Professional Documents
Culture Documents
Welding
Principles and Practices
Third Edition
Objectives
1. List the percentage of usage of SMAW in the industry. 2. Name the components that make up the schematic representation of the shielded metal arc. 3. Know the maximum arc temperature of an SMAW electrode. 4. List the four constant current welding machines.
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Objectives
5. List the common type and uses of constant current welding machines. 6. Name the power supply ratings. 7. Name the characteristics of the four basic types of welding machines. 8. Choose the correct cable size based on the application. 9. List the welders safety equipment.
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Called stick electrode welding Combustion and decomposition of electrode creases gaseous shield
Protects electrode tip, weld puddle, arc, and highly heated work from atmospheric contamination
Additional shielding provided by covering of molten slag (flux)
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SMAW
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Process Capability
Shielded metal arc welding one of most used of various electric arc welding processes
9% 13% 42% 2% SMAW GMAW/FCAW GTAW SAW Others
34%
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SMAW Advantages
Equipment less complex, more portable and less costly Can be done indoors or outdoors, in any location and any position Electrodes available to match properties and strength of most base metals
Not used for welding softer metals Not as efficient in deposition
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Heat of electric arc brings work to be welded and consumable electrode to molten state
Heat intense: as high at 9,000F at center
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Welding Process
Electric arc started by striking work with electrode Heat of arc melts electrode and surface of base metal Tiny globules of molten metal form on tip of electrode and transferred by arc into molten pool on work surface After weld started, arc moved along work
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Constant voltage
Referred to as constant potential
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Output Slope
Relationship between output voltage and output current (amperage) of machine as current increased or decreased
Also called volt-ampere characteristic or curve
Largely determines how much welding current will change for given change in load voltage
Permits welding machine to control welding heat and maintain stable arc
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Output Slope
Indicates type and amount of electric current designed to produce Each arc welding process has characteristic output slope
SMAW and GTAW require steep output slope from constant current welding machine GMAW and FCAW require relatively flat output slope from constant voltage power source Submerged arc welding adaptable to either slop
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Transformer-rectifiers
Use basic electrical transformer to step down a.c. line power voltage to a.c. welding voltage Welding voltage then passed through rectifier to convert a.c. output to d.c. welding current May be either d.c. or a.c.-d.c. machines
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Inverters
Increases frequency of incoming primary power Constant current, constant voltage, or both
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Power Sources
Important to select right power source for each job Table 11-1 "Common types and uses of arc welding machines" should be studied Study of job indicates whether a.c. or d.c.
Shielded metal arc welding and gas tungsten arc welding must use constant current machine Gas metal arc prefers constant voltage machine
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Steeper the slope, the smaller current change Enables welder to control welding current in specific range by changing length of arc
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Arc voltage
Voltage generated between electrode and work during welding
Load voltage
Voltage at output terminals of welding machine when arc is going Combination of arc voltage plus voltage drop in welding circuit
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Arc voltages
Range: 36 volts (long arc) to 18 volts (short arc) Determined by arc length held by welder and type of electrode used
Used chiefly for shielded metal arc welding and gas tungsten arc welding
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Flexible
With proper electrode, can be used in all positions
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Generators
Classified by type of motor that drives generator Consists of a.c. motor, d.c. generator, and exciter built on single shaft Generators used in the field
Miller Electric Mfg. Co. The Lincoln Electric Co.
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Sizes
Determined on basis of amperage Range
100-ampere rated for home 1,500 ampere rated for use with automatic submerged arc welding equipment
Manual welding machine idle sometimes Automatic power supply units 100% duty cycle
Should not be used at or beyond max over extended period
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Maintenance
Contacts of starter switch and control rheostat should be inspected, cleaned frequently and replaced when necessary Brushes need frequent inspection for wear
Check commutator for wear or burning
Rewound and turned on lathe
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Polarity Switch
Electrode negative and electrode positive used in d.c. welding DCEN (d.c. electrode negative)
Electrode connected to negative terminal of power source and work connected to positive terminal
Volt-Ampere Meters
Sometimes serve dual purpose
Can indicate polarity as well as current Others, individual meters for volts and amperes Some, single meter that indicates both volts and amperes
Button engaged to get individual readings Would need second person for monitoring
Increased demand for additional devices so meters have been discontinued by some manufacturers
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Current Controls
Amperage
Quantity of current Determines amount of heat produced at weld
Voltage
Measure of force of current Determines ability to strike an arc and maintain its consistency
Wheel or knob on both amperage and voltage setting devices gives welder continuous control of both
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Remote Control
Welding machines may be installed in remote part of plant Welder may adjust current without leaving job Timesaving on work
Welder does not have to leave fabrication to readjust current
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Air Filters
Wear in arc welding machines costly
Cost of replacement parts and labor Loss of production due to nonuse of machine
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Transformer-Rectifier Machines
Have two basic parts
Transformer for producing and regulating alternating current that enters machine rectifier that converts a.c. to d.c.
Design improves arc stability and makes it easy to hold short arc which is soft and steady No major rotating parts so consume little power
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High frequency arc-starting devices, water/gas flow controls, balance controls for a.c. operation, remote control often built into machine
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Lower cost Decreased power consumption High overall electrical efficiency Noiseless operation Reduced maintenance
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Multiple-Operator Systems
Can be installed away from work site and be connected to control panels close to welding operator When using direct current, all welders must weld with same polarity Most installations are d.c. Power: 600-2,500 amperes Cost less, saves space and cable, lowers operating cost
Miller Electric Mfg. Co.
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Current Output
Rated on basis of current output in amperes Amperage range
200 amperes or less for light or medium work
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Duty Cycle
Percentage of any given 10-minute period that machine can operate at rated current without overheating or breaking down
Rating of 100% means machine can be used at rated amperage on continuous basis
Required by continuous, automatic machine welding
Rating of 60% means machine can be used at its capacity 6 out of every 10 minutes without damage
Satisfactory for heavy SMAW and GTAW
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Efficiency
Relationship of secondary power output to primary power input
Indicated in percent
Determined by losses through machine when actually welding at rated current and voltage Average efficiencies
Motor generator welding machines: 50% Transformer-rectifier: 70% Inverter: 85%
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Power Factor
Measure of how effectively welding machine makes use of a.c. primary line power
Primary power used divided by amount total drawn Expressed in percent
Three-phase d.c. transformer-rectifiers: 75% Single-phase a.c. power units: 55% Welding machines can be purchased with power factor correction
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Power Cable
Conductors of ample capacity and adequately insulated for voltage transmit power Necessary to ground frame of welding machine
Portable cable with extra conductor fastened to machine frame on one end and solid ground on other
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Components
A. Wires stranded for extra flexibility B. Paper wrapping around wires allows conductor to slip within robber covering when bent C. Extra strength from open-braided reinforcement of extra cotton cords D. Special composition and curing of heavy rubber covering
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Work Cable
Not necessary to have flexibility of electrode cable See Table 11-3 to help
choose the right size of welding cable Important considerations Amperage of welding machine Distance from work Usually same cable used
Larger cable
Greater the amperage and greater the distance Resistance increases as diameter of cable decreases
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Cable Lugs
Required on both electrode cable and work cable
Soldered or fastened mechanically Connections MUST be tight and secure
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Work Clamps
Variety of structures to be welded; many types of clamps may be used
Copper hook, heavy metal weight, C-clamp Specialized work clamps
Rotary This clamp stops twisting and turning of type welding cable where work rotates. Clamp welded to part, thus permits work clamp to be attached in seconds. It is generally used in fabricating Spring loaded C-clamp tanks, pressure vessels, and on weld positioners.
Lenco dba NLC. Inc. Lenco dba NLC. Inc.
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Quick Connector
Attached to ends of different lengths of cables Allow quick and easy attachment to any length cable
This connector has cam-type action that ensures positive stop and lock and cannot come loose or accidentally fall apart.
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Cable connections
Entirely insulated Holds electrodes burned to very short stub. Lifeguard insulation Twist-type locking device permits electrodegripping power in excess of 2,000 pounds.
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Available in sizes of 400 and 600 amperes and takes electrodes from 1/16 through 5/16 inch in diameter.
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Carbon electrodes available: 1/4, 5/16, 3/8 inch Alternating current: 30-125 amperes Metal electrode holders not suitable
Carbon electrode hotter than metal electrode
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Temperature produced by arc: 7,500F Current supplied by a.c. welding transformer Hydrogen supplied in cylinders
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May weld hard-to-weld metals Advantages: increased production, low operating cost, and low maintenance cost
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Rays affect eyes within 50 feet; and skin any distance within 20 feet Hand shield so person may hold
Fibre-Metal Products Co.
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Dependable protection
Both hands free to grasp electrode holder
Partial protection
Must also wear leather or nonflammable cap for adequate protection
Fibre-Metal Products Co. Fibre-Metal Products Co.
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Chrome leather helmets ideal for hard-to-get-into areas. Flip-front welding helmet permits welder to inspect and brush weld without lifting the hood.
Wilson Products
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Side exposed to weld pool protected by clear polycarbonate plastic cover lens
Protect costly filter lens from molten metal spatter and breakage (replaced when pitted and clouded)
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Safety Glasses
Should be worn
Also behind hood to prevent severe arc flash reaching eyes
Can Absorb more than 99.9% harmful ultraviolet rays Worn by others who work with welders Light in weight, well ventilated, and comfortable Lenses have light tint (Not dark!) and tented side shields
RobCrandall/The Image Works
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Protective Clothing
Gloves to protect hands
Made of leather or some other type of fire-resistant material
Leather capes, sleeves, shoulder garments with detachable bibs, aprons Split-type apron if sitting down
No place to collect hot particles
High-top shoes
Leggings and spats
Department of Labor
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Protective Clothing
100% cotton or wool Thick enough to prevent injurious untraviolet rays from penetrating to skin Long sleeves Shirts buttoned to neck Shirttails tucked Cuffless pants long enough to cover top of leather boots
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Protective Clothing
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Further Protection
Ear Protection
Full ear muffs that cover entire ear or ear plugs Dangers
Noise Hot weld spatter or slag entering ear canal
Flume Protection
Always use proper ventilation to keep head out of fume plume
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