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3 - Module 3-Final
3 - Module 3-Final
WELDING PROCESS
• Cutting
- results in the removal or separation of material.
1. Arc Welding
2. Solid-State Welding
3. Resistance Welding
4. Oxyfuel Gas Welding
5. Soldering
6. Brazing
7. Other Welding
Brazing Processes
• Torch Brazing
• Furnace Brazing
• Induction Brazing
• Resistance Brazing
• Dip Brazing
• Infrared Brazing
Cutting Processes
• Oxyfuel Cutting
• Air Carbon Arc Cutting
• Plasma Arc Cutting
• Mechanical Cutting
Brazing Processes
• Torch Brazing
• Furnace Brazing
• Induction Brazing
• Resistance Brazing
• Dip Brazing
• Infrared Brazing
Cutting Processes
• Oxyfuel Cutting
• Air Carbon Arc Cutting
• Plasma Arc Cutting
• Mechanical Cutting
8/16/2018
8/16/2018 AWS-CWI
AWS-CWI
Seminar
Seminar 77
WELDING PROCESSES
Electrode:
- a primary element of Shielded Metal Arc Welding
- it is made up of a metal core wire covered with a layer of granular
flux held in place by some type of bonding agent.
- SMAW electrodes used to weld low alloy steels may also have
alpha numeric suffix which is added to the standard designation
after a hyphen.
- The electrode and base metal are by the heat produced from the
welding arc created between the end of the electrode and the
workpiece when they brought close together.
- Limitations :
- Welding speed, the fact that the welder will periodically replaced
a consumed electrode.
- Porosity
the result of presence of moisture content or contamination of
the weld region.
- it can also occur using an arc length which is too high or from
the phenomenon “arc blow”
“ER” - designate the wire as being both and electrode and a filler metal rod.
“XX” - denotes the filler metal tensile strength of the deposited weld metal in
thousand of pounds per square inch (psi). Ex. “70” = 70,000 psi
“S” – stands for solid wire
“X” – dictate the operating characteristics as well as what properties are to
be expected from the deposited weld metal.
Note : the wire should must be kept clean and if allowed to remain
in the open , it may become contaminated with rust, oil, moisture , grinding
dust and other materials.
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GMAW Equipment
Types of Current – most of the gas arc welding is done using steady direct
current (DC). It can be accomplished in two ways which:
- almost used for all welding application of this process because its
gives better penetration than electrode negative
Power Supply – gas metal arc welding uses a constant voltage or constant
potential , power source. This is done using a pre-set value of voltage over
the range of welding currents.
1. Spray Transfer
- considered to be the hottest.
- is the best for heavier sections and full penetration weld joints,
as long as they can be positioned in the flat position.
- the cycle begins when the end of the electrodes tapers down to
a point . Small droplets are formed and electromagnetically
pinched off at the tapered point of the elctrode tip. The droplets
are smaller than the electrode and detach more rapidly than globular
- it is generally associated with higher amperage and voltage levels.
- it produces a very stable arc and produces the least amount of
spatter.
2. Globular Transfer
- the cycle begins when a droplet forms on the end of the
electrode wire. The molten metal droplet grows in size until it is
larger than the diameter of the electrode . The droplet then
detach from the end of the electrode and transfer across the arc
due to force of gravity.
- occurs at relatively low operating currents and voltages
- this mode of transfer is not suitable for many out of position
welding because of the large droplet size and dependence on
gravity to transfer the filler metal esp. in overhead position.
- the equipment required is more complex than the one used for SMAW
- It is very similar to gas metal arc welding in many ways except that
the electrode used is in tubular and contain a granular flux instead of
solid wire used in GMAW.
- the cycle begins when the tubular electrode being fed through the
contact tube of the gun to produce an arc between the electrode and
the work piece. A bead solidified weld metal is deposited covering a
layer of slag.
2 types of electrodes:
1. Self Shielded Electrodes – tubular electrode which does not require
external gas. They are designated by the suffixes 3, 4, 6, 7, 10, 11, 13.
- The electrode for flux cored arc welding consist of metal sheath surrounding
core of fluxing and/or alloying compound.
- Self Shielded electrodes contains more fluxing compound than gas shielded
electrodes.
1. to form a slag coating that floats on the surface and protects during
solidification.
2. To provide deoxidizers and scavengers which help purify the solid weld metal.
3. to produce arc stabilizers which produce a smooth welding arc.
4. to add alloying element to the weld metal to increase strength and improve
other properties of the weld
5. To provide shielding gas for self-shielded electrodes.
-
- The FCAW equipment is very similar to GMAW consisting of :
1. power source
2. controls
3. wire feeder
4. welding guns and welding cables
Power Source: the power source can be classified as either constant current or
constant voltage. In the constant voltage arc system , the arc is maintain at a
relatively constant level.
Types of Current – most of the gas arc welding is done using steady direct current
(DC). It can be accomplished in two ways which:
- metal transfer to most flux cored arc welding resembles a fine globular
transfer.
At low current the droplets tend to be larger than at higher current levels.
If the current is increase, the metal transfer characteristics will change.
The transfer is much more frequent and the droplets becomes small.
-It
uses shielding, obtained from gas or gas mixture which flows out from the
nozzle surrounding the electrode.
-This process may be used for welding of ferrous and nonferrous materials,
also it is an all position welding.
--
GTAW gas an arc which is clearly visible to the welder. No slag is produced
which might be entrapped in the weld
-- There is no filler metal carried across the arc , so there is no or little spatter
- The gas tungsten arc welding process uses the heat produced by an
between a nonconsumable tungsten electrode and the base metal.
The molten metal, heated weld zone and the electrode are shielded
from the atmosphere by an inert gas supplied through the torch.
-The shielding displaces the air, oxygen, nitrogen don not come in
contact with the molten metal.
-The intense heat develop by the arc melts the base metal and filler
metal to make a weld. As the molten metal cools , coalescence occurs
and the parts are joined. The resulting weld is smooth and uniform and
requires minimum finishing.
-Filler metal is not added when thinner materials , edge joints are
welded. This is known as autogenous welding .
- For thicker material filler rod is generally used.
-The filler metal in GTAW is not transferred across the arc , but is
melted by it.
--The weld metal solidifies behind the arc along the joint and
completes the process.
-
AWS Tungsten Electrode Classifications
Pure tungsten is quite often used for the welding of aluminum because
of its ability to form a “ball” end when heated. With a ball end instead
of a sharper point, there is a lower concentration of current which
reduces the possibility of damaging the tungsten.
- Inert shielding gas is used because it will not combine with metal but
will protect it from contaminants . The most common inert gases are
argon and helium which donot from a compound with other elements.
-Gas can have a considerable effect on welding. For best result , the
purity rating should 99.99+%.
-- Better weld puddle weld control in the overhead position and vertical
position
Copper +
Copper Alloys All DCEN Thoriated Ar, Ar-He
Thin Only AC Pure , Zorconimum Ar
Magnesium
Alloys All AC Pure, Zirconium Ar
Thin Only DCEP Zirconium, Thoriated Ar
Nickel +
Nickel Alloys All DCEN Thoriated Ar, Ar-He
Plain carbon
+ Low Alloy
Steel All DCEN Thoriated Ar, Ar-He
-The equipment for welding used for GTAW consist of a power supply ,
a welding cable, gas shielding system
-There are several items of optional equipment that are often used.
These include the following
-- water circulators
- It will make high quality welds in almost all metals and alloys.
-The arc and the weld pool are clearly visible to the welder.
-Because the filler metal does not cross the arc, the amount added is
not dependent on the weld current.
LIMITATIONS
-3. It is not very effective for welding of thick section because the
deposition rates are low.
-4. The arc requires protection from wind drafts which can blow the
stream of shielding gas away from the arc.
-
-The wire is fed in the weld zone much the same way as GMAW . The major
difference is in the shielding method. With submerged arc welding the
granular flux is distributed ahead of or around the wire elect rode to facilitate
the protection of the molten metal.
-As the welding progresses, in addition to the weld bead, there is a layer a
layer formed slag and still-granular flux covering the solidified weld metal .
-The flux should produce weld metal having the mechanical and
chemical properties necessary for the application
-it should be a controlling factor in producing the desired shapes of the
weld bead.
-It should meet the requirements at the lowest possible cost.
-Types of flux:
-1. Fuse flux- a mixture of silica, metal oxides, and portion of halide salt
1. Power Source
2. Wire Feed
3. Mechanism and Control
4. Welding torch
5. Cable assembly
6. Flux hopper
7. Feeding mechanism
3. High deposition rate. It can typically deposit weld metal more efficiently
than any of the more common processes.
4. The SAW process also has high operator appeal because of the lack of a
visible arc which allows the operator to control the welding without the
need for a filter lens and other heavy protective clothing.
5. Less smoke is generated than with some of the other processes.
6. Desirable for many applications is its ability to enetrate deeply.
1. it can only be done in a position where the flux can be supported in the
weld joint.
3. flux which covers the arc during welding , while it does a good job of
protecting the welder from the arc; it also prevents the welder from
seeing exactly where the arc is positioned with respect to the joint.
With a mechanized setup, it is advisable to track the entire length of the
joint without the arc or the flux to check for alignment. If the arc is not
properly directed, incomplete fusion can result.
INHERENT PROBLEMS :
- An additional and separate gas , shields the weld puddle from the
atmosphere
-
1. Both GTAW and PAW uses the same type of power source, but due to
the design of the torch, there is difference in he amount of heating and
penetration.
2. Both GTAW and PAW torches use tungsten electrodes for the creation of
arc. But the PAW torch has a copper orifice within the ceramic nozzle. There
is ionization of gas “plasma” which is forced through this orifice and past the
welding arc resulting in the constriction of the arc.
3. In PAW the this constriction causes the arc to be more concentrated and
more intense.
4. The GTAW arc is gentle mist setting, PAW arc would provide a
concentrated stream of water having a grater force.
Transferred Arc – the arc is created between the tungsten electrode and the
workpiece.
- Equipment for GTAW and PAW are almost identical. However additional
elements are necessary including the Plasma Control Console and
Plasma Gas. A constant power –current type DC power source.
Shielding Gas – Argon , and helium are popular shielding gas choice
Filler Metal – may or may not be used. It is normally used except when very
thin metal is to be welded. The composition of the filler metal should match the
base metal
- The keyhole moves along the joint melting the edges of the base metal
which then flow together and solidified after the welding arc passes.
Disadvantage of PAW:
Problems that may be encountered with this process are two types of metal
inclusions:
• ESW is used when very heavy sections are being joined. It is essentially
limited to the welding of carbon steels in thicknesses greater than ¾ in.
• Advantages of ESW:
Disadvantage of ESW:
Acetylene – is the only gas capable fuel gas capable of high enough
temperatures for effective welding.
Acetylene – exists in the cylinder dissolved in liquid acetone.
With OAW, the energy for welding is created by a flame, so this process is
considered to be a chemical welding method.
- RG – 45 or RG-60
“R” - stands for rod
“G” - Stands for gas “
“45” - relate to the minimum tensile strength of the weld deposit in
thousand of pound per square inch. Ex: 45= 45000 psi
Application
it is mainly used for the welding of thin steel sheet and small diameter
steel piping.
Applied also in maintenance situation.
1. Relatively inexpensive.
2. Can be made very portable.
3. N o electricity Required
Disadvantages
The high energy of the laser beam causes some of the metal at the joint to
vaporize, producing a “keyhole,” which is surrounded by molten metal.
The laser beam has a very small cross section and does not diverge, or
broaden, much. Thus, it can be transported over relatively long distances
through fiber optics and mirrors.
Laser device – is the main element for laser welding and cutting equipment
Laser- is an acronym for “light amplification by stimulated emission of of
radiation.
The laser beam has a very small cross section and does not diverge or
broaden much. Thus it can be transported over long distances through fiber
optics and mirrors.
The beam is focused to a very small spot size at the workpiece through the
use of either lenses or reflective type focusing. These provide the high level
of beam power density.
The laser beam produces a very narrow and deep weld bead.
1. Low overall heat input results in less grain growth in the heat-affected
zone and less workpiece distortion.
2. High depth-to-width ratios (on the order of 10:1) are attainable when
the weld is made in the keyhole welding mode.
3. Single pass laser welds have been made in materials up to 1-1/4 in.
(32 mm) thick.
4. The laser beam can be focused on a small area, permitting the joining
of thin, small, or closely spaced components.
5. A wide variety of materials can be welded, including combinations of
materials with dissimilar physical properties.
- Vacuum chamber
- Control s
- Electron Gun
1. Low overall heat input results in less grain growth in the heat-affected
zone and less workpiece
distortion.
2. High depth-to-width ratio (on the order of greater than 10:1) are
attainable when the weld is
made in the keyhole welding mode.
3. Single pass electron beam welds have been made in steels up to 4 in.
(102 mm) thick.
4. A high-purity environment (vacuum) for welding minimizes
contamination of the metal by oxygen
8/16/2018 AWS-CWI Seminar 74
and nitrogen.
EBW – Equipment
- Vacuum chamber
- Controls
- Electron Gun - heart of the electron beam welding
- Like laser beam welding , EBW is done in the “keyhole”, mode which
produces a very deep and narrow weld beads.
1. Low overall heat input results in less grain growth in the HAZ and less
piece distortion.
5. Rapid travel speeds are possible because of the high melting rates
associated with this concentrated heat source.
8. The focused beam of electrons has a relatively long depth of focus, which
will accommodate a broad range of work distances.
10. Dissimilar metals and metals with high thermal conductivity such as
copper can be welded.
4. The fast cooling rates can produce cracking and embrittlement in the
heat-affected zone and can trap porosity in the weld metal.
6. For high and medium vacuum welding, work chamber size must be large
enough to accommodate the assembly operation. The time needed to
evacuate the chamber will influence production costs.
- It is typically used for sheet metal applications, up to about 1/8 in. (3 mm)
thick. No filler metals or fluxes are used.
1.1 The electrode are typically cylindrical in shape, but ca have various
specification.
1.2 The two electrode apply force to hold the two pieces of sheet metal in
intimate contact.
1.3 Current is then pass through the electrode and the work pieces.
1.4 Resistance to the flow of current produces heat at the faying surfaces
forming a weld nugget.
2.1 The electrodes are typically rotating wheels between which the two
sheets pass.
2.2 Current and pressure are applied in a timed manner to produce a
continues seam weld.
3.1 When the two sheets are placed together , the current is
concentrated to pass through the projection at the faying surface.
3. 2 Large, flat electrodes are used on opposite sides of the sheet.
1. Welding Current
2. Welding Time
3. Electrode Force
- the heat applied is only sufficient for the melting of the filler metal.
When properly applied, the braze joint can develop a strength equal to
or greater than the base metal
2. Once the part is are cleaned and fitted together, heat is applied.
3. Heat the part above the melting point of the filler materials.
4. The filler metal will be drawn into the joint when placed in contact
through capillary action.
Disadvantages of Brazing:
Cutting Processes
- The equipment used for OAW is essentially the same for OFC, the only
difference is the welding tip and is now cutting attachment and includes
an additional lever or valve to turn on the cutting oxygen.
- The cutting tip which is attached at the end of the torch is consists of
series of holes around where the oxyfuel gas mixture flows to provide
preheat.
Advantages of OFC:
Disadvantages of OFC:
Air Carbon Arc Cutting (CAC-A) – This process uses a carbon electrode to
create an arc for heating, along with a high pressure stream of compressed
air to mechanically remove the molten metal.
Operation:
To cut a metal , the carbon electrode is brought close to the work to create
an arc. Once the arc melts the metal. The stream of compressed air is
initiated and blows away the molten metal to produce gouge or cut.
Any nonflammable gas could be used but compressed air is available and far
the least expensive.
Disadvantages of CAC-A:
Plasma cutting is a process that is used to cut steel and other metals (or
sometimes other materials) using a plasma torch. The process uses a high
temperature, high velocity stream of ionized gas to melt and blow metal
from the line of cut.
PAC Operation
Operation:
To cut a metal ,similar to PAW operation, but the arc is even more
constricted, with the plasma temperature so high that the arc can cut any
metal.
1. In this process, an inert gas (in some units, compressed air) is blown at
high speed out of a nozzle
2. At the same time an electrical arc is formed through that gas from the
nozzle to the surface being cut, turning some of that gas to plasma.
3. The plasma is sufficiently hot to melt the metal being cut and moves
sufficiently fast to blow molten metal away from the cut.
- The equipment requirements are similar to the one used in welding , but the
power required is much higher than the one used in welding.
- The transferred arc torch is used because of the increased heating of the
base .
Advantages of PAC:
Disadvantages of PAC:
Disadvantages of CAC-A: