similar or dissimilar metal with or without the application of heat and pressure Types of welding:
There are many types of welding used depending upon
their applications. Among all the welding some of the important and mostly used welding processes are: Shield metal arc welding(SMAW)
Gas shield metal arc welding(GSMAW)
Tungsten metal inert gas welding(TIG) Metal inert gas welding(MIG) Plasma arc welding(PAW) Sub merged arc welding etc SMAW Welding Shield metal arc welding is one of the mostly used welding processes. In this a consumable electrodes is used . An arc is created between the electrode and work piece by striking the electrode on work piece. This arc produces heat which is used for melting electrode and work pieces.
Shielding of the weld pool during metal transfer from
electrode tip to work piece from the atmosphere is done by the gases created during the decomposition of electrode under the heat. But this is not enough for shielding molten flux is used. It protects the pool and also slows down the cooling rate which is very important in getting good metallic properties in the weld bead. Parameters Influencing SMAW Welding For any welding processes there many welding parameters which influence the welding. So to get good welding we have to care of welding parameters. The parameters influencing the SMAW welding are
Power source Constant voltage Constant current
Open circuit voltage(OCT)
Chemical composition of Flux coatings
Cellulose electrode Rutile electrode Basic electrode Welding current Arc voltage Welding speed Electrode orientation Electrode diameter Polarity Direct current straight polarity(DCSP) Direct current reverse polarity(DCRP) Weld thermal cycle Cooling rates Residual stress Details of parameters and its effect on SMAW Welding Flux coating Chemical composition of the flux coating mainly influences : Arc stability Depth of penetration Metal deposition rate Positional welding capability
Flux composition serves the following purposes:
Induce easier arc starting The flux produces favourable gas, which gets ionized more easily, such that the electric arc is initiated very easily. Stabilize the arc Stability of the arc depends on the ionization potential of the gases produced by flux. Improves weld appearance and penetration Reduce spatters Types of electrodes based on flux covering: • Cellulosic – Flux rich in cellulose – Burn to produce hydrogen and carbon monoxide, provides shielding to the arc – Suitable with DC power and electrode positive polarity – presence of these gases in the arc with high ionization potential, this hydrogen and carbon monoxide, they have a high ionizing potential. It results in high arc voltage and therefore a high arc energy results in in deeply penetrating arc , higher melting rate which is favourable for high welding speeds. • A little slag is left on the welding deposit so there is less chances for slag inclusion ,also thin layer of slag produces less annealing effect. • Produces forceful arc and strong plasma jet which will help to weld in any position. The forceful arc will helps to transfer the metal against the gravity in overhead welding . • Deep penetration, suitable for all positional welding and good mechanical properties can obtained by cellulose flux coating electrode. • Hydrogen gas produced causes hydrogen embrittlement in the welding. RUTILE ELECTODE This contains the high proposition of titanium dioxide. The titanium dioxide is another name of rutile and classified as general purpose electrode. This titanium oxide promotes, easy ignition, smooth arc operation, and low spatter. Easy slag removal. It can be used with either polarity and in all positions . We can use either AC or DC. These electrodes are specially suitable for fillet welding in horizontal and vertical positions. Basic electrode • Basic electrodes, these contains high proportion of calcium carbonate and calcium fluoride. These are referred to as low hydrogen electrodes. • The slag more fluid than that in case of rutile coating. It is more fluidic slag. Slag is a fast freezing type, suitable for vertical and overhead position. • It makes them suitable for welding low-alloy steels susceptible to hydrogen heat affective zone cracking. • Resistance to hot cracking make suitable for welding thicker steel and steels with high carbon content. WELDING CURRENT it is one of the imp parameter in welding ,heat generated for melting the electrode depends on the welding current ,if the current increases the rate of melting also increases .To achieve higher welding speed the welding current have to be increased with speed simultaneously.
The welding current affects penetration and deposition rate. A
high current results in a higher and narrower weld, with a greater penetration depth. However, too high a welding current can result in undercuts, an uneven weld convexity, burn-through, thermal cracking, an inappropriate merging angle with the body material and undercutting. Welding voltage voltage is directly proportional to basically arc length, if the arc length increases voltage also increases and This cause widening of the welding arc and Width of the welding arc increases. when the arc length reduce . Voltage drop reduces, the arc becomes narrower. If the arc length become too small, arc may become so narrow, it becomes unstable. Metal transfer will not be proper. if the arc length increase too much. It becomes so wide. Again, it becomes unstable. So, that is how it affects arc length or arc voltage. Effect of voltage on weld bead: Welding speed Welding speed means movement of electrode during welding . Higher the welding speed lesser be the heat transfer, weld metal deposition and penetration . Too high welding speed leads to defects like incomplete filling of weld bead , undercut, slag inclusion etc. Low welding speed results in high metal deposition ,penetration and it also leads to the high thermal stress due to higher the heat transfer rate. Welding technique Welding technique is one of the important parameter which as effect on size of the weld bead and penetration .depending upon the angle and movement of the electrode there are 2 type of techniques are there . They are : Fore hand welding :Electrode point in direction of the travel is called as fore hand welding with lead angle . Back hand welding : electrode pointing against the direction of travel is called as back hand welding with drag angle Techniques of welding and there effects on the bead profile and penetration depth Electrode diameter Increase in the electrode diameter increases the Current carrying capacity which in turn increases the weld deposition. The effect of electrode dia in weld bead and penetration for constant amount of current: polarity • Polarity play an important role in DC power supply. High heat is produced at positve terminal and less will in negative terminal of the supply .There two types of polarities are there • Straight polarity : work piece positive and electrode negative. Used for thick plates • Reverse polarity : work piece negative and electrode positive. Used for thin plates Effect of polarity in weld bead and penetration Residual stress temperature distribution • From the above we can see that temperature distribution is not uniform due this non uniform volumetric expansion will take place due to this residual stress will develop in the work piece Cooling rates
Translated Copy of Translated Copy of (DIN 3996 - 2012-09) - Tragfähigkeitsberechnung Von Zylinder-Schneckengetrieben Mit Sich Rechtwinklig Kreuzenden Achsen
Oxy-Acetylene Welding and Cutting: Electric, Forge and Thermit Welding together with related methods and materials used in metal working and the oxygen process for removal of carbon