ELECTRIC ARC
WELDING
Arc welding is a liquid state welding process
in which electrical energy produced by an
arc between an electrode and a workpiece is
converted into heat and used for fusion
welding
Schematic illustration of the shielded Arc welding
operations (also known as stick welding, because the
electrode is in the shape of a stick).
By the generation of intense heat, the
junctions of two metal pieces is melted and
mixed by an intermediate filler metal
Upon cooling and solidification, the resulting
welded joint metallurgically bonds the
former separate piece into a continuous
structural assembly
ARC THEORY
An electric current is in fact a flow of
electrons. If an air gap occurs in an
electrical circuit the flow of electrons is
obstructed and thus the current is cut off
By ionizing the air gap, however, the flow of
electrons is re-established and the circuit is
closed
On ionization, electrons become displaced
from their normal positions, i.e. electrons
which are not emitted from the atom change
their electron path
Some electrons change to a path with a lower
level of energy and the energy release
thereby appears as electromagnetic waves,
the wavelengths of which are within the
visible light
The extremely bright light that is thus
visible in an electrically conductive air gap
is called an electric arc
Shielded Metal Arc Welding
The electrode tip, weld puddle, arc and
adjacent areas of the workpiece are protected
from atmospheric contamination by gaseous
shield obtained from combustion and
decomposition of the flux covering
To start welding, an arc is struck by touching
the workpiece with the tip of the electrode,
much like striking a match
Schematic illustration of the shielded metal-arc
welding process. About 50% of all large-scale
industrial welding operations use this process.
ADVANTAGES
It takes less time to weld by electric arc
It can be used for joining almost all metals
It is less expensive
Portable equipment is also possible
It can be done by automatic machines
Joints in blind and restricted areas can be
welded
DISADVANTAGES
It is difficult to join thin sheets and alloys
It is not continuous
APPLICATIONS
Almost all metals and alloys can be arc
welded
Finds greater application in pipe welding
for chemical plants
Arc Welding Temperature 5000 Fo to
10,000 F
EQUIPMENT
1- Power Supply 2- Electrode
Holder
3- Ground Clamp 4- Electrical
Cables
5- Protective Shield
6- Chipping Hammer & Brush
POWER SUPPLY / WELDING
MACHINES
The magnitude of the current used directly
effects the melting rate, therefore for
effective welding a constant current type of
machine is required
It should minimize the sudden surges in
current
DC Generator
Driven by an electric motor or gasoline
engine
Welding can be done by straight or reverse
polarity
Polarity indicates the direction of flow of
current in a circuit
In SMAW the significance of polarity is the
amount of heat generated on base metal or
electrode
DCSP (Direct Current Straight
Polarity)
Electrode is negative and current flows
from electrode to the base metal
2/3 of the total heat is released at the base
metal and 1/3 at the electrode
Greater digging action in the base metal
takes place
Used for large deposit on heavy base metal
It is represented by DC -
DCRP (Direct Current Reverse
Polarity)
Electrode is positive and current flows from
base metal to the electrode
1/3 of the total heat is released at the base
metal and 2/3 being released at the
electrode
Electrode melts fast and give good
penetration
Digging in base metal is spreaded
Used for vertical and overhead welding (fast
cooling of base metal)
It is represented by DC+
AC Transformer
Supplies AC where power is taken directly
from a power supply
Freedom from Arc Blow
Rectifier
Essentially transformer but changes AC into DC
SIZE OF THE MACHINE
The size of welding machine is designated
according to their output rating of current
(ranges 150 – 1000 amperes)
The 60 % duty cycle means the machine can
be operated for 6 minutes out of every 10
minutes
ARC BLOW
This is peculiar to DC
The arc, instead of playing steadily, on one spot, is
deflected away from the point of welding due to
the influence of surrounding magnetic fields
created by welding current flowing in the work
It may often be minimized by shifting the earth
clamp to another location of the workpiece or by
simply twisting the electrode lead and the earth
lead loosely together
ARC WELDING TECHNIQUE
Welding position : Horizontal, Flat,
Vertical, and Overhead
Electrode Diameter : Equal to
thickness of the base metal
Types of Joints
Butt, Corner, Edge, Lap, and Tee
Current Setting : Depends on the thickness of
the base metal and the actual welding position
Starting the Arc : Arc is generated by
scratching the end of the electrode on the base
metal
As soon as the arc is started, the electrode is
immediately raised a distance equal to the
diameter of the electrode
Arc Length : This is equal to the diameter of
the electrode
A shorter arc is usually better for vertical
and overhead welding
Travel Speed : It is the rate at which the
electrode travels along the weld Seam
It is influenced by the skill of the welder,
position of weld, type of electrode, and the
required joint penetration
Crater Formation : As the arc comes in
contact with the base metal, a pool or pocket
is formed which is called crater
Electrode Position : The angular position of
the electrode has a direct influence in the
quality of the weld
Single and Multiple : A single pass involves
depositing one layer of Pass Welds weld
metal
On heavier plates two or more layers are
deposited for strength
Weaving the Electrode : Weaving is a
technique used to increase the width and
Volume of the weld
DISCONTINUTIES
Porosity : caused by trapped gases
It can be reduced by Proper selection of
electrodes, Proper cleaning and preventing
contaminants from entering the weld zone,
Slowing the welding speed
Slag Inclusions are compounds such as
oxides, fluxes
Incomplete Fusion produces poor weld beads
Electrode Classification
(for consumable arc-welding processes)
Tensile Strength (in ksi)
Of the deposited weld metal
EXXXX Type of Covering and
current characteristics
Electrode Welding Position
ARC WELDING ELECTRODES
IDENTIFICATION
Next will be either a 4 or 5 digit number
stamped on the electrode.
The first two numbers of a 4 digit number
and the first 3 digits of a 5 digit number
indicate the minimum tensile strength (in
thousands of pounds per square inch) of the
weld that the rod will produce, stress
relieved.
ARC WELDING ELECTRODES
IDENTIFICATION
Examples would be as follows:
E60xx would have a tensile strength of
60,000 psi
E110XX would be 110,000 psi
The next two last digit indicates the position
the electrode can be used in.
ARC WELDING ELECTRODES
IDENTIFICATION
Examples would be as follows:
E60xx would have a tensile strength of 60,000
psi
E110XX would be 110,000 psi
The next to last digit indicates the position the
electrode can be used in.
EXX1X is for use in all positions
EXX2X is for use in flat and horizontal positions
EXX3X is for flat welding
ARC WELDING ELECTRODES
IDENTIFICATION
The last two digits together, indicate the
type of coating on the electrode and the
welding current the electrode can be used
with, i.e. polarity.
Such as:
DC - (Direct Current Straight Polarity)
DC + (Direct Current Reverse Polarity)
A.C.
ELECTRODES AND CURRENTS USED
EXX10 DC+ (DC reverse or DCRP) electrode positive.
EXX11 AC or DC- (DC straight or DCSP) electrode negative.
EXX12 AC or DC-
EXX13 AC, DC- or DC+
EXX14 AC, DC- or DC+
EXX15 DC+
EXX16 AC or DC+
EXX18 AC, DC- or DC+
EXX20 AC ,DC- or DC+
EXX24 AC, DC- or DC+
EXX27 AC, DC- or DC+
EXX28 AC or DC+
Example 1
EE6014
60 represents tensile strength of 60,000 psi
1 means can be used for all positions
14 means can be used for AC, or DC+ DC -
Example 2
EE11015
110 represents tensile strength of 110,000 psi
1 means can be used all positions
15 means can be used for DC+ only
You Tube Link
http://www.youtube.com/watch?v=Q
HF0sNHnttw
