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ARC WELDING
ELECTRIC ARC
WITHOUT ADDITIONAL
AUTOGENEOUS
EXTERNAL SOURCE
NONCONSUMABLE- CONSUMABLE
CONSISTANTLY IMPROVED
1895 N.G. SLAVIANOFF USED METALLIC ELECTRODES
1905 BARE ELECTRODES COATEDSHIELDING--- (SAW)
PORTABLE AND AUTOMATIC WELDING MACHINES
Dr. N. RAMACHANDRAN, NITC
ANODE +
ELECTRON THEORY
CATHODE -
DC
ELECTRON IMPINGEMENT
AND
IONIC BOMBARDMENT
11
ANODE+
HIGH HEAT
ELECTRON IMPINGEMENT
LOW HEAT
MEDIUM HEAT
IONIC BOMBARDMENT
CATHODE -
12
13
POLARITY
AC
1.
2.
3.
4.
5.
6.
14
DCRP
1.
2.
3.
4.
5.
6.
15
DCSP
1.
2.
3.
4.
5.
6.
16
17
METALLURGY OF WELDING
During joining, localized heating occurs.
This leads to metallurgical and physical changes in materials welded.
2.
3.
4.
5.
6.
1) Base Metal
19
20
Gas shield
Arc column makes CRATER on
striking the surface- Temperature
above 1500 C
21
22
EQUIPMENT
23
24
PURPOSE OF COATING
Gives out inert or protective gas- shields
Stabilizes the arc- by chemicals
Low rate consumption of electrode- directs arc and
molten metal
Removes impurities and oxides as slag
Coatings act as insulators- so narrow grooves welded
Provide means to introduce alloying elements
25
26
27
28
SAFETY PRECAUTIONS
Uses
31
32
ARC EYE
33
Signs
Intense lacrimation
Blepharospasm
Photophobia
Fluorescein dye staining will reveal corneal ulcers
under blue light
Management
Instill topical anaesthesia
Inspect the cornea for any foreign body
Patch the worse of the two eyes and prescribe analgesia
Topical antibiotics in the form of eye drops or eye
ointment or both should be prescribed for prophylaxis
against infection
Dr. N. RAMACHANDRAN, NITC
34
What Is Welding ?
Process of joining metals / alloys
The process performed by Heat with or
without Pressure
Filler metal may or may not be used
The joint will be homogeneous
Classification Of Welding
1 Pressure Welding With Heat &
Pressure
Types Of Pressure
Welding
Forge Welding
Resistance Butt / Flash Butt / Stud
Welding
Resistance Spot Welding
Resistance Seam welding
SMAW Process
Core Wire
Pool
Base Metal
Characteristic Of Power
Source
Manual welding
Machine welding
Drooping Cons. A
Linear Cons. V
V1
Vertical
Curve
V2
Horizontal
Curve
V1
V2
A1 A2
A
A1
A2
Electrode
Consumable
Metallic Wire Coated with Flux
Conducts Current and generates Arc
Wire melts & deposited as filler in joint
Function Of Flux In
welding
Stabilizes Arc
Prevents contamination of weld metal
Cleans the weld from unwanted
impurities
Increases fluidity of molten metal
Generates inert gas shielding while metal
transfers
Function Of Flux In
welding
Forms slag after melting & covers weld
Allows deposited metal to cool slowly
Introduces alloying elements in the weld
Increases deposition efficiency
Minimizes the spatter generation
Helps in even & uniform bead finish
Current
Time
required
for burning
in seconds
14
40 60 A
50-55
---
350
12
60 85 A
60-65
---
3.15
450
10
100 130
A
80 -85
120 - 140
450
130 180
A
85-90
110 - 120
450
150 210
A
90-95
80 - 90
6.3
450
240 250
A
95-100
60 -70
Dia
Length
300
2.5
No
Gage
Average
electrodes
consumed in
8 Hrs shift
ASME Classification Of
Electrodes
SFA 5.1
E 7018
E = Electrode
70 = UTS in 1000 psi ( 60/70/80/90/100/ 110)
1 = Position (1= all, 2= 1G, 1F & 2F, 3= 1G
& 1F)
8 = Type of coating (0,1,2,3,5,6,8)
ELECTRODE IDENTIFICATION
Arc welding electrodes are identified using
the A.W.S, (American Welding Society)
numbering system and are made in sizes
from 1/16 to 5/16 .
An example would be a welding rod
identified as an 1/8" E6011 electrode.
The electrode is 1/8" in diameter
The "E" stands for arc welding electrode.
54
55
56
CURRENT TYPES
SMAW is performed using either AC or
DCcurrent. Since DC current flows in one
direction, DC current can be DC straight,
(electrode negative) or DC reversed (electrode
positive). With DC reversed,(DC+ OR DCRP)
the weld penetration will be deep. DC straight
(DC- OR DCSP) the weld will have a faster melt
off and deposit rate. The weld will have medium
penetration.
Ac current changes it's polarity 120 times a
second by it's self and can not be changed as
can DC current.
Dr. N. RAMACHANDRAN, NITC
57
Electrode Table
ELECTRODE
DIAMETER
AMP
RANGE
PLATE
1/16"
20 - 40
UP TO 3/16"
3/32"
40 - 125
UP TO 1/4"
1/8
75 - 185
OVER 1/8"
5/32"
105 - 250
OVER 1/4"
3/16"
140 - 305
OVER 3/8"
1/4"
210 - 430
OVER 3/8"
5/16"
275 - 450
Note! The thicker the material
to be welded, the higher the
current needed and the larger
the electrode needed
Dr. N. RAMACHANDRAN, NITC
OVER 1/2"
58
E6011:
Same characteristics as of the E6010, but can be used with AC and
DC currents.
E6013:
Used with AC and DC currents. It produces a medium penetrating
weld with a superior weld bead appearance.
E7018:
Known as a low hydrogen electrode and can be used with AC or DC.
The coating on the electrode has a low moisture content that reduces
the introduction of hydrogen into the weld. The electrode can
produce welds of x-ray quality with medium penetration.
(This electrode must be kept dry. If wet, it must be dried in a rod oven
before use.)
Dr. N. RAMACHANDRAN, NITC
59
Why Baking?
What Is Preheating?
Heating the base metal along the weld joint to a
predetermined minimum temperature
immediately before starting the weld.
Heating by Oxy fuel flame or electric resistant
coil
Heating from opposite side of welding wherever
possible
Temperature to be verified by thermo chalks prior
to starting the weld
Why Preheating?
Preheating eliminates possible cracking of
weld and HAZ
Applicable to
Stainless Steel
Carbon Steel & LAS with minimum impact
Weld Zone
HAZ
Fusion Line
Weld Zone
Diluted BM
Weld Zone
HAZ
Fusion Line
Weld Zone
Diluted BM
Fusion Line
Diluted BM
What Is Significant Of
Dilution
Weld metal chemistry changes
depending on
the extent of dilution
Chemical elements influence Physical
properties of the joint.
Weld chemistry influences corrosion
resistance of weld overlays
Diluted BM
Weld Zone
HAZ
Fusion Line
Weld Zone
Diluted BM
40 to 50 % Over
Lap
More
Thickness
Less
Thickness
10 to 15 % Over
Lap
More Dilution
What Is Significant Of
Overlap
In
Weld
Overlap of 40
to 50%
resultsOverlay?
in Less Dilution &
Less Dilution
More
Thickness
40 to 50 % Over Lap
Less
Thickness
10 to 15 % Over Lap
More Dilution
Temper Bead
Temper Bead T1 & T2 Not To Generate
HAZ In BM
Temper Beads To Be Ground Flush
Rqd.
Reinforcement
T1
T2
5
4
3
2
1
T1 & T2 To be ground
Flush
4
3
HAZ
Good Engineering
Practices In SMAW
Do Welding with properly baked electrodes
Basic coated CS electrodes to be baked to
250C to 300C for two hours
Baked electrodes to be directly used on job
or to be retained in a hold over oven at
100C to 150C until use
Unused balance electrodes shall be
returned to baking oven
Good Engineering
Practices In SMAW
Do not weld with damp Electrodes
Do not try to heat electrodes by touching
the job (Short circuiting)
Do not use electrodes with damaged coating
Do not use electrodes with cracked coating
Do not bend the electrodes after holding it
in the holder
Good Engineering
Practices In SMAW
Do not weld on groove / surface with
mill scale or rusting
Prior to welding, clean the weld
groove with power wire wheel
Do not weld with unidentified
electrodes
Do not leave balance electrodes
unattended on shop
Good Engineering
Practices In SMAW
All connections with earthing and
welding cables shall be tight fitted
Earthing clamp shall always be
tightly connected to the job
Burn the full length of electrode till
37 mm stub length
Good Engineering
Practices In SMAW
Earthing cable shall directly connect
to the job with an earthing clamp.
Tacks for set up shall be minimum 5
times the electrode diameter
Weaving shall be limited to three
times the electrode diameter.
Only trained & qualified welders
shall be employed for welding
Good Engineering
Practices In SMAW
Do not direct fan or blower to welding arc
Remove paint if any from the area near
welding
While welding in open, area shall be
covered to protect from rain water &
breeze
Weld edge preparation shall be free from
serrations
Good Engineering
Practices In SMAW
Use poison plates between the job
material & structural supports.
Do not damage parent metal while
removing temporary supports.
Locations where from temporary
supports are removed shall be
touched up by welding / grinding
and PT checked.
Good Engineering
Practices In SMAW
Remove visible defects from welds
before placing the subsequent beads
Do not weld over a visible crack
Electrodes kept out side more than 2
Hrs shall be returned to baking oven
Maximum 15 electrodes at a time
shall be taken from oven for welding
Good Engineering
Practices In SMAW
When preheat is required, heat from
opposite side of welding.
Use temperature indicating crayons
for checking temperature
Do not Weld more than specified
weld size- Fillet / Reinforcement.
Safety Precautions in
Shielded Metal Arc Welding
Safety Precautions In
SMAW
Welders shall use safety devises
Hand gloves, Head screen with right
glass & Safety shoes
Welders shall use full sleeve boiler suit
Use welding glass-DIN 11/12 up to 250
Amps and 13 above 250 Amps
Do not look at the arc with naked eyes
Safety Precautions In
SMAW
Do not throw Stubs on ground. They shall
be placed in stub collector.
Do not keep electrode in the holder when
work is not in progress
Do not touch the electrode held on holder
and the the job when the power source is
on
Keep welding cables duly wound near
power source when no welding is done
Safety Precautions In
SMAW
Do not breath welding fumes
When working in confined area,
ensure adequate ventilation / exhaust
Gas cutting torch / preheating burner
shall not be taken inside confined
area unless the flame is lit
When not in use, switch off the the
power source from electric supply
Safety Precautions In
SMAW
Acetone / inflammable liquids
(Chemical for dye penetrant test) shall
not be brought near welding
Gas cutting unit / fuel gas cylinders
shall be away from welding area
Wet safety Shoes or wet hand gloves
shall not be worn while welding