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Electric Arc Welding

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

Inexpensive power source


Relatively inexpensive equipment
Welders use standard domestic current.
Portable equipment is available
Process is fast and reliable
Short learning curve
Equipment can be used for multiple functions

Electric arc is about 9,000 oF

Introduction-cont.
All fusion welding process have thee requirements.
Heat
Shielding
Filler metal

The method used to meet these three requirements is the


primary difference between arc welding processes.

Arc Welding Requirements

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
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Eight Additional Electric Arc Welding Processes


1. FCAW

Flux Core Arc Welding

2. GTAW

Gas Tungsten Arc Welding

3. SAW

Submerged Arc Welding

4. ESW

Electroslag Welding

5. EGW

Electrogas Welding

6. PAW

Plasma Arc Welding

7. ASW

Arc Stud Welding

Safe Practices

Welders need protection from:


Arcs rays
Welding fumes
Sparks
Contact with hot metal

Arc Welding Power Supplies


The current for arc welder can be supplied by line current or by
an alternator/generator.
The amount of heat is determined by the current flow (amps)
The ease of starting and harshness of the arc is determined by the
electrical potential (volts).

Welding current adjustments can include:

Amperage
Voltage
Polarity
High frequency current
Wave form

Arc Welding Power Supplies--cont.


The type of current and the polarity of the welding current are one
of the differences between arc welding processes.
SMAW

Constant current (CC), AC, DC+ or DC-

GMAW

Constant voltage (CV) DC+ or DC-

GTAW

Constant Current (CC) ), AC, DC+ or DC-

Twelve (12) Considerations When Selecting


An Arc Welding Power Supply
1. Maximum Amperage
2. Duty cycle

1. Future needs for a power


supply

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

7. Size and portability

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.

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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.

Duty cycle is based on a 10 minute


interval.
Many power supplies have a
sloping duty cycle.

Note in the picture there is a circle


around the 75 amp setting. Why is it
there?
What is the most likely outcome of
exceeding a power supply duty cycle?
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Five Common Output Currents


For Arc Welding
1. AC (Alternating Current)
2. DC (Direct Current)
3. ACHF (Alternating Current-High Frequency)
4. PC (Pulsed Current)
5. Square wave

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Arc Welding Electrical Terms


To understand how an electric arc welder works, you must understand
the following thirteen (13) electrical terms.
1. Electrical Circuit

1.

Constant potential

2. Direct current (DC)

2.

Constant current

3. Alternating current (AC)

3.

Voltage drop

4. Ampere

4.

Open circuit voltage

5. Volt

5.

Arc voltage

6. Resistance

6.

Polarity

7. Ohms Law

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Electrical Circuit
An electrical circuit is a complete path
for electricity.
Establishing an arc completes an
electric circuit .

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Alternating Current

Alternating current: The type


of current where the flow of
electrons reverses direction
(polarity) at regular intervals.
Recommended current for
SMAW general purpose
electrodes and flat position.

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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.

When the base metal is positive (+),


DCSP or DCEN, the base metal will be
slightly hotter than the electrode.
DC current is required for GMAW
It is frequently used for SMAW

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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?
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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.

Voltage is adjustable in dual control SMAW machines.


Changing the voltage adjusts a GMAW machine for different
metal thickness.

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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?

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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.

Amperage is the harmful portion of


electrical current.
Rearranging Ohms Law for
amperage shows that amperage
(current flow) is determined by the
voltage divided by the resistance.
The higher the resistance, the less
current that will flow for a given
voltage.

What does this principle


mean for SMAW?

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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

In a constant current power supply, the current (amperage)


stays relatively constant when the voltage is changed.
GMAW

In a constant potential power supply, the voltage stays


relatively constant when the amperage is changed.
SMAW
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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.

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Constant Current-cont.
Increasing the voltage from 20
to 25 volts (25%) only
decreases the amperage from
113 to 120 Amp (5.8%).

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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

Characteristic of GMAW power supplies.


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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.

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Joints, Welds & Positions


Electric arc welding uses the same
five (5) types of joints and five (5)
types of welds and five (5) positions.
Five (5) joints:

Corner

Butt
Lap
Edge
T

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Joints, Welds & Positions


Five types of welds
1. Surface
2. Groove
3. Fillet
4. Plug
5. Slot

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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.

Two common applications are for hard


surfacing
and padding.

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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.

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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

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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.

The holes can be made with a drill bit or punch.


The weld is completed by establishing the arc on the bottom plate and
then continuing to weld until the hole is full.

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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.

They are complete the same as plug welds.

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Joints, Welds & Positions


Arc Welding Positions

Flat

Horizontal

Vertical Up

Vertical Down

Overhead
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Weld Nomenclature

Penetration

Bead

Base metal
Joint Angle

Reinforcement
Bead

Root Face
Root Opening

Excessive
Penetration
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Weld Nomenclature-cont.

Reinforcement
Toe
Face
Throat

Leg

Toe

Root

Leg
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Weld Nomenclature-cont.

In multiple pass welds, each pass has a specific function.

If it is not used, the heat of


the weld will cause the joint
to close.

Cover Pass
Filler Pass
Root Pass

Tack Weld

The filler pass is used to fill in the joint.

A tack weld is used to hold


the joint at the desired gap.

The root pass is used to fuse the


root of the weld.
If the root pass does not have
adequate penetration, it must be
cut or gouged out before the
weld is completed.

A pattern bead or multiple stringer beads will be used.


The cover pass isnt used for strength. It is used for appearance and to
fill in surface voids.

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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

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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.

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Common Defects and Causes


Description
The depth of the weld
is less than
specifications.
The weld metal is not
completely fused to
base metal or passes
are not completely
fused.
Weld material flows
over, but is not fused
with the base metal.

Cause(s)
Excessive heat
Excessive speed.

Incorrect angle
Incorrect
manipulation
Insufficient heat

Slow speed

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Common Defects and Causes--cont.


Description
Weld bead does not
extend to the
desired depth.

Small indentions in
the surface of the
weld
Small voids
throughout the weld
material.

Cause(s)
Low heat
Long arc
Incorrect joint design

Excessive gas in the


weld zone.
Moisture
Rust
Dirt

Accelerated cooling

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Common Defects and Causes--cont.


Description

Cause(s)

Usually visible cracks


on the surface or
through the weld

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
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