AWS Module 3 - Metal Joining and Cutting Processes

Module 3 - 1
Module 3
Metal Joining
and
Cutting
Am Processes
W
e r i c a nS e l d i n g o c i e t y
Welding Process Module 3 - 2
Knowledge -
A Benefit to Inspectors
Helps spot problems
Leads to better inspection
Gains respect of welders
Gains cooperation
Am e r i c a n We l d i n g S o c i e t y
WIT Coverage of Welding Module 3 - 3
Processes
Advantages
Limitations
Equipment
Filler Metals
Techniques
Problems
Module 3 - 4
3 Basic Process Groups

Welding
Brazing
Cutting
Module 3 - 5
Weldment
Module 3 - 6
Common Features of
Welding Processes
Source of energy
Source of shielding
Filler metal (optional)
Module 3 - 7
Shielded Metal
Arc Welding
(SMAW)
Module 3 - 8
SMAW
Module 3 - 9
EXXXX
SMAW Electrode Identification System
Electrode
Module 3 - 10
EXXXX
Strength
Module 3 - 11
EXXXX
Position
Module 3 - 12
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
Module 3 - 13
EXXXX
Coating/Operating Characteristics
Electrode Coating
Module 3 - 14
Classification
F #s - Figure 3.4, page 3-5
F1 - EXX20, EXX24, EXX27
F2 - EXXX2, EXXX3, EXXX4
F3 - EXX10, EXXX1
F4 - EXXX5, EXXX6, EXXX8
Module 3 - 15
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
Electrode Suffixes - 1 of Module 3 - 16
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
Electrode Suffixes - 2 of Module 3 - 17
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
Module 3 - 18
Stainless Steel Electrodes

E308, E308L - Weld 304 and 304L
E316, E316L - Weld 316 and 316L
E309 - Weld Stainless to Carbon
Steel
Module 3 - 19
SMAW Equipment
Module 3 - 20
Constant
Current
Power
Source
Module 3 - 21
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
Module 3 - 22
SMAW Advantages
Simple equipment
Inexpensive
Very portable
Welds most alloys
Module 3 - 23
SMAW Limitations
Relatively slow
Slag removal
Electrode storage considerations
Arc blow- solutions noted in text
Module 3 - 24
Magnetic
Aspects of
Current Flow
Module 3 - 25
Arc Blow
Module 3 - 26
SMAW Discontinuities
Porosity
Slag inclusions
Spatter
Incomplete joint penetration
Incomplete fusion
Module 3 - 27
Gas Metal Arc Welding (GMAW)
Module 3 - 28
GMAW Schematic
Module 3 - 29
ERXXS-
X
GMAW Electrode Identification System
Electrode
Module 3 - 30
ERXXS-
X
Rod
(Designation used also for GTAW filler)
Module 3 - 31
ERXXS-
X
Strength
Module 3 - 32
ERXXS-
X
Solid Wire
Module 3 - 33
ERXXS-
X
Chemical Composition
Module 3 - 34
GMAW
Equipment
Module 3 - 35
GMAW Nomenclature
Constant Potential Power Module 3 - 36
Source
Module 3 - 37
Constant Potential Source

Is self-regulating (maintains
constant arc length)
Reduces effect of vertical
movement of gun
Less operator sensitive
Somewhat easier to learn
Module 3 - 38
GMAW Modes
of Transfer - 1
of 4
Spra
y
Module 3 - 39
GMAW Modes
of Transfer - 2
of 4
Globul
ar
GMAW Modes of Transfer - Module 3 - 40
3 of 4
Pulsed Arc
The welding current is variable; it is

pulsed between high and low current
cycles set by the welder
GMAW Modes of Transfer - Module 3 - 41
4 of 4
Short-Circuiting Transfer
Module 3 - 42
Factors for Transfer Modes

Shielding gas
Current level
Voltage level
Power supply
Module 3 - 43
GMAW Advantages
Semiautomatic process
High productivity
No slag to remove
Clean process
Continuous filler metal feed
Welds most alloys
Module 3 - 44
GMAW Limitations
Unsuitable for windy conditions
Little tolerance for contamination
Usually limited to shop welding
Equipment is more complex
Consumables - liners, contact tips
Module 3 - 45
GMAW Discontinuities
Porosity
Incomplete fusion
Incomplete joint penetration

AWS Module 3 - Metal Joining and Cutting Processes

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Module 3 - 1

3 Basic Process Groups

Low Hydrogen Electrodes

Stainless Steel Electrodes

Gas Metal Arc Welding (GMAW)

Constant Potential Source

The welding current is variable; it is

Factors for Transfer Modes

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