Welding

MIG/GMAW Welding
Metal Inert Gas
Gas Metal Arc Welding
Things that control the weld quality
● 25-35 PSI
● CO2 100%
● 75% mix (50% CO2 and 25% Argon)
Power settings
● Making an acceptable weld requires a balancing of the voltage and amperage
● If one or the other is set too high or too low, then poor penetration can result
● Wire feed speed knob: this knob will adjust the wire speed. A wire speed will require ,ore a,[s tp
keep it melting
● Voltage control knob: The bottom controls the voltage. The thicker the metal, the more required
voltage
Travel speed
● The arc needs to be kept right at the front of the weld pool
● Too fast and you can overrun the ability of the arc to melt the base metal which results in poor
fusion
● Too slow and the weld pool gets excessively large and the heat is directed into the weld pool
instead of the base metal resulting in poor fusion
Electrode Extension
● This is the distance from the contact tube to the arc measured along the wire
● Adjustments in this distance cause a change in the wire resistance and the weld bead
● Since GMAW is constant voltage, the amperage adjusts
● Gun tip closure to the weld metal means more amps and more heat
● Gun tip further from the weld metal means equal less amps and less heat
● Optimum space is ¼ inch
4 Types of Welds

● F = Fillet
● G = Groove
● B = Beads
● P = Plug
4 Weld Positions

1. Flat Position
2. Horizontal
3. Vertical
4. Overhead
Metallurgy
Metallurgy: Metal that changes with temperature
● A typical fusion welded joint varies in metallurgical structure due to melting and solidification with
very high temp gradient
● In general, a weld can be divided in four different zones as shown schematically in fur namely
● If metal overheats it can become ductile and loses its tapestry
● The metal in the heat affected zone becomes weaker ( the crystal structure of the metal changes
● Lowest temperature point of carbon steel transition is 1333 degrees ( steel is 0.8% carbon + iron)
Annealing
● Softening of the metal
● Metal is cooled slowly
● Able to mold or smith the metal
● Passed transition temp and cooled in a oven
Tempering
● Slightly soft metal
● Metal can be made into a tool for impact
Normalizing
● Heated above 1600 degrees and cooled in still air
● The metal goes back to its natural state
Hardening - Quenching
● Dunked into water or oil for cooling crystals tighten up and metal becomes hardened but brittle
SMAW Welding
SMAW Electrode Classification Example

E7018
● E indicates electrodes
● 70 indicates 70,000 PSI tensile strength
● 1 indicates use for welding in all position
● 8 indicates low hydrogen
SMAW Safety
● Fumes and Gases can be dangerous
● Keep your head out of the fumes
● Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases from your
breathing zone and the general area
● Electric Shock can kill- to receive a shock your body must touch the electrode and work or ground
at the same time
● Arc Rays can injure eyes
SMAW DCEN
● The american Welding Society defines Smaw as Shielded Metal Arc Welding
● SMAW:
● Is commonly known as stick welding
● DCEN : Direct Current electrode negative
SMAW PRocess
1. The Electrode
2. The Arc
3. The Weld Puddle
4. Shielding Gas
5. Solidified Weld
6. Slag
SMAW Process Variables
● Settings on the machine
● Polarity: AC, DC+, DC-
● Amperage Output
● Operator Controlled Variables
● Work Angle
● Travel Angle
● Arc Length
● Travel Speed
SMAW Angles & Measurements
● Work Angle = 90 Degrees
● Travel Angle= 20/30 degrees
● Arc Length = ⅛”
● Travel Speed : not to fast and not to slow
Smaw Beads
● 90-100 Volts
● 7018 sticks
TIG Welding

Tungsten Inert Gas

What is TIG?
● Tungsten Inert Gas
● GTAW - Gas Tungsten Arc Welding
● Tig welding uses a non-consumable tungsten or tungsten alloy electrode
● Filler metal is added by hand or by a cold wire feeder
● Inert shielding gas protects the weld snf tungsten
TIG Advantages
● High Quality and precision
● Pinpoint control
● Aesthetic weld beads
● No sparks or spatter
● No flux or slag
● No smoke or fumes
● Welds more metals and metal alloys than any other process
TIG Cons
● Slower travel speeds than other processes
● Lower filler metal deposition rates
● Hand-eye coordination is a required skill
● Brighter UV rays than other processes
● Equipment costs can be higher than other processes
TIG Parts
● Collet Body- Threads into the head of the torch and aligns the tungsten u=in the gas cup or nozzle
● Gas Cup(Nozzle)- Attached to the collet body, either threaded or held in place by friction fit.
Directs shielding gas flow weld area
● Collet- inserted into collet body and secures the tungsten electrode by threading and tightening
the back cap
● Back Cap- Secures tungsten by threading into torch head and tightening the collet against the
body
Inverter AC & DC Tungsten Selection
● Usea a sharpened. Tungsten alloy electrode for: Inverter Squarewave AC & DC WElding
● Tungsten alloys: Cerium, Lanthanum, Thorium
● DC is for STEEL
● AC is for ALLOYS
TIG Shielding Gases
● Argon