BASICS IN WELDING

CHAPTER 1

TYPES OF POWER SOURCES

&ITS CHARACTERISTICS
POWER SOURCES FOR WELDING

• TRANSFORMERS [AC]
• GENERATORS AND ALTERNATORS
• RECTIFIERS
WELDING TRANSFORMERS TAKES INPUT OF
HIGH VOLTAGE AC CURRENT AND PRODUCES
LOW VOLTAGE HIGH CURRENT WELDING
POWER.

TRANSFORMER CONSISTS OF PRIMARY COIL,

SECONDARY COIL & IRON CORE IN INTERFACE

THE PRINCIPLE IS INDUCTION MAGNETIC FIELD

INTO SECONDORY BY PRIMARY COIL.
DC MOTOR GENERATORS

• MOTOR GENERATORS PRODUCES DC

CURRENT.
• THIS TYPE GENERATORS ARE DRIVEN BY
ELECTRIC MOTORS,DIESEL
ENGINE,GASOLINE.
• DC GENERATOR WILL PRODUCE STABLE
ARC EVEN ANY ARC COLUMN VOLTAGE.
• BASIC DESIGN CHARACTERISTIC OF THIS
MACHINE DAV, PRINCIPLE IS OCV IS HIGH
DURING STARTING OF ARC THEN DROP.
RECTIFIERS

• RECTIFIED POWER SUPPLY IS AN ‘AC’ TRANSFORMER THAT

ONE WAY CURRENT DIODE/THYRISTER/PCB INSTALLED ON
ELECTRODE SIDE OF SECONDARY COIL, THIS MAKES THE
CURRENT TO FLOW ONLY ONE DIRECTION. DC CURRENT.

• RECTIFIERS AVAILABLE IN SINGLE PHASE AND THREE PHASE.

• SETTING DCRP OR DCSP MUCH EASIER THAN DC GENERATORS

• RECTIFIERS DOES NOT HAVE ANY MOVING PARTS EXCEPT FAN

FOR COOLING.

• REIIABILITY OF DC WELDING CURRENT PURELY DEPENDS

PERFORMANCE OF DIODE/THYRISTER/PCB.
CHARACTERISTICS OF WELDING CURRENT VOLTAGE

• DAV - DROPPING ARC VOLTAGE

• CAV – CONSTANT ARC VOLTAGE

• RAV – RISING ARC VOLTAGE

DAV
• THIS CHARACTERISTIC PROVIDES THE HIGHEST
POTENTIAL VOLTAGE-OCV,NO CURRENT IS FLOWING.

• WHEN ARC COLUMN STARTS, THE VOLTAGE DROPS TO

MINIMUM, WHICH ALLOWS FOR AMPS TO RISE RAPIDLY.

• WHEN LENGTH OF ARC COLUMN IS INCRESED THE

VOLTAGE INCREASES, THE AMPERAGE DEREASES
CONSIDERABLY.

• THIS CHARACTERISTIC IS SUITABLE FOR ‘ SMAW’

PROCESS.
CAV & RAV

• THE MODIFIED PATERN OF CAV, IS CALLED RAV.

• BOTH CAV AND RAV IS SUITABLE AUTOMATIC AND

SEMIAUTOMATIC WELDING PROCESS.

• CAV OR RAV REQUIRES TO SET VOLTAGE

REGARDLESS OF AMPERAGE.

• THIS IS APPLICABLE GMAW, SAW, AUTOMATIC

GTAW etc
WHAT IS ARC COLUMN ?

• LET US DISCUSS IN NEXT

CHAPTER

• CHAPTER 2 – SMAW PROCES

AND SMAW ELECTRODES

• THANK YOU by M.AYYAPPAN

WELCOME TO BASICS IN WELDING

CHAPTER 2

SMAW PROCESS AND SMAW

ELECTRODES
 LET US UNDERSTAND ABOUT
‘ARC COLUMN’
THE ARC COLUMN IS GENERATED BETWEEN AN ANODE,WHICH IS THE
POSITIVE POLE OF A ‘DC ‘ CURRENT POWER SUPPLY,AND THE
CATHODE, THE NEGATIVE POLE.
ARC COLUMN IS THAT THE IONS PASS FROM THE POSITIVE POLE TO THE
NEGATIVE POLE BECAUSE METAL IONS ARE POSITIVELY CHARGED
SO THEY ARE ATTRACTED TO THE NEGATIVE POLE.
IF ANODE AND CATHODE TOUCHED TOGETHER THEN DRAWN APART
AN AIR GAP IS ESTABLISHED, BECAUSE OF ATTRACTION IONS PASS
THROUGH THE AIR GAP DUE TO DISTURBANCE OF ATOMIC
STRUCTURE.
DUE TO THIS ATOMIC STRUCTURE UNBALANCE THE HEAT IS GENERATED
THE METAL START TO MELT ITSELF TO ACHIEVE ATOMIC BALANCE.
THREE AREAS OF ARC COLUMN 1. Cathode area, 2. Anode area, 3.Plasma area.
IN ADDITION TO HEAT, RADIATION RAYS,ULTRAVIOLET IS ALSO IS
GETTING GENERATED.
AWS CODING OF SMAW ELECTRODES

AWS E 7018
E stands for ‘ELECTRODE’

70 Indicates Minimum UTS of the undiluted weld metal

in ‘KSI’ Unit

1 Indicates ‘ Electrode Welding Position”

8 Indicates ‘ Type of Coating and Current Condition’