BASIC WELDING

COMMON WELDING PROCESSES

WELDING TERMINOLOGY
WELD SYMBOLS / JOINT
CONFIGURATION
WELDER RELATED
WELDING SAFETY
 BASIC WELDING
Common Welding Processes

Listed below are some of the more common welding

processes used :

SMAW -Shielded Metal Arc Welding (stick)

GMAW -Gas Metal Arc Welding (mig)
GTAW -Gas Tungsten Arc Welding (tig)
SAW -Submerged Arc Welding
 BASIC WELDING
Common Welding Processes

SMAW- Shielded Metal Arc Welding uses the heat of an

electric arc between a covered metal electrode and the
work (pipe, plate, etc). Shielding comes from the
decomposition of the electrode flux coating. Filler is
supplied by the electrode core wire and covering (iron
powder and alloys).
This process is usually done manually. The basic
equipment is a power source, an electrode holder, a work
clamp and the electrode. Electrodes operate variously on
alternating current, direct current electrode positive
(reverse polarity) or direct current electrode negative
(straight polarity).
 BASIC WELDING
Common Welding Processes

SMAW welding metallurgy

Weld is strengthened by adding alloying elements and
by incorporating iron powder in the electrode
covering(flux). Some ingredients in the covering may
attract and hold moisture (a source of hydrogen) which
causes cracking in certain welds. A group of electrodes
specifically formulated to result in weld deposits having
very low levels of hydrogen are referred to as Low
Hydrogen electrodes. These have identification
numbers ending in 5,6 or 8. Once removed from
containers they require electrically heated storage in a
vented oven capable of holding the electrodes between
250 350 deg F. (Low hydrogen electrodes should be
stored in their original containers until ready for use)
 BASIC WELDING
Common Welding Processes

SMAW ELECTRODE IDENTIFICATION SYSTEM

POSITION

E X X X X
STRENGTH COATING / OPERATING
CHARACTERISTICS

Strength- Tensile strength (I.E. 70, or 60) 70,000 psi / 60,000 psi
Position: 1= all positions. 2= flat and horizontal fillet position only
Example: E-7018, E-6010
 BASIC WELDING
Common Welding Processes

SMAW limiting factors

All of the welding manipulations are controlled by
the welder, such as electrode inclination, arc
length and travel speed. The welder must set the
proper current and select polarity if direct current.
Discontinuities
Almost any discontinuity can be produced, but the
most common is porosity, and slag inclusions.
 BASIC WELDING
Common Welding Processes

GMAW- Gas Metal Arc Welding, sometimes call Mig

uses the heat of an electric arc between a continuous bare
wire filler metal electrode and the work. Shielding is
obtained entirely from an externally supplied inert gas
(argon or helium) or reactive gases (C02 o 02) or a
combination thereof. This process can be semi-automatic
or automatic. GMAW process deposits the weld metal in
the joint by one of the following modes: spray transfer,
globular transfer and short circuiting transfer.
 BASIC WELDING
Common Welding Processes

GMAW MODES:
Spray Transfer Spray transfer occurs with high current
and voltage combinations. Spray transfer mode best
defines the arc and the pool for the welder. Due to high
heat capacity this mode is best suited for flat and
horizontal welding.
Globular Transfer Occurs at low currents compared to
spray transfer. Low current at the tip produces large
irregular drops without much direction which results in
increased amounts of spatter compared to spray mode.
 BASIC WELDING
Common Welding Processes

GMAW MODES
Short Circuiting Transfer (GMAW-S) The short
circuiting mode is a rather cold process and its
misapplication may result in incomplete fusion. It
is mainly used for very light gauge sheet metal
welding. Most refineries and petrochemical plants
do not allow the short circuiting mode of transfer
in their welding specifications to weld on pressure
retaining equipment.
 BASIC WELDING
Common Welding Processes

GMAW Welding Chemistry

Shielded gases protect gas metal arc welds from the
atmosphere. Fluxes are not used in this process. All
deoxidizers and alloying elements are incorporated into the
electrode wire.
Limiting Factors
The semi-automatic features of gas metal arc welding
simplify the training of the welder and should make work
more consistent, however the short circuiting mode may
lead to incomplete fusion.
 BASIC WELDING
Common Welding Processes

GMAW ELECTRODE IDENTIFICATION CHART

CHEMICAL
STRENGTH COMPOSITION

ERXXS-X
ELECTRODE ROD SOLID
WIRE
 BASIC WELDING
Common Welding Processes

Discontinuities
GMAW may result in any of the common
discontinuities with the exception of slag inclusions.

Porosity which is caused by gas trapped in the weld, is

often the discontinuity found in this process.

Incomplete fusion is possible especially in welds made

in the short circuiting transfer mode.
 BASIC WELDING
Common Welding Processes

GTAW Gas Tungsten Arc Welding (TIG) uses

an electric arc between a non consumable
electrode (tungsten) and the work. Shielding is
obtained from an inert gas or inert gas mixture.
Filler metal is added as needed. Welds may be
made with or without filler metal as required.
The most significant feature in GTAW is that the
electrode (tungsten) used is not intended to be
consumed. Only the filler metal is consumed
 BASIC WELDING
Common Welding Processes

Welding Chemistry
The tungsten electrode contributes neither
deoxidation nor fluxing, so it is fortunate that the
melting is essentially slow and that most of the
gases can escape from the weld pool before it
freezes. The filler rod contains the needed
deoxidizers. The slow heating and lower
temperatures combined with slower cooling rates
in GTAW will result in improved weld metal and
heat affected zone mechanical properties.
 BASIC WELDING
Common Welding Processes

Limiting Factors
The outstanding factor of GTAW is the
exceptional cleanliness that can be obtained in the
weld, producing crack free welds in alloys that are
difficult to weld in other process. However the
limiting factor is the high skill level necessary to
produce high quality welds is acquired by long
experience in manipulating the electrode and
feeding the filler wire when used.
 BASIC WELDING
Common Welding Processes

Discontinuities
All of the common types of discontinuities are
possible with the exception of slag inclusions.
Porosity is a common discontinuity due to the
processes low tolerance for contamination.
Tungsten inclusions may also result from
accidental touching (dipping ) of tungsten into the
molten weld pool.
 WELDING TERMINOLOGY
LISTED BELOW IS SOME COMMON WELDING TERMS:
AIR ARC(ARC GOUGE) The process of removing metal by means
of a carbon arc rod (electrode) connected to a welding machine and air
BACKWELD The process of completely welding the one side of a
component, and then back grinding or back gouging the other side and
applying a weld from that side
BACKING WELD The process of applying a weld pass to the back
side of the weld to provide a backing. And then completely welding
out the opposite side
BACKING PLATE OR STRAP The installation of a plate, strip of
plate, usually of the same material as base metal to the back side of the
weldment to aid in welding up large root openings in a weldment
 WELDING TERMINOLOGY
Cap- The finished portion of the weld (last pass)
Consumable insert A type of spacer that is installed in
the root spacing of a pipe or plate to keep the specified root
opening and is made of the same material as the base
metal. This insert acts as the filler metal for the root and is
melted (consumed) with the welding process normally
with GTAW.
Discontinuity an imperfection in the weld
Defect a discontinuity of sufficient size, length, type that
will render that particular object unsuitable for intended
service base on a criteria in an applicable code
 WELDING TERMINOLOGY
Destructive testing- a sampling of the weld that is actually
taken from the weldment and is subjected to a bend,
tension, or other form of test that usually destroys the test
coupon.
Essential variables- are those which a change, is
considered to affect the mechanical properties of the
weldment and shall require requalification of the WPS
Filler metal- The consumable electrode that is used in most
welding processes to fill the weld groove
Flux- The coating on welding electrodes that when
decomposes during welding forming a shielding gas
around the weld.
 WELDING TERMINOLOGY
Heat Affected Zone (HAZ)- The portion of the base metal
that has not been melted, but whose mechanical properties
or microstructure have been altered by the heat of welding
and cutting
Preheat- the process of applying heat to a weldment before
welding. This process reduces the thermal gradients within
a weldment and slows down the cooling rates, resulting in
a more ductile structure with lower residual stress. Preheat
also aids in removing moisture and helps remove
hydrogen.
 WELDING TERMINOLOGY
Post Weld Heat (PWHT)- also known as stress relieving
in carbon and low alloy steels. The metals temperature is
raised to just below the lower transformation temperature
and held for a prescribed time and allowed to cool at a
controlled rate. This process is done to help eliminate the
residual stress in metals and to reduce the hardness of the
weld and adjacent HAZ after welding to back within
acceptable limits, thereby reducing the possibility of
cracking
Porosity- a discontinuity in a weld when gas is trapped in
the solidifying metal which is caused by gas released in the
welding process or gas released from chemical reactions
occurring during the welding process.
Repair any rework on a completed weld that requires re-
welding to correct a fault discovered by visual or non-
destructive testing and is beyond the standard limits of
acceptability
 WELDING TERMINOLOGY
Root Bead- The first or stringer bead that initially joins
two sections of pipe, plate or fitting
Welding Procedure Specification (WPS)- a written
procedure (recipe) prepared to provide direction for
making production welds to a code requirement. It is
supported by a PQR (procedure qualification record)
which is a record of actual variables used in the welding of
the test coupon.
Procedure Qualification Record (PQR) documentation of
what occurred during welding the test coupon and the test
results of the coupon
 JOINT CONFIGURATION
Butt Weld
1= Groove Face 3 6
2= Root Opening
4
3= Groove Angle
4= Root Face 5
5=Plate thickness
6=Bevel Angle 1 2
 JOINT CONFIGURATION
Root Opening A separation at the joint root between the
two work pieces
Root Face The portion of the groove face adjacent to the
joint root
Groove Face The surface of a joint member included in
the groove
Groove Angle The total included angle of the groove
between the two work places
Bevel Angle The angle formed between the prepared
edge of a member and a plane perpendicular to the surface
of the member
Groove weld size The joint penetration of a groove weld
Plate thickness The thickness of the base metals to be
welded
 JOINT CONFIGURATION
Parts of a butt weld

Weld Face Face or Weld

Toe of Weld Reinforcement
both side

Weld Root
 JOINT CONFIGURATION
Parts of a butt weld Weld Metal
Cap
Groove Faces

Base
Metal

Heat Affected
Zone (HAZ)
Root
 WELDING SYMBOL

Finish symbol Groove angle

Contour symbol
Root opening
Groove weld size F
B Length of weld
Depth of A
bevel O Pitch (center to center )
T R
S (E) H L-P Weld all around
Tail Other side
omitted symbol
Arrow side
when S
reference I
not used
D (N) Reference line
The weld symbol
E
both sides or one
side S
Arrow connecting
Number of spot, reference line to arrow
seam or plug welds side member of joint or
arrow side of joint
 WELDING SYMBOL
75 deg. groove angle

Examples: Single V Butt Weld

1/8
75 deg

75 deg
1/8 1/8 root
opening
 WELDING SYMBOL
Staggered intermittent fillet weld

(3/8) 3-10

(3/8) 3-10

10

3/8 Fillet weld side view

WELDING SYMBOL
Single V Groove

Double V Groove

Single Bevel Groove

Double Bevel Groove

 WELDER RELATED
A Welder Performance Qualification test is given to
determine the ability of the welder or welding operator to
make sound welds.
When a welder has not welded with a process for a period
of 6 months or more his qualification shall expire, unless
within the six month period prior to his expiration date, the
welder has welded using a manual or semiautomatic
welding process for that process for which he was
qualified. (Recommend to use a welder continuity sheet)
Or when there is specific reason to question his ability to
make sound welds.
 WELDER RELATED
Welder test positions for pipe
1G- Pipe is horizontal and rotated , welding flat on
or near top of pipe
2G- Pipe or tube is vertical and not rotated during
welding, welding is horizontal
5G- Pipe or tube is horizontal fixed, and not
rotatated, weld is vertical, flat and overhead
6G- Pipe is inclined fixed at a 45 deg angle and
not rotated during welding
 WELDER RELATED
Welder test positions for plate
1G- Plate is horizontal weld position is flat
2G- Plate is vertical axis of weld is horizontal
weld position is horizontal
3G- Plate is vertical and axis of weld is vertical
weld position is vertical
4G- Plate is horizontal weld position is overhead
 WELDER RELATED
Common Discontinuities
IP- or inadequate penetration without hi-low is defined as
the incomplete filling of the weld root. Inadequate
penetration due to hi-low is the condition that exists when
one edge of the root is exposed or un-bonded because the
adjacent pipe or fitting are misaligned.
Hi-Low- is the mismatch of either the root or the OD
surface of the pipe, plate or fittings
Slag Inclusion- is a non metallic solid entrapped in the
weld metal or between the weld metal and parent metal
Burn Thru- is defined as a portion of the root bead where
excessive penetration has caused the weld puddle to be
blown into the pipe
 WELDER RELATED
Common Discontinuities cont.
Concave Root a root bead that is properly fused to and
completely penetrates the sides of the pipe or plate wall
thickness along both sides but whose center is somewhat
below the the inside surface of the ID wall
Porosity- can be cluster, wormhole etc. Porosity is
entrapped gas pockets inside the weld
Undercut- A discontinuity at the edge or toe of the welds
where a groove is created by welding too hot or traveling
too fast during welding.
 WELDER RELATED
Tungsten inclusion- is cause when the welder accidentally
dips his tungsten electrode into the weld puddle, and the tip
of the tungsten electrode breaks off and is left un-fused in
the weld metal.
Incomplete fusion- due to cold lap is defined as an
imperfection between two adjacent weld beads or between
the weld metal and base metal that is not open to the
surface (condition where the two passes or base metal and
weld metal are not fused together)
 WELDING SAFETY

SAFETY IS AN IMPORTANT CONSIDERATION IN

ALL WELDING, CUTTING AND RELATED WORK
THE MOST IMPORTANT COMPONENT OF AN EFFECTIVE
WELDING SAFETY PROGRAM IS LEADERSHIP SUPPORT AND
DIRECTION. MANAGEMENT MUST CLEARLY STATE
OBJECTIVES AND SHOW ITS COMMITMENT TO WELDING
SAFETY
Management must be certain that only approved welding, cutting,
equipment are used. Such equipment includes torches, regulators,
welding machines, electrode holders, and personal protective devices.
Proper use and maintenance of the equipment must be taught
Personnel in areas next to welding and cutting must also be protected
from radiant energy and hot spatter
 WELDING SAFETY
Where arc welding or cutting is regularly performed next to painted
walls, the walls should be painted with a finish having a low
reflectivity of ultraviolet rays
Open flame, electric arcs are a ready source of ignition. The best
protection against fire is to do welding and cutting in specially
designated areas or enclosures made of non combustible materials
Welding helmets containing the appropriate filter plates must be used
by welders and nearby personnel when viewing an arc.
Sturdy shoes, boots and heavy clothing should be worn to protect the
body from flying sparks, spatter and radiation burns. (cuff less pants
and covered pockets are recommend
Durable leather gloves or other suitable material should be worn
Sparks or hot spatter in the ears can be serious, properly fitted , flame
resistant earplugs should be worn whenever such risk is present
Ear plugs should be worn when performing air arc gouging
 WELDING SAFETY
Personnel should be protected from fumes and gases
performed during welding, cutting etc. Protection from this
exposure is usually accomplished by adequate ventilation
Where exposure would exceed permissible limits, with
available ventilation, suitable respiratory protection must
be worn
Last, do not forget x-ray (gamma ray) radiation safety.
Obey all x-ray barrier signs. Do not go into these areas
when radiography is taking place (normally magenta and
yellow tape)

REMEMBER, WELDING SAFETY IS A VERY

IMPORTANT PART OF WELDING
 WELDING WRAP UP
This presentation was only a brief overview of
welding, and was intended to only give a general
understanding and familiarization of some of the
more common processes, safety concerns and
terms.
If you have any questions I will try to answer them
now, if I cannot I will research and look up. I can
be reached at ext. 6885