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INDIABULLS
What Is GMAW ?
A Fusion Welding Process Semi Automatic Arc Between Consumable Electrode &Work Arc Generated by Electric Energy From a Rectifier / Thyrester / Inverter Filler Metal As Electrode Continuously fed From Layer Wound Spool. Filler Wire Driven to Arc By Wire Feeder through Welding Torch Arc & Molten Pool Shielded by Inert Gas through Torch / Nozzle
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A1
A2
A
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Accessories Of GMAW
Power Source Wire Feed Unit Shielding Gas Cylinder, Pressure gauges/ Regulator, Flow meter ( Heater For Co2 ) Welding Torch Water Cooling System (For Water cooled Torch) Earthing Cable With Clam
GMAW Torch
On / Off Switch
Torch Handle
Welding Torch Wire Inside Spring Lining Contact Tip Argon / Co2 Shielding Work
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Pull Type
Feed Rollers Mounted on The Torch Handle Pulls the Wire From A Remote spool
Self Contained
Wire Feeder & The Spool On the Torch
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GMAW CS Wire
Generally Copper Coated
Prevents Oxidation / rusting in Storage Promotes Electric Conductivity in Arcing
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16 24 V
24 35 V
Globular Co2 or Ar
Globular Transfer
Metal transferred in droplets of Size grater than wire diameter Operates in Moderate Amps & Volts Better Deposition Common in Co2 Flux Cored and Solid Wire Suitable for General purpose Welding
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Spray Transfer
Metal transferred in multiples of small droplets 100 to 1000 Droplets per Second Metal Spray Axially Directed Electrode Tip Remains pointed Applicable Only With Inert Gas Shielding Not With Co2 Operates in Higher Amps & Volts Higher Deposition Rate Not Suitable for Welding in Out of Position. Suitable for Welding Deep Grooves
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Porosity
Cause
1) Less Mn & Si In Wire 2) Rusted / Unclean BM / Groove 3) Rusted wire 4) Inadequate Shielding Gas
Remedy
1) Use High Mn & Si Wire 2) Clean & warm the BM 3) Replace the Wire 4) Check & Correct Flow Rate
Porosity
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Spatters
Cause
1) Low Voltage 2) Inadequate Inductance 3) Rusted BM surface 4) Rusted Core wire 5) Quality Of Gas
Remedy
1) Increase Voltage 2) Increase Inductance 3) Clean BM surface 4) Replace By Rust Free wire 5) Change Over To Ar + Co2
Spatters
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Lack Of Fusion
Cause 1) Inadequate Current
2) Inadequate Voltage 3) Wrong Polarity 4) Slow Travel Speed 5) Excessive Oxide On Joint Lack Of Fusion
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Undercut
Cause 1) Excess Voltage 2) Excess Current 3) Improper Torch angle 4) Excess Travel Speed
Under cut
Remedy 1) Reduce Voltage 2) Reduce Current 3) Train & Qualify the Welder 4) Reduce Travel Speed
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Overlap
Cause 1) Too Long Stick Out 2) Inadequate Voltage
Overlap
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Slag
Cause 1) Inadequate Cleaning 2) Inadequate Current 3) Wrong Torch angle 4) Improper bead placement Remedy 1) Clean each bead 2) Use Right Current 3) Train / Qualify welder 4) Train / Qualify Welder
Slag
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Crack
Cause Remedy
1) Incorrect Wire Chemistry 1) Use Right Wire 2) Increase wire Feed 2) Too Small Weld Bead 3) Preheat Uniformly 3) Improper Preheat 4) Post heating or ISR 4) Excessive Restrain
crack
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Lack Of Penetration*
Cause 1) Too Narrow Groove Angle 2) Inadequate Root opening 3) Too Low Welding current 4) Wrong Torch angle 5) Puddle Roll In Front Of Arc 6) Long Stick Out
* Applicable to SSFPW
Remedy 1) Widen The Groove 2) Increase Root Opening 3) Increase Current 4) Train / Qualify Welder 5) Correct Torch Angle 6) Reduce Stick Out
LOP
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Burn through*
Cause 1) Excess Current 2) Excess Root opening 3) Inadequate Root face 4) Too Low Travel Speed 5) Quality Of Gas Remedy 1) Reduce the Current 2) Reduce root opening 3) Increase root face 4) Increase Speed 5) Use Ar + Co2
*Applicable to root pass
Burn trough
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Remedy 1) Increase Current 2) Increase Voltage 3) Increase Travel Speed 4) Increase Inductance 5) Increase Groove Width
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Unstable arc
Cause 1) Improper Wire Feed 2) Improper Gas Flow 3) Twisted Torch Conduit Remedy 1) Check Wire Feeder 2) Check Flow Meter 3) Straighten Torch Cab
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Wire Stubbing
Cause 1) Too Low Voltage 2) Too High Inductance 3) Excess Slope 4) Too Long Stick Out Remedy 1) Increase Voltage 2) Reduce Inductance 3) Adjust Slope 4) Reduce Stick Out
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What Is Preheating?
Heating the base metal along the weld joint to a predetermined minimum temperature immediately before starting the weld. Heating by Oxy fuel flame or electric resistant coil Heating from opposite side of welding wherever possible Temperature to be verified by thermo chalks prior to starting the weld
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Why Preheating?
Preheating eliminates possible cracking of weld and HAZ Applicable to Hardenable low alloy steels of all thickness Carbon steels of thickness above 25 mm. Restrained welds of all thickness Preheating temperature vary from 75C to 200C depending on hardenability of material, thickness & joint restrain
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Thanks
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