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an electric arc.
Transformer Rectifier
Inverter
Reactor
Inductance Coil
Selects Output
Welding Current
Smoothes / Filters
DC Output
DC - Smooth
High Voltage
Low Amperage
AC - 20,000 Hz DC - Rippled
Low Voltage
Low Voltage
High Amperage High Amperage
DC - Rippled
AC - 50/60 Hz
High Voltage
High Voltage
Low Amperage Low Amperage
Transformer
Bridge Rectifier
Changes AC to DC
DC - Smooth
Low Voltage
High Amperage
AC - 20,000 Hz
High Voltage
Low Amperage
Benefits
Wt (Kg)
60
1,740
10,000
50,000
100,000
200,000
Eff (%)
19.5
3.05
2.7
1.9
1.7
1.5
90
96
97
98.1
98.2
98.3
Alex Anderson, EFW
November 10, 1911
Paper Presented to AIEE
More Efficient
Lighter Weight
More Portable
Smaller Size
More Compact
Advanced Desig
Superior Output
Direct Current
DC -
+
Heat Concentrated at
Heat Concentrated at
Workpiece
Electrode
Lower Penetration
Medium to Deep
Penetration
+
Increased Deposition
Rates
9
AC Polarity
10
AC/DC - 225/125
Alternating Current
AC - 225C
Medium Penetration
Medium Travel
Speeds
11
12
PWPW-355M
R3R - 500
IDEALARC 250
V275V275-S
13
14
RANGER GXT
RANGER 10,000
RANGER 33-Phase
15
16
Constant Current
Constant Voltage
Welding Circuit
Welding Circuit
Consists of Power
Source, Electrode and
Work Cables/Leads
The Power Source
Keeps the Current as
Constant as Possible
even when the Operator
Varies the Arc Length
Voltage is Proportional
to Arc Length
17
Consists of Power
Source, Wire Feeder,
and Work and Electrode
Cables/Leads
Voltage is Proportional
to Arc Length
Current Changes
Dramatically to Maintain
Constant Arc Length
18
Arc
Welding Processes
19
20
21
22
SMAW
Electrode
Extruded covering
Gaseous shield
Molten pool
23
Slag
Arc stream
Weld
Base metal
24
Advantages
Limitations
Low Start Up
Low Efficiency
Costs
Portability
Outdoor
All Position
Welding
Variety of
Materials
Mechanical
Properties
(65%)
Operating Factor
Operator Skill
Restarts
Amperage Limit
Slag
Spatter
25
26
FCAW-G
AWS Numbering System-SMAW
E7018
Electrode
Tensile Strength (ksi)
Position
Type of coating & current
27
28
FCAW-S
FCAW-g
29
30
Wire Feeders
FCAW-g
31
32
Advantages
Limitations
Bead Appearance
Little to No Spatter
Portability
High Deposition
Rates
Mechanical
Properties
High Efficiencies
(90+%)
Easy Re-strike
All Position Welding
Low Hydrogen Weld
Deposits
Outdoor Weldability
Potential
for Gas
Marks
High Radiated Heat
Slag
33
34
Advantages
Outdoor Usability
FCAW-s
Minimize Restarts
No Shielding Gas
Costs
High Deposition
Rates
Mechanical Properties
Effective Smoke
Removal
Analysis Steels
36
Limitations
AWS Classification
E7XT-Y
Electrode
Spatter
Slag (Cleaning
Welding Position
Time)
Break Electrode to
Restrike
37
38
GMAW
Gas nozzle
Arc
Contact tube
Weld metal
Base metal
Weld pool
39
Advantages
40
Limitations
Variety of Metals
Various Thickness
Cost
of Materials
High Efficiency
Applications
High Radiated Heat
All Position Welding
Quality Welds
Little to No Slag
Low Spatter
Portability
Outdoor Welding
Operator Skill
41
42
AWS Classification
AWS Classification
ER70S-X
Electrode
Rod
70,000 psi Min. Tensile Strength
Solid
Chemistry, Amount of Deoxidizers (Silicon,
Manganese and/or Aluminum, Zirconium and
Titanium) X=2,3,4,6,7 or G
E70C-Y
Electrode
70,000 psi Min. Tensile Strength
Metal Core Electrode
Usability & Performance Capabilities
43
44
SAW
Contact Tube
Slag
Flux
Weld
45
Automatic
46
Mechanized SAW
Mechanized
SAW
SAW
47
48
Mechanized
SAW:
Mechanized
Semiautomatic
Handheld SAW
SAW
SAW
49
Advantages
50
Limitations continued
Portability
High Deposition
Downhand Welding
Rates
Typically Deep
Penetration
Only
Abrasive Nature of
Flux on Machinery
Housekeeping and
Storage of Flux
Slag
51
52
GTAW
AWS Classification
Electrodes & Fluxes
FXYZ-EM12K-Ni1
Flux
Min. Tensile Strength
Type of Heat Treatment
Low Temp Impact Strength
Solid Electrode Wire
Level of Manganese
Nominal Carbon Content
Silicon Killed Steel
Type and Amount of Alloy in the Weld Deposit
53
54
GTAW
GTAW
55
56
Process Selection/Application
GTAW
58
10