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Arc Welding: Dr. N. Ramachandran, Nitc 1
Arc Welding: Dr. N. Ramachandran, Nitc 1
CONSISTANTLY IMPROVED
CALLED
ELECTRON IMPINGEMENT
AND
IONIC BOMBARDMENT
Dr. N. RAMACHANDRAN, NITC 11
ANODE+
HIGH HEAT
ELECTRON IMPINGEMENT
LOW HEAT
CATHODE -
1) Base Metal
(
Intense lacrimation
Blepharospasm
Photophobia
Fluorescein dye staining will reveal corneal ulcers
under blue light
Management
• Instill topical anaesthesia
• Inspect the cornea for any foreign body
• Patch the worse of the two eyes and prescribe analgesia
• Topical antibiotics in the form of eye drops or eye
ointment or both should be prescribed for prophylaxis
against infection
Dr. N. RAMACHANDRAN, NITC 34
Shielded Metal Arc Welding
What Is Welding ?
Process of joining metals / alloys
Forge Welding
Resistance Butt / Flash Butt / Stud
Welding
Resistance Spot Welding
Resistance Seam welding
Fusion Welding Process
Metal parts locally heated to melt along the joint.
Inverter- DC
Thyrester – DC
Rectifier – DC
Transformer - AC
Characteristic Of Power
Source
Manual welding Machine welding
Drooping – Cons. A Linear – Cons. V
V V
V1
Vertical Horizontal
V2
Curve Curve
V1
V2
A A
A1 A2 A1 A2
Electrode
Consumable
Stabilizes Arc
Prevents contamination of weld metal
Cleans the weld from unwanted impurities
Increases fluidity of molten metal
Generates inert gas shielding while metal
transfers
Function Of Flux In welding
Note! The thicker the material 5/16" 275 - 450 OVER 1/2"
to be welded, the higher the
current needed and the larger
the electrode needed Dr. N. RAMACHANDRAN, NITC 58
SOME ELECTRODE TYPES
• E6010 :
Used for all position welding using DCRP. It produces a deep
penetrating weld and works well on dirty,rusted, or painted metals
• E6011:
Same characteristics as of the E6010, but can be used with AC and
DC currents.
• E6013:
Used with AC and DC currents. It produces a medium penetrating
weld with a superior weld bead appearance.
• E7018:
Known as a low hydrogen electrode and can be used with AC or DC.
The coating on the electrode has a low moisture content that
reduces the introduction of hydrogen into the weld. The electrode
can produce welds of x-ray quality with medium penetration.
(This electrode must be kept dry. If wet, it must be dried in a rod oven
before use.)
Dr. N. RAMACHANDRAN, NITC 59
Why Baking?
Preheating
Post Heating or Dehydrogenation
Intermediate Stress leaving
Inter pass Temperature
Post Weld Heat Treatment
What Is Preheating?
Heating the base metal along the weld joint to a
predetermined minimum temperature immediately
before starting the weld.
Heating by Oxy fuel flame or electric resistant coil
Heating from opposite side of welding wherever
possible
Temperature to be verified by thermo chalks prior
to starting the weld
Why Preheating?
Preheating eliminates possible cracking of weld
and HAZ
Applicable to
Hardenable low alloy steels of all thickness
Carbon steels of thickness above 25 mm.
Restrained welds of all thickness
Heat In Put
Heat Effected Zone – HAZ
Dilution
Overlap In Weld Overlay
Tempering Bead
What Is Heat In Put In Welding?
The extent of heat energy generated in Joules per
unit length while making each weld bead.
“Heat In Put” is the Function of Welding Current,
Arc Voltage, And the Welding Speed
It is measured in Joules -
Heat In Put In Joules / mm
= (A x V x 60) ÷ Travel Speed in mm / min
Why Control On Heat in Put?
More Thickness
Less Dilution Less Thickness More Dilution
More Thickness
Less Dilution Less Thickness More Dilution
5 5
4 4
3 3
2
1
HAZ
Good Engineering Practices In
SMAW
Do Welding with properly baked electrodes
Basic coated CS electrodes to be baked to 250°C
to 300°C for two hours
Baked electrodes to be directly used on job or to
be retained in a hold over oven at 100°C to
150°C until use
Unused balance electrodes shall be returned to
baking oven
Good Engineering Practices In
SMAW