1

TUGAS PPT WELDING

-01 GROUP A
1706037213 Alfian Novakusuma
1706021764 Girsha Cahya Maharini
1706022123 M. Murtaza Arbiansyah
1706025163 Claire Ditya Lousiana M
1706025434 Frida Zahara
1706037213 Natalin
SECTION
1.1
 +
Higher joint efficiency
+
Higher tightness of water and oil which
can preserve lifetime of the product
Comparing to + Less material consumption
riveting, welding + Applicable to thick plate
has various
_
advantages and Distortion may occur
_
disadvantages, Generates residual stress
_
List 3 each Brittle fracture might be occur due to
discontinuity because of particular
design and fabrication of weld structures
Match the welding process with the
energy sources in alphabetic above
1 MAG welding
2 Aluminothermic welding a. Electrical energy
3 Electron beam welding
4
Oxyfuel gas welding b. Mechanical energy
5
Friction stir welding
6
Laser welding c. Chemical energy
7
Manual metal arc welding (SMAW)
8
Explosion welding
d. light energy
9
TIG welding
10
Electroslag welding
SECTION
1.2
When two electric
conductors that are
positioned in Answer:
parallel carry the
same directional AAttractive force
currents, ..... can be
induced between
the conductors by
electromagnetic
force.
The arc column can
be deemed to be a
group of gaseous
parallel conductors. Answer:
Therefore,
electromagnetic B Contracts the cross-sectional
force can be area of the arc column
generated by the
arc currents. This
force, ......
The nature of an
arc that ignites Answer:
straightly in the
direction of the
AArc stiffness
electrode is
called, ......
With increases in Answer:
thermal pinch
effect and current ABecomes higher
density, the
pressure at center
of an arc
column, ......
The gas flow that is
induced by the Answer:
axial pressure
difference in the
CPlasma stream
central part of an
arc is called,....
SECTION
1.3
THE DIAGRAMS 12

1 Show the external characteristic

curve as a solid line in the figure
below.
Show the characteristics curve of
2
MMA welding as dotted line in the
same figure.
Show the locations of no-load voltage
3
as mark ‘o’ and the operation point of
arc as mark ‘.’
 Explain the control system of the wire feeding for
submerged arc welding using the power source with 13

droping characterictic

Since the area at the proximity of the working point of the power
source with drooping characteristic has almost the constant current
characteristic as shown in the Figure, the welding current i,e. the wire
melting rate hardly varies due to the variation in the arc length. However,
the feeding speed of the feed motor must be controlled in order to keep
the arc length constant during welding. Therefore, the arc voltage is fed
back to control the feeding speed of the feed motor. For example, when
the arc voltage becomes high due to the elongation of arc, the voltage is
conveyed to the feed motor, resulting in the faster wire feeding speed. On
the contrary, If the arc length comes shorter, the wire feeding speed
becomes slower, so that the arc length is kept constant, providing
favorable welding conditions.
 In the case of mechanized arc welding using the DC power
source with constant voltage (potential) characteristic, 14
constant speed wire feeding system is generally used.
Explain the reason.

In case the wire is fed at a high speed, it is difficult to make the control of wire speed because of the
feed motor inertia. However, in the case of the power source with constant voltage (potential)
characteristic, the arc length self regulation characteristic of the power source (ie the melting rate of the
wire increases due to the increase in welding current when the arc length gets shorter, keeping balance
with the wire feed rate) can be utilized, so that the suitable arc can be obtained even at constant rate of
wire feed. (See Figure)
 There is an AC arc welding power source. Its rated secondary current is
300 Amp and rated duty cycle is 40%. Evaluate by calculation on the 15
possibility of burning when this power source is used for welding with
current of 200 Amp and duty cycle of 60%.

When the welding power source with rated secondary current Ir and rated duty cycle a is
given, the acceptable duty cycle B at welding current I can be calculated by the following
equation
β=(IR²/IA²) x α >>> β=300²/200² x 40 = 90%
In other words, the power source can be used up to 90% of duty cycle at 200 Amp, so
that when used at the duty cycle of 60%, the power source can be safely used without
burning. The heat generated in the power source is due to the joule's heat. So, the
acceptable duty cycle is given by the ratio of the square of the rated current to the
square of the used current as shown in the above equation.
 Multiple choice 16

The control frequency of inverter type welding power sources is approximately a few kHz to a few
1 teh kHz
The control response of the inverter type welding power source is superior to that of the thyristor
2 type welding power sources
One of the features of the inverter type welding power sources is that the output of the welding
3 current waveform can be controlled to the changes in the arc condition. How is the control speed?
High speed
The size of the inverter type welding power sources is inversely proportional to the control
4 frequency.
The size of the inverter type welding power source is smaller than that of the thyristor type
5 welding power sources
 Describe the role of the voltage reducing device which
commonly is combined with the AC welding power source. 17
Then explain briefly the principle of voltage reducing
device
Role: The voltage reducing device protects the person doing welding work from the electric shock
1 by keeping the voltage between the holder and the parent material lower than the no-load voltage
(below 25V in the case of JIS standard) when the arc is not generated.

Principle When the arc is not generated, the safety voltage is regulated to be 25V or lower. When
2 the welder starts the arc, he/she makes the electrode contact to the parent material and then a
signal current flows. This flow is detected by the device and the main circuit of the power source is
switched on to give the no-load voltage within 0.06 seconds to ignite easily the arc. After igniting
the arc, the arc voltage is safe because it is around 25 to 35 volts. When the arc is distinguished,
the voltage becomes no-load voltage. However within about one second, the voltage becomes
initial safety voltage.
 List items of cautions in using a
moving vore type welding power 18

source.
To check that the movable iron core and the driving parts are not vibrating
1
abnormaly
To clean the interior of power source as needed because dust accumulation can
2
deteriorates the air-cooling function and the insulation performance of the coil
To lubricate the rotating part of the adjusting wheel and the sliding surfaces of
3
the movable iron core to prevent abrasion
To measure the insulation resistance and the grounding resistance of the coil
4
periodically checking for the requirements
5 To check the connecting cable for looseness
SECTION
1.4
 Answer:
Give one welding TIG welding. An arc is ignited between a
process in which tungsten electrode and a base material
the welding power under shielding of inert gas such as
source with argon or helium. Usually a filler wire or a
dropping rod is fed manually or automatically. The
characteristic is welding is achieved so that both filler
usually used. And material and base material are melted by
Then explain its the arc and mixed together. Both DC and
welding process AC power source may be used
briefly
 Answer:
Give one welding MIG Welding. Relatively fine diameter
process in which wire is fed as an electrode under
the welding source shielding of inert gas such as argon or
with constant helium. An arc is ignited between an
voltage (potential) electrode and a base material. The
characteristic is welding is achieved so that both wire
usually used. And electrode and base material are melted
then explain its by the arc and mixed together. Usually a
welding process solid wire and a DC power source are
briefly used.
Give one process of
gas-shielded metal arc Answer:
welding using the DC Welding process (MIG welding )
power source with
constant voltage Shielding gas (Ar or He)
characteristic. And Wire feeding (Constant speed feeding)
then give the kind of
Polarity of wire electrode (Electrode positive)
shielding gas, the
control of wire feeding
and the polarity of
electrode appleade in
that welding process
Give one process of non-
consumable electrode
gas-shielded arc welding Answer :
using the DC power Welding process ( TIG welding )
source with constant
current characteristic. - Shielding gas ( Ar, He)
And then give the kind of - Material of electrode ( Tungsten )
shielding gas, the - Polarity of wire electrode ( Electrode negative
material of electrode and
the polarity of electrode,
when the process is
applied on welding of
stainless steel.
 Arc Welding Process 24

Arc Welding Characteristic of Wire feeding Shielding gas

Process power source system
MMA welding Droping - -
(SMAW)
TIG welding Constamt current - Argon or Mixture
or Drooping argon and helium
MAG welding Constant voltage Constant speed Mixture of argon
control and helium
MIG welding Constant voltage Constant speed Argon or Mixture of
control argon and helium

SAW (thick wire Drooping Arc voltage -

electrode) feedback control
 MAG/MIG Welding 25

Items MAG welding MIG welding

Shielding gas CO2 or Ar 80% - CO2 20% Ar, He or mixture of Ar
and He
Possible metal transfer Globular or Short Globular, Splay o Short
mode circuiting transfer (for circuiting transfer
CO2), Globular, Splay or
Short circuiting transfer
( for Ar 80 % - CO2 20%)
Applicable base metal Mild steels, Low alloy Al or Ti
steels or stainless stelss
 Answer:
Regarding the 1 Current and polarity used regulary in TIG welding of
electric current stainless steels (direct current, electrode negative )

type and the 2 Current and polarity used regulary in TIG welding of
aluminium alloys (alternating current)

electrode 3
Current and polarity used regulary in CO2 gas
shielded arc welding of mild steels (direct current,
polarity used in electrode positive)

gas-shielded arc 4
Current and polarity used regulary in pulsed MAG
welding of high strength steels (direct current,
welding. electrode positive)
Current and polarity used regulary in MIG welding of
5 aluminium alloys (direct current, electrode positive)
 Describe MAG welding 27

1. Wire extension is defined as the distance between – the edge of the contact tip
and the edge of the welding wire where the arc is igniting
2. Melting rate of the wire is – determined by the heat supplied from the arc and
Joule heat of the current in the wire extension
3. In the case of using 100% CO2 gas as shielding and solid wire – arc voltage should
be increased when the welding penetration becomes too shallow
4. “Heat efficiency” is defined as - the ratio of the heat transferred in the base metal
to welding heat input
5. In MAG wekding with 100% gas shielding and smaller diameter wire, usually –
contant voltage (potential) characteristic power source is used
 Answer:
1 The arc condition – becomes quiet and
In MAG welding of stable
steels with a solid 2 The metal transfer mode – changes to the
wire, how does the globular transfer
change of the 3 Regarding the appearances of the weld
shielding gas from bead and the slag – the bead surface
becomes smooth, and the amount of slag
CO2 to a mixture of decreases
80% Ar + 20% CO2
Regarding spatter – the particle size of
affect the following 4
spatter becomes smaller
matters?
 Answer:
Advantages

List advantages and + In higher welding current, arc is stable and

metal transfer mode becomes spray type
disadvantages if
In higher welding current, the amount of
MAG welding +
spatter is low
shielded by a
+ Bead appearance is uniform and smooth
mixture gas of Ar
Disadvantages
and CO2 compared
with MAG welding - The penetration depth is small

shielded by CO2 -
The cost of shielding gas is high
Magnetic arc blow is apt to occur
Electrode negative
polarity is applied
Answer:
usually in TIG 1 The consumption of tungsten
welding of steels. electrode is small
List advantages of 2 The penetration is deep because of
electrode negative high arc concentration on the base
polarity compared metal
with electrode 3 Welding efficiency is high because
positive polarity in larger welding current is applicable
the case
 Answer:
List three features
1 Slag free welding available
of TIG welding
comparing with 2 Very easy in all position
MMA welding welding
3 Stable arc and less spatter
 Answer:
Advantages
+ Welding of uniform quality is possible
List three With higher deposition rate, the efficiency
advantage and + is higher
three Necessary weld metal deposition is less
+
disadvantages of Disadvantages
SAW comparing
with MMA welding - Equipment is large and complex
Confined to flat an horizontal position
- welding
To need edge preparation of higher
-
accuracy
SECTION
1.5
Which is an Answer:
operation to move
the welding torch DTeaching playback
on the weld line
without arc for
setting welding
data ?
Which is an
operation to Answer:
simulate welding COff-line teaching
on a display of
computer for
setting welding
data ?
Which is a sensor Answer:
to search the weld
line in welding BArc Sensor
using wire
electrode ?
Which is a sensor
to search the weld Answer:
line without AWire touch sensor
welding using wire
electrode ?
Which is a sensor Answer:
to search the arc
and the weld pool DOptical Sensor
in welding ?
 Explain the function of sensors for an arc welding robot
bellow. 39
1. Wire touch sensor
2. Arc sensor

1 Wire in MAG welding is used as a probe to detect the base metal. Wire as a sensor recognizes the
position of weld line by detecting a change in current or voltage when the welding wire tip touches
the base metal without arcing. The objects of the sensor are to detect the position of the groove,
edges (starting point and finishing point) and weld line

In gas metal arc welding, when an arc is oscillated across a welding groove, the welding current (or
2 the arc voltage) changes according to the change in arc length depending on the characteristics of
welding power source. An arc sensor detects a weld line (groove wall) with the change of welding
current (or arc voltage) by weaving torch
Which welding Answer:
process is widely
applied for arc BMAG Welding
welding robots
The movement Answer:
data and welding
parameters are BTeaching
preset to a robot.
Which is this
operation?
 Answer:
Which is specified
for arc welding in To equip a safety fence
accordance with Caround the robot
the industrial safety
and health law of
japan?
Which is the
function of the arc
Answer:
sensor equipped ATo track a welding seam by
with an arc welding utilizing the arc characteristics
robot?
Which is the
function of the Answer:
wire-touch sensor DTo detect the position of
equipped with an weld joint
arc welding robot?
SECTION
1.6
 Answer:
1. The powder cutting
process is a variation of D. Flame Cutting

2. The non-thermal cutting

process is A. Water Jet Cutting

3. The process unable to be

applied for cutting nonferrous D. Flame Cutting
metals such as aluminum
alloy is
C. Laser Cutting
4. The process most suitable
for the precision cutting of
sheet metal is B. Plasma Arc Cutting
5. The process utilized the arc
discharge is
 Answer:
1. A cutting process uses an
abrasive A. Water Jet Cutting

2. A cutting process uses an

assist gas C. Laser Cutting

3. A cutting process uses

iron powder mixed into the E. Powder Cutting
cutting gas flow

4. A cutting process uses a D. Flame Cutting

divergent nozzle to cut thick
paste
B. Plasma Arc Cutting
5. A cutting process uses a
special nozzle that restricts
the arc
 Why is flame (oxy-fuel gas) cutting
process difficult to cut stainless 48

steels?
As the percentage of alloying elements in steel increase, the oxy-fuel gas cutting
becomes less effective. Oxides of the alloy elements, such as Cr and Al, have higher
melting points than those of iron oxides and are refractory.
On the other hand, main iron oxides have melting points lower than the melting point
if iron, so the oxides become fluid and are easily removed from the cutting zone as the
molten slag.

Unlike iron oxides, some alloy’s oxides are not removed easily and disturb the
chemical reaction of Fe and O2 in the cutting zone
Effect of assist gas in
laser cutting carbon
steels

To improve cutting speed Name of the effective assist gas

To remove the metal melted Oxygen or air
or evaporated by laser beam
To protect a focusing lens
against flying metal particles
To remove laser plasma
(plume)
Laser Cutting compared with flame cutting
process
Advantages
Applicable to the materials Disadvantages
other than ferrous Applicable plate thickness is
materials limited
High accuracy cutting The equipment is complicated
Less cutting distortion and expensive

HAZ (heat affected zone) is Protection from laser beam

narrow radiation is necessary

For thin plate, the cutting

speed is high
 Plasma arc cutting process compared with
laser cutting process
Advantages Disadvantages
The process is able to cut A kerf width is larger
thicker plate Bevel angle is larger
Manual cutting operation is Dimensional accuracy on
possible cutting is poor
A cutting machine is cheaper Heat affected zone is wider
The process is unable to cut
nonmetallic materials
 Answer:
1. The water jet cutting process D. 100~400 Mpa
usually uses water pressure of …

2. There are two types of water jet

cutting processes. One is the type C. Metals
of using only water to cut. Another
is the type of using an abrasive
mixed in water. The latter process
is usually used for the cutting of…

3. For cutting more than 50 mm C. Flame Cutting

thick mild steel … process is
practically used

4. In plasma arc cutting, precaution

C. Generation of Series Arc
for … should be taken

5. Air-arc gouging process uses … B. A Carbon Electrode Coated with

Copper
 Answer:
1. Which cutting process is origin of A. flame cutting
powder cutting?

2. Which cutting process(es) use(s)

an abrasive for cutting metals? D. water jet cutting
3. Which cutting process(es) use(s)
an assist gas?
C. laser cutting
4. Which cutting process(es) can
cut stainless steel plates of 12mm
thickness?
C. powder cutting; D. water jet cutting
5. Which cutting process(es) can
cut aluminum alloy plates of 6mm
thickness?
B. plasma arc cutting; D. laser cutting
 Answer:
1. Which material can be cut by D. High Strength Steel
flame (oxy-fuel gas) cutting? D high
strength steel

2. Which material can be cut by A. Aluminium

plasma arc cutting? A. aluminum

3. Which material can be cut by

powder cutting B. stainless steel B. Stainless Steel
4. Which material can cut thicker
steel plate? A. flame cutting
A. Flame Cutting
5. Which gas is generally used as
the assist gas in the laser cutting of
carbon steel plates? C. oxygen
C. Oxygen
THANK YOU
PRESENTED BY GROUP A