Welding Inspector

Welding processes
Arc Energy & Heat Input
Arc Energy & Heat Input

Arc energy & heat input are just different way of

measuring the amount of heat generated by the
welding arc.

Effect
It effect many parameters i.e.
Joint properties
Pre heat values
Distortion etc
Arc Energy
Arc Energy: The amount of heat generated in the
welding arc per unit length of weld.

Units: Expressed in kilo Joules per millimetre

(kJ/mm).
Formula:

Arc energy (kJ/mm)= Volts x Amps

Travel speed(mm/s) x 1000
Legend:
Volts = Voltage
Amps= Amperage (Current)
Travel Speed= Speed of arc (mm/sec)
Heat Input
 Heat Input: The amount of energy supplied by the welding arc to
the work piece.

Units: Expressed in kilo Joules per millimetre (kJ/mm).

Formula:
Heat Input (kJ/mm)= Arc Energy x thermal Efficiency value

ASME IX : Heat Input = Arc Energy

BS EN ISO 15614 : Heat Input = Arc Energy x K Factor
 Arc Energy & Heat Input
What is the deference between arc energy & heat input ?

Arc Energy: The amount of heat generated in the

welding arc per unit length of weld.

Heat Input: The amount of energy going into the weld.

There would be a difference between these values as certain amount of

energy is lost across the arc.
Therefore, heat input would be lower depending on the welding process
being used. So, the type of welding process is added into heat input
calculation thermal efficiency value or K factor
Arc Energy & Heat Input

What are the Factors that influence arc energy / heat

input ?

•Current

•Voltage

•Travel Speed
 Arc Energy & Heat Input
Process Process K - Factor
No.
121 Submerged arc welding with wire (SAW) 1.0
111 Manual metal arc welding with covered electrodes(MMA)/ 0.8
Shielded metal arc welding (SMAW)
131 Metal inert gas (MIG)/ 0.8
Gas metal arc welding(GMAW/MIG)
135 Metal active gas (MAG)/ 0.8
Gas metal arc welding(GMAW/MAG)
136 Flux-cored wire metal arc welding with active gas shield(FCAW) 0.8

137 Flux-cored wire metal arc welding with inert gas shield (FCAW) 0.8

141 Tungsten inert gas (TIG) / 0.6

Gas Tungsten Arc Welding (GTAW)
Why Monitoring Heat Input

When impact requirements and/or hardness requirements are

specified, impact test shall be taken from the weld in the highest
heat input position and hardness tests shall be taken from the
weld in the lowest heat input position in order to qualify for all
positions

Typical HI = 1.0 ~ 3.5 KJ/mm

Arc Energy Calculation

Example:
A MAG weld is made and the following conditions were recorded.

•Arcvoltage = 20
•Welding amperage = 300
•Travelling Speed = 250 mm/min

What is Arc Energy And Heat Input ?

Arc Energy Calculation

Volts x Amps
AE (kj/mm) =
Travel Speed( mm/sec) x 1000

20 x 300
AE (kj/mm) =
(250 / 60) x 1000

6000
AE (kj/mm) =
4266

AE (kj/mm) = 1.4 kj / mm
Heat Input Calculation

Volts x Amps x K
HI (kj/mm) =
Travel Speed( mm/sec) x 1000

20 x 300 X 0.8 20 x 300 X 0.8 x 60

HI (kj/mm) = OR
(250 / 60) x 1000 250 x 1000

4800
HI (kj/mm) =
4266

HI (kj/mm) = 1.125 kj / mm
Arc Energy Calculation

Question:
What is the Arc Energy using process121 when the parameters
are
•Voltage = 20 V Current = 225 A T/S = 250 mm/min

a.1.3 kj / mm
b.1.08 kj / mm
c.0.57 kj / mm
d.3.2 kj / mm
Arc Energy Calculation

Question:
What is the Heat Input using TIG Process when the parameters
are
•Voltage = 20 V Current = 125 A T/S = 50 mm/min

a.2.42 kj / mm
b.1.02 kj / mm
c.1.80 kj / mm
d.0.8 kj / mm
Arc Energy Calculation

Question:
Which of the following is true?

a.Forthe same material, the heat input increase with decreasing

hydrogen levels.
b.As preheat increase, the heat input increases.
c.A higher heat input cannot eliminate preheat.
d.For a lower heat input, higher preheats are required