Professional Documents
Culture Documents
Section 8
Unit 25 & 26
Introduction
Electric arc welding
A group of fusion welding processes that use an electric arc to
produce the heat required for melting the metal.
Advantages
Introduction-cont.
All fusion welding process have thee requirements.
Heat
Shielding
Filler metal
Process
Heat
Shielding
Filler
Material
SMAW
Electric
Arc
Inert Gas
(Flux)
Stick
Electrode
GMAW
Electric
Arc
Inert Gas
(Cylinder)
Wire
Electrode
In this class you will have the opportunity to use two (2) arc welding
processes:
SMAW
GMAW
4
2. GTAW
3. SAW
4. ESW
Electroslag Welding
5. EGW
Electrogas Welding
6. PAW
7. ASW
Safe Practices
Amperage
Voltage
Polarity
High frequency current
Wave form
GMAW
GTAW
3. Amperage range
2. Available skills
4. Amperage adjustment
3. Safety
mechanism
5. Input power requirements
6. Initial cost and operating cost
4. Manufacturer's support
5. Open circuit voltage
1: Amperage Output
The maximum output of the power
supply determines the thickness of metal
that can be welded before joint beveling
is required.
185 to 225 amps is a common size.
For an individual weld, the optimum
output amperage is determined by the
thickness of the metal, the type of joint,
welding position and type of electrode.
10
2: Duty cycle
The amount of continuous welding time
a power supply can be used is
determined by the duty cycle of the
power supply.
Duty cycle may be 100%, but usually is
less.
12
1.
Constant potential
2.
Constant current
3.
Voltage drop
4. Ampere
4.
5. Volt
5.
Arc voltage
6. Resistance
6.
Polarity
7. Ohms Law
13
Electrical Circuit
An electrical circuit is a complete path
for electricity.
Establishing an arc completes an
electric circuit .
14
Alternating Current
15
Direct Current
Direct current: The type of
current where the flow of
electrons (polarity) is in
one direction.
Controlling the polarity
allows the welder to
influence the location of
the heat.
When the electrode is
positive (+) DCRP or
DCEP it will be slightly
hotter than the base
metal.
16
Ampere
Amperes: the unit of measure for current flow.
One ampere is equal to 6.241509481018
electrons passing by a point per second.
Electricity passing through a resistance causes
heat.
An air gap is a high resistance
The greater the amperage flowing through the resistance (air
gap)--the greater the heat.
The electrode also has resistance.
Excessive amperage for the diameter of the electrode (current
density) over heats the electrode.
Insufficient amperage for the diameter of electrode makes the
electrode hard to start.
What are the characteristics of an electrode that was used with
excessive current density?
17
Voltage
Voltage is the measure of electromotive
force (Emf).
Emf is measured in units of volts
The voltage at the electrode for SMAW
determines the ease of starting and the
harshness of the arc.
Higher voltage = easier starting.
Starting voltage is called OCV.
18
Resistance
Def: that characteristic of a material that impedes the flow of an
electrical current.
Measured in units of Ohms ( )
When an electrical current passes through a resistance heat
(BTU) is produced.
The amount of heat produced is a function of the amount of
resistance (Ohms) and the amount of current (amps).
Is the resistance adjustable in the SMAW process?
19
Ohms Law
Ohm's law states that, in an electrical
circuit, the current passing through a
material is directly proportional to the
potential difference.
Commonly expressed as:
Ohms law also be used to teach a
principle of electrical safety.
20
Constant Current
In the normal operation of a transformer as amperage is
increased, the voltage decreases, and vies versa.
Electrical arc welding power supplies are modified so that either
the voltage or the amperage is relatively constant as the other
factor changes.
This allows two different types of power supplies:
Constant current
Constant potential
Constant Current--cont.
Characteristics of constant current power supply.
The machine provides a high voltage for striking the arc.
Open circuit voltage (OCV)
OCV is not adjustable for most machines
When the arc is struck the voltage drops to the welding voltage.
Arc voltage
Arc voltage varies with the arc length.
As the welding proceeds the current will not vary much as the
arc length changes.
22
Constant Current-cont.
Increasing the voltage from 20
to 25 volts (25%) only
decreases the amperage from
113 to 120 Amp (5.8%).
23
Constant Potential
The constant potential power supply is modified to produce a
relatively constant voltage as the amperage changes.
80
70
60
50
40
Vo lt s
30
20
10
0
0
50
100
150
200
250
Anpe r e s
Voltage Drop
Voltage drop is the reduction in voltage in an electrical circuit
between the source and the load.
Primary cause is resistance.
When an excessive voltage drop exists, the electrical circuit will
not perform as designed.
Localized resistance (connection) can cause excessive heat.
Excessive heat can cause component failure.
When extra long welding leads are used, the amperage must be
increased to have the same heat at the weld.
25
Corner
Butt
Lap
Edge
T
26
27
1. Surface Welds
Surface welds are welds were a material has been applied to the surface
of another material.
May or may not be blended with the work piece.
28
2. Groove Welds
Groove welds are used to fuse
the sides or ends of two pieces
of metal.
The primary use of groove
welds is to complete butt joints.
29
3. Fillet Welds
Fillet welds have a triangular cross section and are used to fuse
two faces of metal that are at a 90 degree angle to each other.
Lap Joint
Outside Corner
T Joint
30
4. Plug Welds
Plug welds are used to
attach two surfaces together
when a complete joint is not
required and the design
does not allow for any weld
bead outside the dimensions
of the metal.
31
5. Slot Welds
Slot welds are identical to plug welds except for the shape of the
holes. For slot welds, slots are machined or stamped in the upper
plate.
32
Flat
Horizontal
Vertical Up
Vertical Down
Overhead
33
Weld Nomenclature
Penetration
Bead
Base metal
Joint Angle
Reinforcement
Bead
Root Face
Root Opening
Excessive
Penetration
34
Weld Nomenclature-cont.
Reinforcement
Toe
Face
Throat
Leg
Toe
Root
Leg
35
Weld Nomenclature-cont.
Cover Pass
Filler Pass
Root Pass
Tack Weld
36
Bead Patterns
Pattern beads are used
whenever a wider bead is
needed.
Hardsurfacing
Filler pass
Cover pass
Reduce penetration
Common patterns:
Circle
Crescent
Figure 8
37
Weld Defects
A weld defect is any physical characteristic in the completed
weld that reduces the strength and/or affects the appearance of
the weld.
The mark of a good welder is the ability to identify weld defects
and adjust the welding parameters to eliminate them.
Defects that are not visible must be detect by using destructive
or nondestructive testing.
If the defects in a weld exceed the specifications, the weld must
be removed and redone.
Welds are removed by grinding, gouging and cutting.
Eliminating a weld defect is time consuming and expensive -you must be able to complete the weld correctly the first time.
38
Cause(s)
Excessive heat
Excessive speed.
Incorrect angle
Incorrect
manipulation
Insufficient heat
Slow speed
39
Small indentions in
the surface of the
weld
Small voids
throughout the weld
material.
Cause(s)
Low heat
Long arc
Incorrect joint design
Accelerated cooling
40
Cause(s)
Accelerated cooling
Constrained joint
Small weld volume
Cracks in the
transition zone
between the weld and
base metal
Induced hydrogen
Incompatible electrode
or wire
Accelerated cooling
Misshapen
and/or uneven
ripples
Inconstant speed
Incorrect manipulation
Incorrect welder settings
41
42