GROUP - 7

ANALYSIS OF VARIOUS PROCESS

PARAMETERS OF SUMERGED
ARC-WELDING
Presented by:
Ankit Kumar(03610403610)
Konark Parashar(02310403610)
Roshan Chaudhary(02710403610)
Inderkant Prabhakar(02910403610

Mentor- Mr. Anil Kumar

OBJECTIVE:
The objective is to study the effect of welding
parameters and to use magnetic field
advantageously to improve the weld qualities and
properties (such as strength and hardness).
To study the effect of magnetic-field on weld-quality
and weld geometry when the field is applied-
longitudinal to electrode.
To compare the process of arc-welding with
magnetic-field and without magnetic-field.

WELDING
Welding is a process in which materials of the same
fundamental type or class are brought together and caused to
join (and become one) through the formation of primary
chemical bonds under the combined action of heat and
pressure

Types of arc Welding processes: -

GTAW (Gas Tungsten Arc Welding)
GMAW (Gas Metal Arc Welding)
SMAW (Shielded Metal Arc Welding)




Welding Processes
GTAW Gas Tungsten Arc Welding (TIG)
Non-consumable electrode
a.k.a. TIG - Tungsten Inert Gas
Shield gas usually argon
Used for thin sections of Al, Mg, Ti.
With or without filler metal
Power 8-20 kW
Current I (200 A DC)
(500 A AC)
Most expensive, highest quality
Welding Processes
GMAW Gas Metal Arc Welding (MIG)
DC reverse polarity - hottest arc
MIG - Metal Inert Gas
Consumable wire electrode
AC - unstable arc
Groover, M., Fundamentals of Modern Manufacturing,, p. 734, 1996
Gas Metal Arc Welding (GMAW) Torch
Shielding provided by gas
Double productivity of SMAW
Easily automated
Welding Processes
GMAW Gas Metal Arc Welding (MIG)
DC reverse polarity - hottest arc
MIG - Metal Inert Gas
Consumable wire electrode
AC - unstable arc
Groover, M., Fundamentals of Modern Manufacturing,, p. 734, 1996
Gas Metal Arc Welding (GMAW) Torch
Shielding provided by gas
Double productivity of SMAW
Easily automated
Welding Processes
SMAW Shielded Metal Arc Welding
Slag keeps oxygen off weld bead during cooling
Consumable electrode
Flux produces protective gas around weld pool
Flux coated rod
Power = VI 10 kW
Power... Current I (50 - 300 amps)
Voltage V (15 - 45 volts)
General purpose weldingwidely used
Thicknesses 1/8 3/4
Portable
DEFECTS IN WELD-PIECES:-

The defects which occur in the weld-pieces due to the imperfect welding conditions and their
causes are as follows:

1. Undercutting:- Undercutting is the burning away of the base metal at the toe of the weld.

CAUSES:

Current adjustment that is too high.
Arc gap that is too long.
Failure to fill up the crater completely with weld metal.

2. Incomplete penetration:-This term is used to describe the failure of the filler and base
metal to fuse together at the root of the joint.

CAUSES:

The rate of travel is too high.
The welding current is too low


3. Lack of fusion:-Lack of fusion is the failure of a welding process to fuse
together layers of weld metal or weld metal and base metal.
Causes:
Failure to raise to the melting point the temperature of the base metal or the
previously deposited weld metal.
Dirty plate surfaces.
Improper electrode size or type.
Wrong current adjustment.

4. Slag inclusion:-Slag inclusions are elongated or globular pockets of metallic oxides
and other solid compounds. They produce porosity in the weld metal.

Causes:
Failure to remove the slag between the layers causes slag inclusions.

5. Porosity: Porosity is the presence of pockets which do not contain any solid
material. They differ from slag inclusions in that the pockets contain gas rather than a
solid.

Influence of Magnetic Field:

Application of external magnetic field has been reported in the literature to affect
the characteristics of the welding arc and the weld properties. Magnetic field can
be applied to the welding arc in three different modes. If magnetic field is in the
direction of electrode travel, it is considered to be a longitudinal magnetic field. if
the field is perpendicular to the direction of electrode travel and electrode axis, it
is referred to as a transverse field.

Factors which affect the arc behavior during the application of a magnetic field
are as follows:

1. Distance between the electrodes
2. Magnetic field intensity
3. Arc current
4. Weld material




EFFECT OF MAGNETIC FIELD
ON WELDED PIECES

Visual effects
Welding speed
Spatter on weld metal
Effect on weld properties
Tensile strength
Hardness
Bead width
Penetration
Reinforcement Height

PROJECT PLANNING
Project work
distribution

JAN
Week
1 2 3 4
FEB
Week
1 2 3 4
MARCH
Week
1 2 3 4
APRIL
Week
1 2 3 4
MAY
Week
1 2 3 4
Literature
survey &
Data
Collection.
Collection of
Components
Experimental
Conduct.
Testing and
Evaluation.
Report.
REFERENCES
Serdyuk, d. b., and Kornienko, a. n.1963. The welding arc in an alternating
transverse magnetic field. Automatic welding (10):713.
A study on the modeling of magnetic arc deflection and dynamic analysis of arc
sensor by Y. H. Kang and s. j. na. Welding journal 13-s.
Mallya, U. D., and Srinivas, h. s. 1993. Magnetic steering of arc and bead
characteristics in submerged arc strip cladding. welding journal 72 (11): 517-s to
522s
Engineering Principles of Welding- processes, physics, chemistry and metallurgy
by Robert, Wissler 2004, and welding journal.
Dennary F., (1966), Electric field distribution in welding arc, physics of welding
arc, sym.IW, Cam UK.
Amstead, B.H., P.F. Ostwald, and M.L.begman (1979), manufacturing processes,
john wiley, N. Y.
Serdjuk, G.B.,(1966), magnetic forces in arc welding metal transfer, physics of
welding arc, SYM. IW, Cambridge, London.
Khan M.I. (1979), a study of Hardfacing under magnetic field, proc. ISME conf.
New Delhi, paper E.P. 4.1 Dec., PP.174.-176.

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