always clean painted materials
• All welding booths should be cleaned thoroughly
• Have a fire extinguisher ready
• Inspect area for fires 30 minutes after welding
• Watch for sharp metal edges
• Cool all welded metal in the water tank.
 Ear Protection
• Loud noises can damage your hearing
• Keep loud noises at a safe level by using proper
hearing protection such as:
– Ear plugs
– Ear muffs
 Protective
Clothing
•Welders must wear protective
clothing for
oProtection from sparks,
spatter and UV radiation
oInsulation from electric
shock

• Protective clothing includes …

oFire-proof clothing without
rolled sleeves, cuffs or frays
oWork boots
oWelding gloves, shirts
jackets, bibs, and fire-proof
pants
oWelding cap, helmet and
safety glasses
oEar protection – ear plugs
and muffs
oMost importantly safety
glasses are to be worn at all
times in the shop
 Improper Protective Clothing
• List and describe
what is wrong
in this picture