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Explosion welding
Consumable electrode Non consumable Other processes
electrode
Gas metal arc welding Laser beam welding
Gas tungsten arc welding
Shielded metal arc welding Thermit welding
Atomic hydrogen welding
Submerged arc welding Electron beam welding
Plasma arc welding
Flux cored arc welding
Electrogas welding
Electroslag welding
Definition of welding groups
• Arc welding A group of welding processes that produce
coalescence of work pieces by heating them with an arc. The
processes are used with or without the application of pressure and
with or without filler metal.
E7018
E indicates electrode
70 indicates 70,000 psi tensile strength
1 indicates use for welding in all positions
8 indicates low hydrogen
E7018-A1-H8R
Coating Materials -Partial List
Quality Issues
Discontinuities associated
with manual welding
process that utilize flux
for pool shielding
Slag inclusions
Lack of fusion
Other possible effects on
quality are porosity, and
hydrogen cracking
Shileded Metal Arc Welding
Limitations
Low Deposition Rates
Low Productivity
Operator Dependent
Other Limitations
Heat of welding too high for lead, tin, zinc, and their
alloys
Inadequate weld pool shielding for reactive metals such
as titanium, zirconium, tantalum, columbium
Gas Metal Arc Welding
ER - 70S - 6
Composition
Electrode 6 = high silicon
Solid Electrode
Rod (can be used
with GMAW) Minimum ultimate tensile
strength of the weld metal
Gas Metal Arc Welding
Shielding Gas
Shielding gas can affect
Weld bead shape
Arc heat, stability, and
starting
Surface tension
Ar He CO2 Drop size
Ar-He Puddle flow
Spatter
Gas Metal Arc Welding
GMAW Advantages
Deposition rates higher
than SMAW
Productivity higher than
SMAW with no slag
removal and continuous
welding
Easily automated
Gas Metal Arc Welding
Limitations
Equipment is more
expensive and complex
than SMAW
Process variants/metal
transfer mechanisms make
the process more complex
and the process window
more difficult to control
Restricted access
GMAW gun is larger than
SMAW holder
Flux-Cored Arc Welding
E70 T - 1
Electrode
Type Gas, Usability
Minimum UTS and Performance
70,000 psi
Flux Cored /Tubular
Position Electrode
Advantages
High deposition rates
Deeper penetration than
SMAW
High-quality
Less pre-cleaning than
GMAW
Slag covering helps with
larger out-of-position welds
Self-shielded FCAW is
draft tolerant.
Flux-Cored Arc Welding
Limitations
Slag must be removed
More smoke and fumes
than GMAW and SAW
Spatter
FCAW wire is more
expensive
Equipment is more
expensive and complex
than for SMAW
Submerged Arc Welding
F7A2-EM12K
F indicates flux
70-95 ksi UTS, 58 ksi minimum yield strength, 22% elongation
A - as welded; P - postweld heat treated
2 - minimum impact properties of 20 ft-lbs @ 20°F
E indicates electrode (EC - composite electrode)
M - medium manganese per AWS Specifications
12 - 0.12% nominal carbon content in electrode
K - produced from a heat of aluminum killed steel
Submerged Arc Welding
Advantages
High deposition rates
No arc flash or glare
Minimal smoke and fumes
Flux and wire added
separately - extra dimension of
control
Easily automated
Joints can be prepared with
narrow grooves
Can be used to weld carbon
steels, low alloy steels,
stainless steels, chromium-
molybdenum steels, nickel
base alloys
Submerged Arc Welding
Limitations
Flux obstructs view of
joint during welding
Flux is subject to
contaminationporosity
Normally not suitable for
thin material
Restricted to the flat
position for grooves - flat
and horizontal for fillets
Slag removal required
Flux handling equipment