Documente Academic
Documente Profesional
Documente Cultură
Prof.S.Sundaresan
L&T Welding Chair
M.S.University, Baroda
Basic ideas
&
Terminology
• Fusion and pressure welding
• Heat sources
Arc, gas, power beam,
electrical resistance
• Shielding
Flux (MMAW, SAW)
Gas (GTAW, GMAW)
Vacuum (EBW)
Welding
direction
Unaffected
parent material
Voltage Operating
point
SCC
Current
Friction welding
GMAW
Including
FCAW
Manual metal arc welding
(Shielded metal arc welding)
• Flux-coated electrode
• Manual mode
Manual metal-arc welding (MMAW)
Metal transfer
Welding direction
• Iron-powder electrodes
Increase in productivity
• Low-hydrogen electrodes
Need for baking electrodes
• Advantages of MMAW
Cheap
Flexible
Versatile
• Disadvantages
Slow (current limitation)
Discontinuous
• POROSITY
• SLAG INCLUSIONS
• SPATTER
• INCOMPLETE JOINT PENETRATION
• INCOMPLETE FUSION
ARC STRIKE
• STARTING POROSITY
From reel
Arc
Work
• SLAG INCLUSIONS
• POROSITY
• INCOMPLETE FUSION
• ARC BLOW
Gas tungsten-arc welding (GTAW)
• Why gas shield?
• Aluminium, other non-ferrous alloys,
alloy steels
• Non-consumable electrode
• Shielding gas only inert (Ar or He)
• Electrode polarity (DCEN or AC)
• Advantages, applications, disadvantages
Gas tungsten-arc welding (GTAW)
Water cooling of torch
Gas tungsten-arc welding (GTAW)
GTA WELDING WITH
FLUX ACTIVATION (A-TIG ROCESS)
• Application of flux as thin coating
Dramatic increase in penetration depth
– Reduction in distortion
• Possibility of microstructural
modification, believed due to
enhanced constitutional undercooling
GTAW DISCONTINUITIES
• POROSITY
• INCOMPLETE FUSION
• INCOMPLETE JOINT PENETRATION
• TUNGSTEN INCLUSIONS
Gas metal-arc welding (GMAW)
• Consumable electrode process
Wire-feed drive
• Aluminium, other non-ferrous alloys,
alloy steels, unalloyed
steels
• Electrode polarity (always DCEP)
• Shielding gas - Inert ( Ar / He) or
active (CO2)
Gas metal-arc welding (GMAW)……
• Advantages, applications
Gas metal-arc welding (GMAW)
GMAW DISCONTINUITIES
• POROSITY
• INCOMPLETE FUSION
• INCOMPLETE JOINT
PENETRATION
Flux-cored arc welding (FCAW)
• Variant of MMAW, for continuous welding
• Also variant of GMAW, with flux addition
• Designed for ferrous materials
• POROSITY
• INCOMPLETE FUSION
• INCOMPLETE JOINT
PENETRATION
Plasma arc welding (PAW)
• TUNGSTEN INCLUSIONS
• COPPER INCLUSIONS
• TUNNELING – KEYHOLE
• INCOMPLETE FUSION
• INCOMPLETE JOINT PENETRATION
Friction stir welding
Region of metal surrounding probe (and below it) heated up and thermally
conditioned
Flow of material around the probe and coalescence behind it (as tool
traverses forward)