Module 3

Metal Joining
and
Cutting Processes

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Welding Process Knowledge A Benefit to Inspectors

Helps spot problems
Leads to better inspection
Gains respect of welders
Gains cooperation

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WIT Coverage of Welding

Processes
Advantages
Limitations
Equipment
Filler Metals
Techniques
Problems
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3 Basic Process Groups

Welding
Brazing
Cutting

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Weldment

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Common Features of Welding

Processes
Source of energy
Source of shielding
Filler metal (optional)

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Shielded Metal Arc

Welding(SMAW)

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SMAW

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EXXXX
SMAW Electrode

dentification System
Electrode

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EXXXX
SMAW Electrode Identification System

Strength

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EXXXX
SMAW Electrode
Identification System
Position

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Position Description
1 - used in all positions
2 - used in flat or horizontal fillets

only
3 - not used at present time
4 - used for downhill progression
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EXXXX
SMAW Electrode
Identification System
Coating/Operating
Characteristics

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Electrode Coating
Classification

F F1
#s- -EXX20,
FigureEXX24,
3.4, page
3-5
EXX27

F2 - EXXX2, EXXX3, EXXX4

F3 - EXX10, EXXX1
F4 - EXXX5, EXXX6, EXXX8

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Low Hydrogen Electrodes

Types end in a 5, 6, or 8
Purchase in sealed, metal containers
Store after opening in heated, vented
oven
Limit atmospheric exposure

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Electrode Suffixes - 1 of 2
- A1

0.5% Mo

- B1

0.5% Mo; 0.5% Cr

- B2

0.5% Mo; 1.25% Cr

- B3

1.0% Mo; 2.25% Cr

- B4

0.5% Mo; 2.0% Cr

-W

Weathering
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Electrode Suffixes - 2 of 2
- C1

2.5% Ni

- C2

3.5% Ni

- C3

1.0% Ni

- D1

0.3% Mo; 1.5% Mn

- D2

0.3% Mo; 1.75% Mn

-G

0.2% Mo; 0.3% Cr; 0.5% Ni;

1% Mn; 0.1% V
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Stainless Steel Electrodes

E308, E308L - Weld 304 and 304L
E316, E316L - Weld 316 and 316L
E309 - Weld Stainless to Carbon Steel

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SMAW Equipment

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Constant Current Power

Source

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Constant Current
As arc voltage, V, drops, arc current, A, rises
Arc V related to distance from electrode to

work
Electrode moved closer, Arc V falls, Arc A rises
Electrode moved away, Arc V rises, Arc A
drops
Arc current directly related to heat input
Welder controls heat input to work
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SMAW Advantages
Simple equipment
Inexpensive
Very portable
Welds most alloys

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SMAW Limitations
Relatively slow
Slag removal
Electrode storage considerations
Arc blow- solutions noted in text

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Magnetic Aspects of Current

Flow

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Arc Blow

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SMAW Discontinuities
Porosity
Slag inclusions
Spatter
Incomplete joint penetration
Incomplete fusion
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Gas Metal Arc Welding

(GMAW)

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GMAW Schematic

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ERXXS-X
GMAW Electrode
Identification System
Electrode

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ERXXS-X
GMAW Electrode
Identification System
Rod
(Designation used also for
GTAW filler)
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ERXXS-X
GMAW Electrode
Identification System
Strength

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ERXXS-X
GMAW Electrode
Identification System
Solid Wire

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ERXXS-X
GMAW Electrode
Identification System
Chemical Composition
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GMAW Equipment

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GMAW Nomenclature

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Constant Potential Power

Source

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Constant Potential Source

Is self-regulating (maintains

constant arc length)

Reduces effect of vertical movement
of gun
Less operator sensitive
Somewhat easier to learn
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GMAW Modes of Transfer -1

of 4

Spray

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GMAW Modes of Transfer - 2 of

4

Globular

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GMAW Modes of Transfer - 3 of

4
Pulsed Arc
The welding current is variable; it is
pulsed between high and low current
cycles set by the welder

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GMAW Modes of Transfer - 4 of

4
Short-Circuiting Transfer

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Factors for Transfer Modes

Shielding gas
Current level
Voltage level
Power supply

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GMAW Advantages
Semiautomatic process
High productivity
No slag to remove
Clean process
Continuous filler metal feed
Welds most alloys
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GMAW Limitations
Unsuitable for windy conditions
Little tolerance for contamination
Usually limited to shop welding
Equipment is more complex
Consumables - liners, contact tips
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GMAW Discontinuities
Porosity
Incomplete fusion
Incomplete joint penetration

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