1. Arc welding machine have the polarity to be set before start the welding process.

a) Define the welding polarity for arc welding machine. Having a positive or negative charge. During submerged arc welding, the electrode and the workpiece form a pair of poles: one negative and one positive. b) Explain two(2) types of welding polarity of arc welding machine

-Straight Polarity Electrode is made negative pole and workpiece is made positive pole. It is also called as electrode negative. -Reversed Polarity Electrode is made positive pole and workpiece is made negative pole. It is called electrode positive too. As we know that two third of the total heat is generated at positive pole and only one third at negative pole. Polarity is decided according to the requirement of heat at either pole. 2. Figure 1 shows the welding distortion named lack of penetration. a) Discuss two(2) reasons of this welding distortion.

Because welding involves highly localised heating of joint edges to fuse the material, nonuniform stresses are set up in the component because of expansion and contraction of the heated material. Initially, compressive stresses are created in the surrounding cold parent metal when the weld pool is formed due to the thermal expansion of the hot metal (heat affected zone) adjacent to the weld pool. However, tensile stresses occur on cooling when the contraction of the weld metal and the immediate heat affected zone is resisted by the bulk of the cold parent metal. The magnitude of thermal stresses induced into the material can be seen by the volume change in the weld area on solidification and subsequent cooling to room temperature. For example, when welding CMn steel, the molten weld metal volume will be reduced by approximately 3% on solidification and the volume of the solidified weld metal/heat affected zone (HAZ) will be reduced by a further 7% as its temperature falls from the melting point of steel to room temperature. If the stresses generated from thermal expansion/contraction exceed the yield strength of the parent metal, localised plastic deformation of the metal occurs. Plastic deformation causes a permanent reduction in the component dimensions and distorts the structure.

b) Explain two(2) methods to overcome it.

Lack of fusion results from too more heat input and / or too rapid traverse of the welding torch (gas or electric). Excess penetration arises from to high a heat input and / or too slow transverse of the welding torch (gas or electric). Excess penetration - burning through - is more of a problem with thin sheet as a higher level of skill is needed to balance heat input and torch traverse when welding thin metal. 3. Figure 2 shows the welding electrode with a code specefication. Explain four(4) specification of the welding electrode according to Figure 2. E- Indicates that this is an electrode 70 -Indicates how strong this electrode is when welded. Measured in thousands of pounds per square inch. 1 -Indicates in what welding positions it can be used. 6- Low Hydrogen, Potassium Medium AC, DCEP Indicates that there are more requirements. 4. Arc length is greatly affecting the result of the weldment. With suitable diagram, describe the effect of arc length on welding.
There's some detailed information including a video demonstrating the effect of arc length on the learning arc welding page. Beginners will commonly have too long an arc length and too great a lead angle. Note that an excessive rod lead angle will also increase the arc length. Arc Length Too Short This weld was laid with the end of the rod covered by the molten slag. The surface of the weld is uneven where it has been dragged along by the rod, and the weld will be low on power and contain slag inclusions. Arc Length OK A normal arc weld. The weld has a consistent profile and minimal spatter. Arc Length Too Long Too great a distance between the rod and the work will increase the voltage resulting in a flat and wide weld with a great deal of spatter. It also makes the arc unstable, and the slag will be difficult to remove from the edges of the weld. Sectioning this weld reveals undercutting to the left side. Arc welding is a constant current process, but the arc length has an effect on voltage. Reducing the arc length will decrease the voltage, and this reduces the heat in the weld. Increasing arc length will increase the voltage. Arc length faults can share many similarities with the current faults later on this page.