Co2 Presentation by Schwing Stetter

Basics Of CO2
Welding
Duration : 1 Hr
© SSIPL 2009
Theory + Practical
© SCHWING Stetter (India) Private Limited
Safety First!
Wear Face Shield Before Welding
1/20/19
Safety First!
Wear Nose Mask Before Welding
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Safety First!
ELECTRIC SHOCK can kill
• Do not touch electrically live parts or electrode with skin or wet

clothing.
• Insulate yourself from work and ground.
Close fitting protective clothing, a leather apron &

spats must be worn.
Rings & jewellery should NOT be worn while using any

welding equipment
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Safety First!
Wear Gloves Before Starting Work
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Safety First!
Wear Grinding glasses
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SYNOPSIS:
• Welding Machine & Accessories

• Welding symbols
• Welding positions
• Types of weld joints
• Types of defects
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Process Schematic diagram :
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Schematic diagram of Torch:
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Primary Gases for Fabrication :
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Cylinder pressure Gauge Kit :
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Welding Coils :
The predominantly used welding coil for welding MS material is ER 70 S 6
E R 70 S 6
Electrode Rod /Wire Tensile Solid wire Chemical

Strength in Composition
N/mm2
(700 N/mm2 )
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Preliminary Welding Symbols :
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Preliminary Welding Symbols :
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WELDING POSITIONS:
PA Flat position
PB Horizontal vertical Position
PC Horizontal position
PD Horizontal Over head Position
PE Over Head Position
PF Vertical up Position
PG Vertical down Position
Arrow Position indicates the torch Angle

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Welding Process:
Proper welding depends on the following factors:
• Selection of WPS based on job to be welded .

• Correct Edge preparation of work to be welded based on WPS
• Selection of the correct electrode/wire based on WPS
• Correct welding current based on WPS
• By maintaining Proper arc length
• By maintaining Proper travel speed
• By maintaining Proper angle of electrode or wire
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Types of Joints:
The predominant joints used in most of the welding
processes are
• Butt Joint
• Fillet Joint
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DETAILED VIEW OF BUTT & FILLET:
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FILLET WELD : Symbol
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Arc Length Parameters :
The electrical stick-out is the distance between the end of the contact tip and the end
of the wire. It is either called STICK OUT or ARC LENGTH
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Concave Fillet Weld :
 A fillet in which the contour of the weld is below a straight line

joining the toes of the weld.
 Concave fillet weld of a specified leg length has a throat thickness less than the
effective throat thickness for that size fillet.
 This means that, when a concave fillet weld is used, the throat thickness must not
be less than the effective measurement.
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Convex Fillet Weld :
 A fillet weld in which the contour of the weld metal lies outside a
straight line joining the toes of the weld.
 A convex fillet weld of specified leg length has a throat thickness

in excess of the effective measurement.
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Effect of Travel Speed :
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Torch angle for Fillet Weld :
When welding fillet welds, the torch should

be positioned at an
angle of 45° from the bottom plate.
When welding Multi layer fillet welds, the

torch should be positioned and tilted at an
angle of ±15° from the vertical plane.
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BUTT WELD:
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When welding butt welds, the torch should be
positioned within the
centre of the groove and positioned at an angle
of 90⁰
When welding butt welds of Multi layer , the

torch should be positioned within the
centre of the groove and tilted at an angle of
±15° from the vertical
plane.
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The travel speed will influence the weld bead profile and the reinforcement
height.
 If the travel speed is too slow, a wide weld bead with excessive
rollover will result.
 Conversely, if the travel speed is too high, a narrow weld bead with
excessive Reinforcement will result.
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WELD DEFECTS :
The major weld defects are classified as ,
1) Porosity
2) Weld cracks
3) Lack of penetration
4) Excess penetration
5) Undercut
6) Under fill
7) Excess concavity
8) Excess Convexity
9) Burn through
10) Lack of fusion
11) Excess weld reinforcement
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OVERVIEW OF WELDING DEFECTS:
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OVERVIEW OF WELDING DEFECTS:
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POROSITY
Porosity − small cavities or holes resulting from gas pockets in weld metal.
POSSIBLE CAUSES CORRECTIVE ACTION

Oil, heavy rust, scale etc on plate Check hoses ,gas valves are without leak.
Small nozzle Use fresh and dry electrodes
Shielding problem , wind Use preheating / warm up work piece
Welding over slag from covered electrode Store the Electrodes properly
Set correct Gas flow parameter No Gas flow

,Damaged gas hose, excessive gas flow
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WELD CRACK

Joint is not Clean Pre-heat to remove moisture content
Improper Fit up Reduce the heat input
Poor quality of material being welded Adjust root opening
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LACK OF PENETRATION:
shallow fusion between weld metal and base metal.

Weld joint too narrow Use proper joint geometry & root gap .
Incorrect weld preparation Reduce root face height.
Incorrect Welding current parameter Use wider root opening.
Incorrect torch angle. Follow correct welding current and technique.
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EXCESS PENETRATION
Excessive Penetration − weld metal melting through base metal and hanging underneath
weld.

Welding Current too high Set proper Current
Travel speed too low. Use Appropriate travel speed
Root gap too wide. Proper Joint Fit up to be used
Root face too thin
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UNDERCUT
Incorrect current and voltage . Use the correct welding current and voltage
Travel speed too low Use Appropriate travel speed
Avoid the excessive heating of base metal
Make the arc length proper
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UNDER FILL
Improper Welding voltage & current parameters Set proper Current and voltage parameters
Increased Travel speed. Use Appropriate travel speed
Increase the layer of runs so as fill the weld gap
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EXCESS CONCAVITY
Welding Current too low.. Set proper Current
Travel speed very high Use Appropriate travel speed
Improper Joint preparation Proper Joint Fit up to be used
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EXCESS CONVEXITY
Welding Voltage too High. Proper voltage to be maintained
Travel speed too low Appropriate travel speed to be used
Weld joint too narrow. Proper Weaving technique to be used
Excessive electrode extension
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BURN THROUGH
Burn-Through − weld metal melting completely through base metal resulting in holes
where no metal remains.

Welding current and voltage too high Use appropriate welding parameters
Travel speed too low. maintain steady travel speed
Decrease width of root opening Proper Fit up to be done
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LACK OF FUSION
Failure of weld metal to fuse completely with base metal or a preceding weld bead.

Incorrect welding current and voltage Proper Welding parameters to be used
Welding over convex bead. Correct electrode angle
Improper angle & position of torch Plan the welding passes for proper fusion
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EXCESS WELD REINFORCEMENT
Welding voltage too high Use optimum voltage
Travel speed too low. Use appropriate Travel speed
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SPATTERS
Scattering of molten metal particles that cool to solid form near weld bead.

Poor welding techniques Hold proper arc length
Incorrect weld parameters Adjust for proper welding parameters
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Thank you….
1/20/19

Co2 Presentation by Schwing Stetter

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Basics Of CO2

• Do not touch electrically live parts or electrode with skin or wet

• Insulate yourself from work and ground.

Close fitting protective clothing, a leather apron &

Rings & jewellery should NOT be worn while using any

• Welding Machine & Accessories

Electrode Rod /Wire Tensile Solid wire Chemical

PB Horizontal vertical Position

PD Horizontal Over head Position

PE Over Head Position

PG Vertical down Position

Arrow Position indicates the torch Angle

Proper welding depends on the following factors:

• Selection of WPS based on job to be welded .

 A fillet in which the contour of the weld is below a straight line

 A convex fillet weld of specified leg length has a throat thickness

When welding fillet welds, the torch should

When welding Multi layer fillet welds, the

When welding butt welds of Multi layer , the

The major weld defects are classified as ,

POSSIBLE CAUSES CORRECTIVE ACTION

Set correct Gas flow parameter No Gas flow

POSSIBLE CAUSES CORRECTIVE ACTION

Improper Fit up Reduce the heat input

Poor quality of material being welded Adjust root opening

POSSIBLE CAUSES CORRECTIVE ACTION

Incorrect weld preparation Reduce root face height.

Incorrect Welding current parameter Use wider root opening.

Incorrect torch angle. Follow correct welding current and technique.

POSSIBLE CAUSES CORRECTIVE ACTION

Travel speed too low. Use Appropriate travel speed

Root gap too wide. Proper Joint Fit up to be used

Root face too thin

POSSIBLE CAUSES CORRECTIVE ACTION

Travel speed too low Use Appropriate travel speed

Avoid the excessive heating of base metal

Make the arc length proper

POSSIBLE CAUSES CORRECTIVE ACTION

Increased Travel speed. Use Appropriate travel speed

Increase the layer of runs so as fill the weld gap

POSSIBLE CAUSES CORRECTIVE ACTION

Welding Current too low.. Set proper Current

Travel speed very high Use Appropriate travel speed

Improper Joint preparation Proper Joint Fit up to be used

POSSIBLE CAUSES CORRECTIVE ACTION

Welding Voltage too High. Proper voltage to be maintained

Travel speed too low Appropriate travel speed to be used

Weld joint too narrow. Proper Weaving technique to be used

Excessive electrode extension

POSSIBLE CAUSES CORRECTIVE ACTION

Travel speed too low. maintain steady travel speed

Decrease width of root opening Proper Fit up to be done

POSSIBLE CAUSES CORRECTIVE ACTION

Welding over convex bead. Correct electrode angle

POSSIBLE CAUSES CORRECTIVE ACTION

Welding voltage too high Use optimum voltage

Travel speed too low. Use appropriate Travel speed

POSSIBLE CAUSES CORRECTIVE ACTION

Incorrect weld parameters Adjust for proper welding parameters

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