Welding, Brazing & Cutting Process

By: Dhing Torres

11/21/2007

Types of Welding Process:

SMAW Shielded Metal Arc Welding
GMAW Gas Metal Arc Welding
FCAW Fluxed Cored Arc Welding
GTAW Gas Tungsten Arc Welding
PAW Plasma Arc Welding
SAW Submerged Arc Welding
ESW Electroslag Arc Welding
OAW Oxyacetylene Arc Welding
SW Stud Welding

SMAW
- uses the heat of electric arc between a covered metal electrode & the work
shielding comes from the decomposition of the electrode flux coating.

ADVANTAGE: Simple & Inexpensive

DISADVANTAGE: Slow Process

SMAW ELECTRODE IDENTIFICATION SYSTEM

E XX X X
Coating Operating Characteristics
Position:
#1: All position
#2: Vertical
#4: Flat
Tensile Strength

GMAW
- uses the heat of an electric arc between a continuous bare wire filler metal
electrode & the work shielding comes from the decomposition of the electrode
flux coating.
- can be semi-automatic, machine/automated process.

ADVANTAGE: Porosity due to excessive contamination of the base metal.

GMAW Welding Transfer

1. Spray Transfer
2. Globular
3. Short Circuiting
4. Pulsed
GMAW ELECTRODE IDENTIFICATION SYSTEM

E R XX S -X
Chemical Composition
Solid Wire
Strength
Electrode Rod
Electrode Rod

FCAW
- same as GMAW except the electrode is tubular & contains a granular flux
instead of a solid wire used in GMAW.

ADVANTAGE: Provides high productivity particularly in hand held process.

FCAW ELECTRODE IDENTIFICATION SYSTEM

E XX T - X
Chemical Composition / Operating Characteristics
Tubular
Tubular
Strength
Electrode Rod

GTAW
- uses an electric arc between a non-consumable electrode and the work.

ADVANTAGE:
- Capable of welding virtually all metals, even extremely thin materials.
- High quality welds with excellent visual appearance can be produced.
- Process is quite clean & there is no slag to remove after welding.

DISADVANTAGE:
- Base and filler metals must be extremely clean prior to welding.
- Slowest of the available welding processes.

PAW
- is a process which utilizes a constricted arc between the electrode & the work
piece (transferred arc) or the electrode & the constricting nozzle. (non-
transferred arc)
- similar to GTAW
ADVANTAGE:
- PAW process is easy to control.

DISADVANTAGE:
- PAW is limited to materials 1inch thick or less, requires greater operator skill
due to more complex equipment.

SAW
- uses heat of an electric arc or arcs between the electrode or electrodes and the
work, all shielded by a blanket of granular flux.

ADVANTAGE:
- can be performed on a numerous metals due to high rate of weld.

SAW FILLER METAL CLASSIFICATION SYSTEM

F XXX - E XXX
Classification

OAW
- chemical welding process which relies on the chemical reaction between the
OA frame and the base metal to produce the necessary heat for melting the
base & filler metal.

SW
- is a two step process used to join attachments to metal surfaces.
- studs may be welded in all positions.

ADVANTAGE:
- Economical & effective method.

* Weldability, Welding Metallurgy

Ref. Code AWS D1.1 Structural Welding Steel
WELD AND BASE DISCONTINUITIES

DISCONTINUITIES
- are imperfections in welds or base metals
- discontinuity becomes a defect when it exceeds acceptable limits
imposed by acceptable standard.

A DEFECT IS REJECTABLE

WELD INSPECTION PROFILE & TYPES OF DISCONTINUITIES

1. Incomplete Penetration
2. Porosity
3. Lack / Incomplete Fusion
4. Undercut
5. Overlap
6. Lamination
7. Delamination
8. Inclusion
9. Crack
Brazing
- is a group of joining processes.

Current Brazing Methods:

1. Torch Brazing (TB)
2. Furnace Brazing (FB)
3. Induction Brazing (IB)
4. Resistance Brazing (RB)
5. Dip Brazing (DB)
6. Infra-red Brazing (IRB)
7. Diffusion Brazing (DFB)

Typical Imperfections:
1. Silica Inclusions
2. Lack of Side Wall Fusion
3. Porosity
* Weldability, Welding Metallurgy
Ref. Code AWS D1.1 Structural Welding Steel

Classification of Metal

* FERROUS METAL
- "ferrum" means containing iron
- magnetic

2 types of Ferrous Metal:

1. Steel
2. Cast Iron

Composition of Mild Steel:

1. Low Carbon - 0.2%
2. Mild - 0.5%
3. High - 0.8%

Types of Cooling Treatment:

1. Annealing
- is a heat treatment wherein a material is altered, causing changes in
tis properties such as strength & hardness.
- is used to induce softness, relieve internal stresses, refine the
structure & improve cold working properties.

2. Normalizing
- applicable to ferrous metal only
- same as annealing
- but the purpose is to remove the internal stresses induce by heat
treating, welding, casting, forging, forming or machining.
- normalized steels are harder and stronger than annealed steels.

3. Quenching
- done by cooling at a sufficiently high rate to avoid warpage.

* NON-FERROUS METAL
- do not contain iron
- common non-ferrous metals:
> Aluminum
> Tin
> Copper
 > Zinc
> Gold
> Silver
> Brass

* STAINLESS STEEL
- defined as an iron-carbon alloy with a minimum of 10.5% chromium content

* AUSTENITIC
- or 300 Series
- 0.15% Carbon (Max), 16% Chromium

* MARTENSITIC
- Chromium (12-14%)
- Molybdenum (0.2-1%)
- 00 Series

* STAINLESS STEEL
200 Series - Austenitic Chromium-Nickel-Manganese Alloys
300 Series - Austenitic-Chromium-Nickel
301 Series - Highly Ductile, Good Weldability
302 Series - Same corrosion resistance as 304, with slightly higher
strength due to additional carbon.
303 Series - Easier machining version of 304
- Also referred to as "A1" in accordance with ISO.
304 Series - most common Grade.
- classic 18/8 stainless steel referred to as "A2" in
accordance with ISO.
309 Series - Better temperature resistance than 304.

ISO International Organization for Standardization