Professional Documents
Culture Documents
on
Welding
Mukesh Mishra
Topics
1. Introduction 1. Introduction
2. Welding Processes Welding is a Process of joining two materials
3. Welding Position & Joints
parmenently,
4. SMAW Process
5. SAW Process • with or with out using heat,
6. Main variables effect • with or without applying pressure,
7. Welding defects
• with or without using filler Materials.
8. Welding Consumables
9. Flux Management
10. Welding Procedure and
performance qualification
11. Remainder
Topics
1. Introduction
2. Welding Processes 2. Welding Processes
3. Welding Position & Joints
4. SMAW Process
5. SAW Process
6. Main variables effect
7. Welding defects
8. Welding Consumables
9. Flux Management
10. Welding Procedure and
performance qualification
11. Remainder
2. Welding Processes
SAW
Increasing deposition rate
High productivity
Flat position
MIG / MAG
(GMAW)
Productivity
Manual Easy automation
MMA Versatile
(SMAW)
TIG
(GTAW)
High speed
Laser Accurate
(LBW) Quality
2. Welding Processes
SMAW (Shielded metal Arc welding process)
+ Versatile
+ All kind of preparation
+ All positions
- Low deposition rate
butt
lap
tee
corner
edge
3.Welding Position & Joints
Single V Groove angle
Groove weld
Root face
Root gap
Double V
Groove weld
Groove angle
1G
3G
2G
4G
3.Welding Position & Joints
1G 2G
5G 6G
45°
3.Welding Position & Joints
Topics
1. Introduction
2. Welding Processes
3. Welding Position & Joints
4. SMAW Process 4. SMAW Process
5. SAW Process
6. Main variables effect
7. Welding defects
8. Welding Consumables
9. Flux Management
10. Welding Procedure and
performance qualification
11. Remainder
4.Shielded Metal Arc welding Process
4.Shielded Metal Arc welding Process
4.Shielded Metal Arc welding Process
Wire
Flux hopper
Power source
Wire
Process features
SAW involves formation of an arc between a
continuously-fed bare wire electrode and the
work piece.
Better wetting
DC + DC -
1/3 2/3
2/3 1/3
DC + Greater penetration DC -
DC + AC DC -
U U U
L1 L2 L3
6.Main Variables & Effect
Voltage :
Flashes
Wire and • Height too low
Porosity
contact tip
Suppression of the arc
Narrow bead
Flux • Height too deep
Poor slag removal
D1 D2
P1 P2
ESO
Flux
height
6.Main Variables & Effect
Wire Spacing I:
• Closing the distance between the 1st and 2nd arc can
increase penetration (It brings the arcs to a position where
they are acting almost as a single heat source).
“Hat-shaped” bead
Concave bead
6.Main Variables & Effect
The travel speed :
• Electrode angle and penetration
P0 P1
3 to 5 °
V V
P2 P3
Topics
1. Introduction
2. Welding Processes
3. Welding Position & Joints
4. SMAW Process
5. SAW Process
6. Main variables effect
7. Welding defects 7. Welding defects
8. Welding Consumables
9. Flux Management
10. Welding Procedure and
performance qualification
11. Remainder
7.Welding defects
• Porosity :
•Causes:
•Poor steel (high sulfur content)
•Organic contamination - oil
•Rusty joint or wire ( moisture bond in the rust)
•Contaminants in the flux (moisture, dirt and “mil scale)
•Electrode contamination under unusual storage
•Insufficient flux
•Tack welds
•Arc blow
•Trapped flux
7.Welding defects
Cracks:
•causes:
•Bead shape (see the “hat shaped” bead and the W / D
ratio)
•Steel analysis (see after)
•Hydrogen content of the weld metal (see after)
•Mechanical stress (see after)
•Arc blow
•Admixture
•Improper procedure (solidification cracking)
•Movement of joint
7.Welding defects
Slag:
•As slag is the residue of the flux coating in MMA welding, it is principally a deoxidation
product from the reaction between the flux, air and surface oxide.
•Slag may also become entrapped in cavities in multi-pass welds through excessive
undercut in the weld toe or the uneven surface profile of the preceding weld runs,
7.Welding defects
Lack of fusion:
•Causes
•The principal causes are too narrow a joint preparation,
• incorrect welding parameter settings,
• poor welder technique and magnetic arc blow.
•Insufficient cleaning of oily or scaled surfaces can also contribute to lack of
fusion.
•These types of imperfection are more likely to happen when welding in the
vertical position.
7. Welding Defects
Lack of penetration:
Causes
• Low current,
• High welding speed,
• Low voltage,
• Poor welding technique
7. Welding Defects
Undercut:
Causes
• High welding speed,
• Improper electrode angle,
• High welding current,
• Improper manipulation of electrodes
7. Welding defects
Weld Reinforcement:
Basicity of flux :
• 2 ovens
• Each oven has 7 trays
• Fresh flux & recycled flux within closed loop is used
• Unique system for handling is used
• System comprises of hoppers, holding tanks, dry air
inlet, recovery
• Temperature for holding can be set
9.Administration-Operating procedure
• Oven is loaded with trays filled for 2” height
• Oven is set for 3500C
• Time of loading is recorded
• Batch number is recorded
• After 3500C temperature is reached, time is
recorded
• Flux is held for 2 hours
• After 2 hours, time is recorded &
1. Either flux is removed & fed to hopper or
2. Temperature is reduced to 80-1000C
• Unloading time is recorded
• Next loading starts
9.Administration-OD welding station
• 2 ovens
• Each oven has 7 trays
• collected by suction, fed to feeding tank
Administration-Operating
procedure
• Shift :
• Welding engineer
• 2 for ID oven, 2 for OD oven , 4 for recycling of
used flux
Topics
1. Introduction
2. Welding Processes
3. Welding Position & Joints
4. SMAW Process
5. SAW Process
6. Main variables effect
7. Welding defects
8. Welding Consumables 10. Welding Procedure
9. Flux Management
10. Welding Procedure and and Performance
performance qualification
11. Remainder Qualification
Edge Preparation - Need
Poor penetration
Poor access at root
Poor strength
Good penetration
Good access at root
Good joint strength
Basic Joint Types
butt
lap
tee
corner
edge
Applicable Welds for Butt
joint
Square Groove weld V Groove weld
J Groove weld
Applicable Welds for Butt joint
Root face
Root gap
Double V
Groove weld
Groove angle
1G
3G
2G
4G
Welding Position – Groove
1G 2G
5G 6G
45°
Dilution
Area A
Area B
• P1 - P11 Steel
• P21 - P25 Al alloys etc.
•Removal of backing
•Change in Pipe diameter
•Change in P number
•Change in F Number
•Change in thickness of weld deposit
•Change in welding position
•Change in vertical welding
Welding Performance Qualification
11.Reminder
11.Reminder
Possibilities for Welding-Seam Monitoring by
Personnel in Submerged-Arc Welding Plants
•If these points are not complied with, this results in contamination of the
welding seam
by slag and pores and in irregularities in the arc and thus poorer seam
geometry and
penetration notches.
11.Reminder
B) Checking of Specified Production Data
•In principle, every operator must convince himself at the start of the shift
that the production data specified for the order in question (current
intensity, voltage, welding speed and welding-wire position) has been set
correctly.