*ARC WELDING IN DETAIL*

PRESENTED BY:
210280119508 - SOHEN PATEL
210280119512 – RAHUL SINGH
210280119515 – NIKET BHARADIA
SEMESTER: 5
DIVISION: B
  ARC WELDING
• The welding in which the electric arc is produced to give heat for
the purpose of joining two surfaces is called electric arc welding.
• The joining is done by fusing of two or more pieces of metal
together by using the heat produced from an electric arc.
• The arc is like a flame of intense heat that is generated as the
electrical current passes through a highly resistant air gap.
• Many things around us are welded
Pipelines that bring fresh water
Towers that carry electricity to houses
Cars and buses that take people
• Arc welding continues to be used extensively in the
construction of steel structures and in industrial fabrication.
The process is used primarily to weld iron and steels but
aluminum, nickel and copper alloys can also be welded with
this method.
• It dominates other welding processes in the maintenance and
repair industry.
  METAL JOINING PROCESSES

• These processes form a permanent joint between metal parts is

known as metal joining process. Welding, Brazing & Soldering are
the some processes used for permanent joint. There are 3 basic
metal joining processes.
1. Welding
2. Brazing
3. Soldering
• Welding is a material joining process which produces coalescence
of materials by heating them to suitable temperatures with or
without the application of pressure and with or without the use of
filler material .
  CLASSIFICATION OF WELDING
Solid State Liquid State Welding Liquid -Solid
Welding State Welding
Friction Electrically heat generated Chemically Brazing
heat gen
Diffusion Arc Welding Resistance Gas Welding Soldering
Explosive Carbon arc Spot Thermit Braze Welding
Welding
Ultrasonic Submerged arc Seam
Forge Plasma arc Projection
TIG Percussion
MIG
Stud arc
  PRINCIPLE OF ARC
• A suitable gap is kept between the work and electrode
• A high current is passed through the circuit.
• The electric energy is converted into heat energy, producing a
temperature of 3000°C to 4000°C and at the centre of the arc, it is
6000°C to 7000°C.
• Thiss heat melts the edges to be welded and molten pool is
formed. On solidification the welding joint is obtained
• At the contact points through
which the current will flow,
when we bring the electrode in
contact with the work.
• When we withdraw the electrode
from the work, contact become lesser.
We know current density = current/current flow area.
• Due to lesser contact area current density increases, however the
current that is flowing is same.
• Now more amount of current will flow through the remaining
contact area and hence these contacts starts vibrating and
electrons are emitted by both electrode and the work.
• This electrons emitting is called Thermionic Emission.
• Negative electrons will be emitting from electrode and will be
attracted towards work. But in between due to the presence of air
it strikes to it. From air a electron with ions will emit which is called
secondary electron.
• Primary electrons will strike to the work while secondary electrons
will strike to the electrode.
• Now heat will be generated and arc generation take place.
• With increase in the air gap more air will come in between the
electrode and work and that primary electron will not able to
ionize that much amount of air, hence arc stops due to increase in
arc gap.
  WELD POOL AND HAZ
Weld pool: Weld pool commonly refers
to the dime-sized workable portion of a
weld where the base metal has reached its
melting point and is ready to be infused
with filler material. The weld pool is central
to the success of the welding process.

Heat Affected Zone:

A zone is formed between the melted
metal and the unaffected base metal called
the heat affected zone (HAZ). In this zone, the metal is not melted but
the heat has led to changes in the metal’s micro-structure.
  CURRENT IN ARC WELDING

• AC stands for alternating current, while DC stands for direct current. In

AC current, the direction of the flow alternates, while there is only one
direction in DC.
• Polarity is extremely important in welding because choosing the right
polarity is what affects the strength and quality of the weld. With the
wrong polarity, you could get lots of spatter, bad penetration, and lose
control of your welding arc.
• Three types of polarity
i. Direct current straight polarity
ii. Direct current Reverse polarity
iii. Alternating current polarity
• Alternating current polarity
• If the power source provides an AC current, then both straight and
reverse polarity will occur one after the other in each cycle. For half
the cycle, the electrode will be negative, and hence the base plates
are positive. In the other half, the base plates will be negative and the
electrode, positive. The number of cycles that occur within a second
depends on the frequency of the supply.

• Direct Current Electrode Positive (DCEP) polarity in arc welding

• With a direct current (DC) power supply, if the electrode is connected
to the positive terminal and the base plates to the negative terminal,
it is termed as Direct Current Electrode Positive – or Reverse Polarity.
• It is generally accepted as a rule that about two-thirds of the entire
arc heat is generated at the electrode while the rest is generated at
the base plate. This causes the electrode to melt quickly, and the
deposition rate for consumable electrodes increases.
• Pros of DCEP
It reduces distortion, residual stress, and complete cutting, so there is
better performance for welding-thin plates. It is also suitable for joining
metals with low melting points such as copper.
• Cons of DCEP
• DCEP has a shorter electrode life for non-consumable electrodes.
There is a high level of reinforcement if speed is not adjusted
properly.
• With insufficient melting and low penetration, you cannot fuse thick
plates or metals with high melting points together properly.
• Direct Current Electrode Negative (DCEN) polarity
• when the electrode is connected to the negative terminal and the
base plates to the positive one, it is termed Direct Current
Electrode Negative – or Straight Polarity. Electrons flow from the
electrode to the base plates.
• This causes more heat to be generated at the base plate than at the
electrode – again, the opposite of DCEP – and this means that the
metal deposition rate at the electrode reduces.
• There is no arc cleaning action in DCEN, so the chances of inclusion
defects rise. There is also a high distortion level and a high residual
stress generation.
  WELDING ELECTRODES
• The choice of electrode depends on a number of factors, including
The weld material
Welding position and
The desired weld properties.
Bare electrodes
Coated electrodes
The composition of the electrode core is generally similar and
sometimes identical to that of the base material. But even though a
number of feasible options exist, a slight difference in alloy
composition can strongly impact the properties of the resulting weld.
• Coated Electrodes
The electrode is coated in a metal mixture called flux, which gives off gases as it
decomposes to prevent
• Weld contamination
• Introduces deoxidizers to purify the weld
• Causes weld-protecting slag to form
• Improves the arc stability.
• Provides quality and alloying
• The arc welding electrodes can have different types of coating material
depending upon the welding power source, material to be welded, etc.
6 types of electrode coatings are mentioned below.
Cellulose type Rutile type Acid type
Acid rutile type Oxidizing type Basic type
Cellulose type coatings contain around 30% of organic materials like
wood floor, charcoal, cotton, cellulose, yarn, paper wrappings, gums
as deoxidizers, liquid sodium as a binder silicate.
The rutile type coated electrodes contain about 50% titanium
dioxide (TiO2).

Acid type electrodes contain the flux materials like iron, manganese
compound, silica, potassium silicate.
Acid rutile type have properties of acid type as well as rutile type
electrodes.
The oxidizing type electrodes contain a coating of iron oxide and
silicate with or without manganese oxides.
Basic type of coating has a high amount of calcium carbonate and
calcium fluoride
• Function of flux covering:

• Provides the gaseous shield to protect the molten metal from

deoxidation.
• Provide deoxidizers and fluxing agent to deoxidize and cleanse the
weld metal. The solid slag also protects the weld metal from
oxidation.
• Arc stabilization- Provide arc stabilizers which are compounds such
as potassium oxalate and lithium carbonate . They readily
decompose into ions in an arc, which increase electrical conductivity.
• Metal addition - Provide alloying elements (for composition control)
and metal powder (increase deposition rate) to the weld pool.
 DESIGNATION OF
ELECTRODES
  ARC WELDING POWER SUPPLIES

• The current to the arc welder can be supplied through line current
of by generator/alternator.
• The amount of heat is determined by the current flow (amps).
• The ease of starting and harshness of arc is determined by the
electrical potential (volts).
• Welding current adjustments include
Amperage
Voltage
Polarity
Waveform
  WELDING TRANSFORMERS
• There are mainly two types of transformers used
• Constant current
• Constant voltage

• Constant current type

• An arc welding power source that
maintains current at a relatively
constant level, regardless of fairly
large changes in voltage caused
by changes in arc length.
• This type of power sources is used with manual processes like Shielded
Metal Arc Welding (SMAW) and Gas Tungsten Metal Arc Welding
(GTAW), Plasma Arc Welding (PAW), as well as with some Submerged
Arc Welding (SAW) applications.
• Constant current power sources are sometimes called droopers
because the volt-ampere curve that demonstrates the relationship
between output voltage and output current is steep.

• Constant voltage type

• An arc welding power source that
Maintains voltage at a relatively
constant level, regardless of fairly large
changes in current caused by caused
by changes in arc length.
• This type of power source is used primarily with processes that
employ a continuously fed wire electrode. These include
Gas Metal Arc Welding (GMAW), Flux Cored Arc Welding (FCAW),
and Submerged Arc Welding (SAW).
• Constant voltage power sources have a flat volt-ampere
curve. See also Welding Power Source and Constant Current
Power Source.
  ARC WELDING EQUIPMENTS
Welding cables:
welding cables are made of aluminum or copper cables insulated with
either red, black, or blue color. It is used for connecting or transferring
current from the power source to the electrode holder and produces
arc to the work piece back to the power source.

Electrode holder:
The electrode holder is designed to
have the capacity of clipping the
electrode manually in order to
receive current and create the arc.
It is available in sizes that range
from 150 to 500 amps
Welding electrode: an electrode
is a piece of wire or rod of metal.
• Hand screen:
• hand screen is used for supervising weld bead and for protection of
the eye.
• Protective clothing:
• These types of arc welding equipment are used to protect the body
of the operator, protecting clothing include; apron, booth, goggles,
etc.
• Chipping hammer
• It is used for striking the slag from the weld bead region
  WELDING DEFECTS

• Weld Crack
• This is the most unwanted defect of all the other welding defects. Welding
cracks can be present at the surface, inside of the weld material or at the
heat affected zones.
• Hot Crack –
• It is more prominent during crystallization
of weld joints where the temperature can rise
more than 10,000-degree Celsius.
• Cold Crack –
• This type of crack occurs at the end of the welding process where the
temperature is quite low. Sometimes cold crack is visible several hours after
welding or even after few day
• Undercut
• When the base of metal melts away from
the weld zone, then a groove is formed
in the shape of a notch, then this type of
defect is known as Undercut. It reduces
the fatigue strength of the joint.
• Spatter
• When some metal drops are expelled
from the weld and remain stuck to the
surface, then this defect is known as Spatter.
• Porosity
Porosity in the condition in which
the gas or small bubbles gets trapped
in the welded zone.
• Overlap
When the weld face extends beyond
the weld toe, then this defect occurs.
In this condition the weld metal rolls and
forms an angle less than 90 degrees.
• Crater
• It occurs when the crater is not filled
before the arc is broken, which causes
the outer edges to cool faster than the crater.
This causes a stress and then crack is formed.
• Slag Inclusion
• If there is any slag in the weld, then
it affects the toughness and metal
weldability of the given material. This
decreases the structural performance of the
weld material. Slag is formed on the surface
of the weld or between the welding turns.
• Incomplete fusion
• Incomplete fusion occurs when the welder
does not accurately weld the material and
the metal pre solidifies which leads to a gap
which is not filled with the molten metal.
• Incomplete Penetration
These defects occur only in the butt welds
where the groove of the metal is not filled
completely. It is also called as incomplete
penetration defect.
  DIFFERENT ARC WELDING
PROCESSES
• Tungsten Inert Gas Welding
• Tungsten inert gas (TIG) welding is one type of arc welding method where we
use a non-consumable tungsten electrode, to weld the two metallic bodies. The
weld spot is protected from contamination by helium, argon and other inert
shielding gases.
• With this process, there is no longer a need for filler metal that is typically used
in the process of arc welding. This process makes this kind of weld highly
resistant to the effects of corrosion.
• Metal Inert Gas Welding
• This welding is same as Tig welding except a non-consumable electrode
replaced by consumable electrode wire. This process is automated or semi-
automated arc welding process in which inert gases are used as shielding gas
and a consumable wire electrode is used. This welding was developed to
welding aluminum or other non-ferrous metals in 1940. 
• Plasma Arc Welding (PAW)
• It is a liquid state welding process in which the metal-to-metal
joint forms in a molten state with the help of hot ionized gases
known as Plasma. These hot ionized gases are used to heat the
work plates, and the joint is created due to fusion. 
• Atomic Hydrogen Welding (AHW)
• It is a combination of electric are and gas welding technique. It is
a thermo-chemical arc welding process in which the work pieces
are joined by heat obtained on passing a stream of hydrogen
through an electric are struck between two tungsten electrodes.
• Submerged-arc welding (SAW)
• It is a common arc welding process that involves the formation of an
arc between a continuously fed electrode and the work piece. A
blanket of powdered flux generates a protective gas shield and a
slag (and may also be used to add alloying elements to the weld
pool) which protects the weld zone. A shielding gas is not required.

• Stud welding
• It is a complete one-step fastening system, using fasteners called
weld studs. Weld studs come in a variety of designs, threaded,
unthreaded, tapped, etc., sizes and shapes for a wide range of
applications. Stud welding, also known as “drawn arc stud welding”,
joins a stud and another piece of metal together by heating both
parts with an arc.
 SURPRISING FACTS ABOUT ARC WELDING

• Arc welding has origins dating back to the 1800s, during which a Russian
scientist named Vasily Petrov produced a controlled electric arc. 
• arc welding is usually performed with an arc temperature of roughly 10,000
degrees Fahrenheit. Of course, this still cooler than plasma torch welding,
which can reach up to 50,000 degrees Fahrenheit.
• Arc welding played a key role in World War I by streamlining the production
of battleships. Arc welding proved more effective and efficient, however,
allowing Great Britain to build more battleships in less time.
• There are roughly a half-dozen different types of arc welding, each of which
uses a different approach.
• The Egyptians used welding to build their amazing pyramids, and they used
it to create huge statues that served as representations of their gods.
 Y O U *
*TH AN K