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Electric Arc Welding

Section 8
Unit 25 & 26
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ntroduction
A group of fusion welding processes that use an electric arc to
produce the heat required for melting the metal.
Advantages
nexpensive power source
Relatively inexpensive equipment
Welders use standard domestic current.
Portable equipment is available
Process is fast and reliable
Short learning curve
Equipment can be used for multiple functions
Electric arc is about 9,000
o
F
Electric arc welding

ntroduction-cont.
All fusion welding process have thee requirements.
Heat
Shielding
Filler metal
The method used to meet these three requirements is the
primary difference between arc welding processes.

Arc Welding Requirements

Process Heat Shielding
Filler
Material
SMAW
GMAW
Electric
Arc
Electric
Arc
nert Gas
(Flux)
nert Gas
(Cylinder)
Stick
Electrode
Wire
Electrode
n this class you will have the opportunity to use two (2) arc welding
processes:
SMAW
GMAW
5
Eight Additional Electric Arc Welding Processes
1. FCAW
2. GTAW
. SAW
. ESW
5. EGW
6. PAW
7. ASW
Flux Core Arc Welding
Gas Tungsten Arc Welding
Submerged Arc Welding
Electroslag Welding
Electrogas Welding
Plasma Arc Welding
Arc Stud Welding
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Safe Practices
Welders need protection from:
Arc's rays
Welding fumes
Sparks
Contact with hot metal
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Arc Welding Power Supplies
The current for arc welder can be supplied by line current or by
an alternator/generator.
The amount of heat is determined by the current flow (amps)
The ease of starting and harshness of the arc is determined by the
electrical potential (volts).
Welding current adjustments can include:
Amperage
Voltage
Polarity
High frequency current
Wave form
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Arc Welding Power Supplies--cont.
The type of current and the polarity of the welding current are one
of the differences between arc welding processes.
SMAW Constant current (CC), AC, DC+ or DC-
GMAW Constant voltage (CV) DC+ or DC-
GTAW Constant Current (CC) ), AC, DC+ or DC-
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Twelve (12) Considerations When Selecting
An Arc Welding Power Supply
1. Maximum Amperage
2. Duty cycle
. Amperage range
. Amperage adjustment
mechanism
5. nput power requirements
6. nitial cost and operating cost
7. Size and portability
8. Future needs for a power
supply
9. Available skills
10. Safety
11. Manufacturer's support
12. Open circuit voltage
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1: Amperage Output
The maximum output of the power supply
determines the thickness of metal that
can be welded before joint beveling is
required.
185 to 225 amps is a common size.
For an individual weld, the optimum
output amperage is determined by the
thickness of the metal, the type of joint,
welding position and type of electrode.
2: Duty cycle
The amount of continuous welding time
a power supply can be used is
determined by the duty cycle of the
power supply.
Duty cycle may be 100%, but usually is
less.
Duty cycle is based on a minute
interval.
Many power supplies have a sloping
duty cycle.
Note in the picture there is a circle
around the 75 amp setting. Why is it
there?
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What is the most likely outcome of
exceeding a power supply duty cycle?
12
Five Common Output Currents
For Arc Welding
1. AC (Alternating Current)
2. DC (Direct Current)
. ACHF (Alternating Current-High Frequency)
. PC (Pulsed Current)
5. Square wave
1
Arc Welding Electrical Terms
1. Electrical Circuit
2. Direct current (DC)
. Alternating current (AC)
. Ampere
5. Volt
6. Resistance
7. Ohms Law
8. Constant potential
9. Constant current
10. Voltage drop
11. Open circuit voltage
12. Arc voltage
1. Polarity
To understand how an electric arc welder works, you must understand
the following thirteen (1) electrical terms.
1
Electrical Circuit
An electrical circuit is a complete path
for electricity.
Establishing an arc completes an
electric circuit .
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Alternating Current
Alternating current: The type
of current where the flow of
electrons reverses direction
(polarity) at regular intervals.
Recommended current for
SMAW general purpose
electrodes and flat position.
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Direct Current
W Direct current: The type
of current where the flow
of electrons (polarity) is in
one direction.
W Controlling the polarity
allows the welder to
influence the location of
the heat.
W When the electrode is
positive (+) DCRP or
DCEP it will be slightly
hotter than the base
metal.
W When the base metal is positive (+),
DCSP or DCEN, the base metal will be
slightly hotter than the electrode.
W DC current is required for GMAW
W t is frequently used for SMAW
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Ampere
W Amperes: the unit of measure for current flow.
W One ampere is equal to 6.215098c10
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electrons passing by a point per second.
W Electricity passing through a resistance causes
heat.
W An air gap is a high resistance
W The greater the amperage flowing through the resistance (air
gap)--the greater the heat.
W The electrode also has resistance.
W Excessive amperage for the diameter of the electrode (current
density) over heats the electrode.
W nsufficient amperage for the diameter of electrode makes the
electrode hard to start.
What are the characteristics of an electrode that was used with
excessive current density?
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Voltage
Voltage is the measure of electromotive
force (Emf).
Emf is measured in units of volts
The voltage at the electrode for SMAW
determines the ease of starting and the
harshness of the arc.
Higher voltage = easier starting.
Starting voltage is called OCV.
Voltage is adjustable in dual control SMAW machines.
Changing the voltage adjusts a GMAW machine for different
metal thickness.
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Resistance
Def: that characteristic of a material that impedes the flow of an
electrical current.
Measured in units of Ohm's ( )
When an electrical current passes through a resistance heat
(BTU) is produced.
The amount of heat produced is a function of the amount of
resistance (Ohm's) and the amount of current (amps).
s the resistance adjustable in the SMAW process?
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Ohm's Law
Ohm's law states that, in an electrical
circuit, the current passing through a
material is directly proportional to the
potential difference.
Commonly expressed as:

=
E
R

E = R
Ohm's law also be used to teach a
principle of electrical safety.
Amperage is the harmful portion of
electrical current.
Rearranging Ohm's Law for
amperage shows that amperage
(current flow) is determined by the
voltage divided by the resistance.
The higher the resistance, the less
current that will flow for a given
voltage.
What does this principle
mean for SMAW?
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Constant Current
W n the normal operation of a transformer as amperage is
increased, the voltage decreases, and vies versa.
W Electrical arc welding power supplies are modified so that either
the voltage or the amperage is relatively constant as the other
factor changes.
W This allows two different types of power supplies:
Constant current
Constant potential
W n a constant current power supply, the current (amperage)
stays relatively constant when the voltage is changed.
W GMAW
W n a constant potential power supply, the voltage stays
relatively constant when the amperage is changed.
W SMAW
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Constant Current--cont.
W Characteristics of constant current power supply.
W The machine provides a high voltage for striking the arc.
W Open circuit voltage (OCV)
W OCV is not adjustable for most machines
W When the arc is struck the voltage drops to the welding voltage.
W Arc voltage
W Arc voltage varies with the arc length.
W As the welding proceeds the current will not vary much as the
arc length changes.
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Constant Current-cont.
ncreasing the voltage from 20
to 25 volts (25%) only
decreases the amperage from
11 to 120 Amp (5.8%).
2
Constant Potential
The constant potential power supply is modified to produce a
relatively constant voltage as the amperage changes.
0
10
20
30
40
50
60
70
80
0 50 100 150 200 250
350708
Characteristic of GMAW power supplies.
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Voltage Drop
Voltage drop is the reduction in voltage in an electrical circuit
between the source and the load.
Primary cause is resistance.
When an excessive voltage drop exists, the electrical circuit will
not perform as designed.
Localized resistance (connection) can cause excessive heat.
Excessive heat can cause component failure.
When extra long welding leads are used, the amperage must be
increased to have the same heat at the weld.
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Joints, Welds & Positions
Butt
Lap
T
Corner
Edge
Electric arc welding uses the same
five (5) types of joints and five (5)
types of welds and five (5) positions.
Five (5) joints:
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Joints, Welds & Positions
Five types of welds
1. Surface
2. Groove
. Fillet
. Plug
5. Slot
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1. Surface Welds
W Surface welds are welds were a material has been applied to the surface
of another material.
May or may not be blended with the work piece.
W Two common applications are for hard
surfacing and padding.
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2. Groove Welds
Groove welds are used to fuse
the sides or ends of two pieces
of metal.
The primary use of groove
welds is to complete butt joints.
0
. Fillet Welds
Fillet welds have a triangular cross section and are used to fuse
two faces of metal that are at a 90 degree angle to each other.
Lap Joint
Outside Corner T Joint
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. Plug Welds
Plug welds are used to
attach two surfaces together
when a complete joint is not
required and the design
does not allow for any weld
bead outside the dimensions
of the metal.
The holes can be made with a drill bit or punch.
The weld is completed by establishing the arc on the bottom plate and
then continuing to weld until the hole is full.
2
5. Slot Welds
Slot welds are identical to plug welds except for the shape of the
holes. For slot welds, slots are machined or stamped in the upper
plate.
They are complete the same as plug welds.

Joints, Welds & Positions

Arc Welding Positions
Horizontal
Flat
Vertical Up
Overhead
Vertical Down

Weld Nomenclature
Penetration
Bead
Base metal
Joint Angle
Reinforcement
Bead
Root Face
Excessive
Penetration
Root Opening
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Weld Nomenclature-cont.
Root
Throat
Face
Toe
Reinforcement
Leg
Leg
Toe
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Weld Nomenclature-cont.
n multiple pass welds, each pass has a specific function.
Tack Weld
Root Pass
Filler Pass
Cover Pass
A tack weld is used to hold
the joint at the desired gap.
f it is not used, the heat of
the weld will cause the joint
to close.
The filler pass is used to fill in the joint.
A pattern bead or multiple stringer beads will be used.
The root pass is used to fuse the
root of the weld.
f the root pass does not have
adequate penetration, it must be
cut or gouged out before the
weld is completed.
The cover pass isn't used for strength. t is used for appearance and to
fill in surface voids.
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Bead Patterns
Pattern beads are used
whenever a wider bead is
needed.
Hardsurfacing
Filler pass
Cover pass
Reduce penetration
Common patterns:
Circle
Crescent
Figure 8
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Weld Defects
A weld defect is any physical characteristic in the completed
weld that reduces the strength and/or affects the appearance of
the weld.
The mark of a good welder is the ability to identify weld defects
and adjust the welding parameters to eliminate them.
Defects that are not visible must be detect by using destructive
or nondestructive testing.
f the defects in a weld exceed the specifications, the weld must
be removed and redone.
Welds are removed by grinding, gouging and cutting.
Eliminating a weld defect is time consuming and expensive --
you must be able to complete the weld correctly the first time.
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Common Defects and Causes
The depth of the weld
is less than
specifications.
Excessive heat
Excessive speed.
The weld metal is not
completely fused to
base metal or passes
are not completely
fused.
Description Cause(s)
ncorrect angle
ncorrect
manipulation
nsufficient heat
Weld material flows
over, but is not fused
with the base metal.
Slow speed
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Common Defects and Causes--cont.
Weld bead does not
extend to the
desired depth.
Description Cause(s)
Low heat
Long arc
ncorrect joint design
Small indentions in
the surface of the
weld
Excessive gas in the
weld zone.
Moisture
Rust
Dirt
Accelerated cooling
Small voids
throughout the weld
material.
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Usually visible cracks
on the surface or
through the weld
Common Defects and Causes--cont.
Description Cause(s)
Accelerated cooling
Constrained joint
Small weld volume
Cracks in the
transition zone
between the weld and
base metal
nduced hydrogen
ncompatible electrode
or wire
Accelerated cooling
Misshapen
and/or uneven
ripples
nconstant speed
ncorrect manipulation
ncorrect welder settings
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