MIG-MAG Eng 260710 @1544

MIG/MAG &
Flux Cored Arc Welding

Koray YURTIŞIK
yurtisik@gmail.com
yurtisik@metu.edu.tr
Content
• Review of Part I and II
Definition
– Advantages
– Disadvantages
Application Fields
Equipment
Filler Metals (Wire electrodes)
Shielding Gases
Internal Control System (Principle)
Forces acting on the Arc
Types of Arc
• Setting-up of a MIG/MAG Welding Unit
Welding Parameter Influences
• Pulsed Arc
• Possible Defects when MIG/MAG Welding
• Weld Bevel Preparation
• Backing
MIG/MAG & Flux Cored Arc Welding, 2 of 85
Definition
• A fixed composition of gas shields the weld metal.
• Filler metal is an electrode at the same time (a
difference w.r.t. TIG)
• Filler metal is continuous ( a difference w.r.t. TIG &
MMA)
• Naturally born Semi-mechanized
• DCEP (reverse polarity),
DCEN is seldom used because of poor transfer
of molten metal from the wire electrode to the
workpiece.
• Advantages
All positions are available
Less and sometimes even no slag removal (man-
hour),
Metal Deposition Rate is high,
Fast (2 times more than MMA),
Less distortion,
Low cost filler metal (w.r.t. MMA & UP)
• Disadvantages
Lack of Fusion
– At start
– Filler metal melts on to cold
substrate
– When low linear welding speed
– Weld pool flowing in front of the arc
Sensitive to environmental conditions
Fields of Application
• Constructional steel or aluminum members,
• Shipyards,
• Automotive,
• Pipe Lines,
• Pressure Vessels and Processing Equipments,
Heat Exchangers, Boilers, Piping
Equipment
• Power supply
• Wire feed unit
• Hose assembly
• Torch
• Blowtorch
Blow torch
.
Wire feed unit
Hose assembly Torch
Wire electrode
Arc
Vessel of Power supply Neutral cable Work piece
Shielding gas
Power Supply
• Constant potential power supply
The potential change between 3 to 5 Volts corresponds to current amplitude of 100 A
Self correcting arc
Kural olarak güç elemanları ayarlanabilen endüktansa sahiptir.
– Endüktans kaynak akımındaki sapmaları azaltır ve akım artış hızını değiştirir. Örneğin tutuşma
sırasında hızlı bir akım artışı avantajlıyken, kısa devreyle ark sırasında yavaş bir akım artışı daha az
sıçrantı oluşturur.
• Types;
Conventional
With Trystor
With transistor ‘rectifier’
With transistor ‘inverter’
Wire Feed Unit
• 1.5 m/min – 20 m/min
Wire Feed Unit
• 1.5 m/min – 20 m/min
Wire Feed Unit
• One or more than one driving unit
are possible
Wire Feed Unit
Hose Assembly
• Carries;
Cooling air (lower
than 250 A) or
water,
Wire electrode,
Shielding gas,
Welding current and
potential.
Torch
(1) Torch handle,
(2) Moulded phenolic dielectric (shown in white)
and threaded metal nut insert (yellow),
(3) Shielding gas diffuser,
(4) Contact tip,
(5) Nozzle output face
[Reference: Mysid, TTlightningRod]
Wire Electrodes
Wire Electrodes
Solid Flux Cored
Less welding current for the
same metal deposition rate.
Metal Özlü Cüruf Özlü
Rutile
Basic
Wire Electrodes
Wire Electrodes for Steels
Solid Flux Cored
C-steel Stainless Steel C-steel Stainless Steel
ISO 14341 ISO 14343 ISO 17632 ISO 17633
Wire Electrodes
ISO 14341
Wire Electrodes
ISO 14341
Wire Electrodes
ISO 14341
Wire Electrodes
ISO 14341
Wire Electrodes
ISO 14341
Wire Electrodes
ISO 14341
Wire Electrodes
ISO 17632 -
Wire Electrodes
ISO 17632 -
Wire Electrodes
ISO 17632 -
Wire Electrodes
ISO 17632 -
Shielding Gases
Shielding Gases
Shielding Gases
• Plain carbon, low-alloyed and high-alloyed steels except stainless steels
M2, M3 & C
• Stainless steels
M1
• Aluminium, Titanium, Magnesium
I
• Nickel and its alloys
I & M1
Shielding Gases
Spatter
Forces in Arc and on to the Droplet
• Pinch effect; Surface
tension
An electromagnetic force
Proportional to the square of current amplitude, I
• Surface tension;
Oxide patches on the droplet reduse the surface 20%
tension
The higher surface tension, the bigger droplets
• Metals evaporating;
100% Ar 100% CO2
Pressure against to the droplet
• Plasma beam;
• Gravitation;
Process Variations – Metal Transfer
• Short Circuit Transfer (Short Arc) Welding [15 –
20 V] V
Metal is transferred from the wire to the weld
pool only when contact between the two is
made, or at each short circuit.
The wire short circuits to the work piece 20 to 20
200 times per second
Uses small wire in the range of .8 to 1.2 mm
diameter
Operates at low arc lengths (low voltages) and
welding currents
Fast-freezing weld puddle is obtained A
This welding technique is particularly useful for
joining 150
– thin materials in any position,
– thick materials in the vertical and
overhead position,
– and for filling large gaps
Short arc welding should also be used where
minimum distortion of the work piece is a
requirement because of its low heat input
C, M2 and M3 gases.
Hard to control and easy to leave defect.
• Globular Transfer (Long Arc) Welding [ > 20
V]:
Metal transferring through the arc,
Usually, the drops of molten metal have a
greater diameter than the wire itself,
The metal transfer with spatter and V
occasional short circuiting,
Occurs with gases consisting more than
20% CO2,
Such gases have good thermal
conductivity, so the interface between the
electrode and the arc is very narrow, 20
No use for hard welding positions,
Metal transfer efficiency is very low, in
between 87 and 93%,
Lack of fusion risk is very high.
A
150
• Spray arc [higher than 25 V]: V
By raising the welding current and voltage still
further, the metal transfer will become a true spray
arc.
– The minimum welding current at which this occurs is
called the transition current, above the transition
current pinch effect becomes effective. 20
– The transition current depends on the metal wire
diameter and shielding gas.
– However, if the shielding gas for welding carbon steel
contains more than about 20% CO2 there is no
transition from globular transfer to spray transfer.
The molten drops from the wire are very small,
affording good arc stability, short circuiting is rare.
Little spatter, high deposition rates of weld metal,
A
more than 98%.
3 mm and greater in thickness
150
• Spray arc V
20
A
150
• Pulsed Arc;
A variation of the spray arc technique is known as ”pulsed” spray welding.
The current is varied between a high and low value.
– The low level of current is below the transition current while the high level is well into the spray arc region.
Metal is only transferred to the work during the period of high current.
– Usually one droplet is transferred during each high current pulse.
– The peak current is in the spray arc region, arc stability is similar to that of conventional spray arc welding.
The period of low current maintains the arc and serves to reduce the average current.
– Producing a spray arc at lower average current levels than are required for conventional spray arc welding.
– The lower average current makes it possible to weld thinner gauge materials with spray type transfer
– It can also be used for out-of-position welding of heavier sections.
LWS of 1.2 meter per minute.
• Pulsed Arc
• Pulsed Arc
V-I Characteristics for Power Supply
V1, I1 V2, I2
V
(V1) (I1) = P = (V2) (I2)
V1, I1
V2, I2
5V
I
100 A
V-I Characteristics for the Arc
R=ρL/A
V=IR
V L
R A
I
V-I Characteristics for the Arc
Long arc lengths
Maximum possible arc length Optimum arc length
V
Short arc lengths
Stable Arc Zone
Minimum possible arc length
I
Setting-up of a MIG/MAG Welding Unit
• V-I Characteristics for Power Supply
Constant potential characteristics
V
I
• V-I Characteristics for Power Supply and for the Arc
V
I
• (Nearly) Constant Potential
3 V 100 A
V
3V
V2
V1
I2 I1 I
100 A
Internal Control System (Self Correcting Principle) in MIG/MAG
• Constant potential
• Constant wire feed speed
WFS 5.6 m/dk 5.6 m/dk 5.6 m/dk 5.6 m/dk 5.6 m/dk
I 200 A 150 A 200 A 250 A 200 A
Melting Rate 5.6 m/dk 4.3 m/dk 5.6 m/dk 6.8 m/dk 5.6 m/dk
I
V V V
200 A 150 A I 250 A I
I
The single switch
operation
• Simple power supplies
show two buttons for the
arc set-up;
the voltage and
the wire feed.
• Better equipped welding
units also contain an
adjustable inductivity
(valve).
• An increasing wire feed
velocity always requires a
higher arc voltage.
arc set-up;
the voltage and
the wire feed.
(valve).
arc set-up;
the voltage and
the wire feed.
(valve).
arc set-up;
the voltage and
the wire feed.
(valve).
arc set-up;
the voltage and
the wire feed.
(valve).
arc set-up;
the voltage and
the wire feed.
(valve).
arc set-up;
the voltage and
the wire feed.
(valve).
arc set-up;
the voltage and
the wire feed.
(valve).
Changing the voltage while WFS is
constant:
Length of the arc and weld profile
change,
The current and and the rate of
deposition remain constant.
The arc voltage determines the arc
length and therefore the seam width.
High V flat and wide seam
Undercuts such as inconvenient seam
changes can occur because of the
magnetic blow effect.
If the arc is too long alloy elements can
be combusted in the arc and the smoke
formation raises.
Low V narrow and strongly
reinforced seams
Short-circuits.
Changing the voltage while WFS is
constant:
Length of the arc and weld profile
change,
The current and and the rate of
deposition remain constant.
The arc voltage determines the arc
length and therefore the seam width.
High V flat and wide seam
Undercuts such as inconvenient seam
changes can occur because of the
magnetic blow effect.
If the arc is too long alloy elements can
be combusted in the arc and the smoke
formation raises.
Low V narrow and strongly
reinforced seams
Short-circuits.
Changing the WFS while
retaining the voltage constant:
Length of the arc, weld profile, the
current and and the rate of
deposition change.
WFS ≈ the deposition
efficiency, the welding
amperage.
A raising wire speed increases the
amperage and the penetration
depth.
The seam width is barely
influenced. The seam
reinforcement raises because of
the increased deposition
Efficiency if LWS is constant.
Combinations of V and WFS
• The connection between a wire
electrode with a thickness of 1.2 mm
and different shielding gases:
CO2 mixed gases and argon-
containing mixed gases with
higher amounts of CO2 demand
an increased arc voltage which
contrasts argon mixed gases or
mixed gases with a high amount
of argon containing less than
20% of CO2.
Positioning the Welding Torch
Positioning the Welding Torch
Linear Welding Speed, LWS
• At constant welding data, the higher LWS, the narrower seam cross section.
• The ergonomic manual welding velocities are at between 40 and 60 cm/min:
Is the welding speed reduced to values below 40 cm/min, a molten pool running ahead of the welding area
can strongly reduce the penetration with poor fusion as a result.
It is better to quickly weld a seam in three layers than to slowly weld it in only one.
• Usually for series productions are welding velocities of 1 – 1.5 m/min.
• At too high speed undercuts can occur and the weld turns out to be reinforced and narrow.
Setting-up of the Pulsed MIG/MAG
• Five setting points are needed to correctly set up the metal transfer:
wire speed,
impulse frequency,
pulse width,
pulse height, and
background current height.
• The pulse width and height is to select in order to achieve an arc with low spatter formation and no short-
circuits.
• Advantages:
Low spatter,
Flatter beads,
Better seam shape,
Lower heat input.
• Disadvantages:
Higher investment cost,
Setting-up is diffucult,
Good wire quality is needed,
Gap-bridging ability is poor.
Possible Welding Defects
• Cracking
• Porosity
• Lack of Fusion
• Spatter
• Unfavorable Seam Geometry
• Lack of Fusion
It is possible that the first drops transferring in
the arc meet an incompletely molten base
material. The drop energy itself is not enough
to melt the base material. The drop lays
without any fusion to the base material.
When weld bevel angle is less than enough
(60 degrees total).
When the root face is too high or root opening
is too low.
When there is Hi-Low on Fit-up.
When the thickness of the reinforcement is
too much.
• Lack of Fusion
Too low arc power, too much LWS and too
high torch spacing or arc length.
When molten pool is running ahead of the arc
due to too LWS, improper torch inclination.
Wrong bead sequence or placement.
Restricted welding access.
Wrong torch positioning.
• Lack of Fusion
• Lack of Fusion
• Lack of Fusion
• Lack of Fusion
• Porosity
Dirts and defects on the torch.
Magnetic blow effect.
Draught.
Too long arc.
Inappropriate shielding gas.
Contamination.
Cavities.
Nitrogen on edges cut by laser, plasma.
• Porosity
Draught.
Too long arc.
Contamination.
Cavities.
• Porosity
Too long arc.
Contamination.
Cavities.
• Porosity
Draught.
Too long arc.
Contamination.
Cavities.
• Porosity
Too long arc.
Contamination.
Cavities.
• Porosity
Too long arc.
Contamination.
Cavities.
• Porosity
Too long arc.
Contamination.
Cavities.
• Porosity
Too long arc.
Contamination.
Cavities.
• Porosity
Too long arc.
Contamination.
Cavities.
• Finalizing
Weld Bevel
• Steel
> 60o
1-2
3-4
Weld Bevel
• Aluminium
Backing

MIG-MAG Eng 260710 @1544

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MIG-MAG Eng 260710 @1544

Uploaded by

Copyright:

Available Formats

MIG/MAG &

Flux Cored Arc Welding

You might also like