Moving Along with Technological Innovations: Advancements in

Arc Welding Processes and Equipment

Ilhar Ul Hassan M S
Solution Engineer, Kemppi India Private Limited

Abstract
As the technology around us evolves and improves there is always a scope of
advancement in every field. Welding being one of the major process in the fabrication
industry assimilate the scopes and innovates welding processes and equipment technologies.
New processes and variants of the established processes are being developed and perfected to
tackle the challenges from the industry. Welding equipment manufacturers are also
developing and improving their equipment to boost its capabilities and deliver quality
welding. Now the industry stands at a point where the welding systems are getting upgraded
to embrace the wave of industry 4.0. Even still large share of welding practiced in the
industry is still by arc welding processes.In GTAW and GMAW welding current wave form
control process variants like pulsed and modified short circuit process for GMAW have
emerged. The current trend in the industry is to move towards automation. Every innovationis
loomedfor improvement in efficiency and productivity.
Keywords: Arc welding processes, Arc welding equipment, Process variants, Industry 4.0.

1. Introduction

Welding as a process and the welding industry have grown remarkably in all these
years. The development and the boom of the various new process can be observed in the first
half of 20th century. As new developments and innovations occur in the technology around
us, welding processes and especially welding equipment evolves assimilating them and
enhances its capabilities. Improvements in welding equipment mainly in power sources are
essential in perfecting a welding process.

New welding processes and variants of the existing process are being developed,
studied and implemented in the industry. Friction stir welding (FSW) is a recently developed
solid state welding process. Dissimilar combinations and materials non-weldable by fusion
welding processcan be joined by FSW. Hybrid laser arc welding (HLAW) is also new
process that a combine laser and arc welding process. Even though all the arc process can be
combined with laser beam welding, Gas Metal Arc Welding (GMAW) is mostly used. It is a
high-speed process creating a weld bead of high depth to width ratio with lower heat input
and distortion. HLAW eliminates the problem such us the lower tolerance to gaps and fit up
in laser beam welding and give a better weld cap profile.

In the welding industry arc weldingprocesses dominates in fabrication, construction

and other areas like repair and maintenance. Improvements attainable in the process and the
equipment are never ending. In this paper a study of major arc welding process, its
equipment, process improvements and introduction of technology are discussed.

2. Welding Equipment

An arc welding equipment or a machine for welding process primarily consist of a

power source. The necessity of a special power source emerges from the fact that a low
voltage and high current is required forarc welding. In a broad sense the welding power
source can be classified into two; rotating and static. In rotating power source, the output for
welding is delivered by a generator or an alternator which is either driven by engine or motor.
A welding generator can provide both AC and DC output while alternator welding machine
delivers AC output. Even though rotating type was the first kind of welding power source,
they are still in use for on-site application where normal electrical supply is not available.
Static power source takes their input from the main electrical supply and delivers the required
output. So, the static power source will invariably have a transformer to step down the high
voltage input which either single or three phase.

During welding in manual process arc length is maintained by the welder while in
semi-automated it is done by the wire feeding mechanism. Wire feeders are part of the
welding system when considering semi-automated process like GMAW. This requires the
welding power source to have two types of arc characteristics namely; constant current and
constant voltage. Manual process such us SMAW and GTAW should have a power source
with constant current characteristics and constant voltage characteristics for semi-automated
process like GMAW and FCAW.

2.1 Static welding power sources

Welding transformers were the first static type power source and it delivers AC
output. Tapping the secondary coil by plugs or by tapping switches will allow the control
over the output current but in this method precise control of current is not possible.
Continuous adjustment of the welding current can be done by mechanical and electrical
means. In mechanical method or magnetic leakage type the core of the transformer or the
primary winding is moved in and out to control the current. An auxiliary circuit is used in
electrical method or magnetic amplifier type for variable saturation of the transformer core or
the reactor to vary the output current. Generally welding transformers are less expensive, but
it is not compact and is having lower efficiency.

Welding Rectifier includes a rectifier unit along with the transformer to convert AC to
DC according to the requirement. The selenium rectifiers were used in earlier machines until
it was replaced by silicon rectifiers, mostly referred as diodes. They can operate on both
single and three phase supply. Thyristor welding machines are a type of welding rectifier
where a silicon controlled rectifier (SCR) is used instead of diode. Thyristor machines allows
more control over the welding output than the diode welding rectifier. It is a closed loop
system with feedback. SCR can operate in three modes, forward conduction, forward
blocking and reverse blocking. The conduction in a half cycle is initiated by controlled
signals which can be timed as per the output requirement. Power consumption and efficiency
are moderate for these machines.

Fig. 1. Schematic of Inverter Welding Power Source

The current technology of inverter welding machines came in late 1980s pioneered by
Kemppi. These are highly efficient systems with low power consumption. The size of the
welding power source came down drastically by this technology making the machine
compact and portable. Fig.1 represent the schematic of an inverter welding power source. The
power source first rectifies and filter the input supply to DC and then switch it to a high
frequency AC which is then fed to a step-down transformer. The rectified DC form the first
rectifier is switched to high frequency AC by a power switching device either an Insulated
Gate Bipolar Transistor (IGBT) or Metal Oxide Semiconductor Field Emission Transistor
(MOSFET). The frequency is generally above 10 kHz which is quite high when compared to
the 50/60Hz supply frequency. The size of the transformer and other components have an
inverse relation to the supply frequency. So, the size of the transformer and consequently the
size of the power source got reduced. Output from the step-down transformer is then fed to a
rectifier to deliver the DC current for welding. Inverter machine can operate on both single
phase and three phase delivering AC and DC. It is closed loop system with better control over
the delivered output.

The power switching devices are microprocessor-controlled semiconductor devices

which can be software programmed for precise control in real time with fast response. So
advanced functions can be programmed and installed in these machines. Welding curves or
programs giving best arc characteristics and quality welding are developed and installed as
per the welding requirement. Welding current waveform can be controlled precisely for
specific welding application. Even upgradation of an existing welding machine can be done
to boost its capabilities and to add functions as like a smart phone.

3. Welding Processes

3.1Shielded Metal Arc Welding

Shielded metal arc welding (SMAW) or manual metal arc welding is one of the first
established arc welding process. It finds it application in various areas such as pipeline,
construction, maintenance, repair and in site welding. Welding in confined spaces can be
made with SMAW. The process allows welding of ferrous and some non-ferrous material.
The metal deposition rate is comparatively less for SMAW and the slag must be removed in
between the passes and after welding. Since the shielded electrodes are having certain fixed
length it should be frequently changed during welding and the stub goes as waste. All these
facts make SMAW a less productive process. SMAW power sources are simple,
comparatively inexpensive and requires less maintenance.

Gravity welding was developed as variant for SMAW in the 1970s. It was essentially
a mechanism with a guide bar at an angle for the electrode holder to slide in such a way that
the electrode tip will move along the joint line as the welding progress. The angle should be
in selected suitably that it gives the sliding speed for the required deposition rate. The process
is best suitable for horizontal fillet joints. Heavily coated electrodes with larger size and
length are used to increase deposition and productivity. An operator can handle multiple
welding units at a time, he just have to initiate the welding and attend when the welding is
finished or to change the electrode. This minimize the training requirement and the skill level
as compared to SMAW.

SMAW machines deliver DC output with constant current characteristics. Today the
arc welding machine comes with advanced features which increases it capabilities and results
in better productivity. The compactness and portability of the inverter- based power source
allows easy mobility and reduces welder fatigue. Voltage reduction devices (VRD) provides
safety to the welder in damp and humid conditions. By VRD the open circuit voltage is
reduced to a value generally below 35V or even 12V as per standards. The VRD works by
detecting the resistance across the terminals and suitably switch the open circuit voltage to
the higher value for the welding to initiate. Antifreeze functionality reduces the current to
minimum such that the electrode sticking to the work piece is avoided and prevents the
damage to the electrode. Most of the SMAW welding machines are currently capable of lift
TIG. Features such as hot start, arc force, remote control capability all helps in improving
welding and its quality.

3.2 Gas Tungsten Arc welding

GTAW or TIG welding uses a non-consumable tungsten electrode for welding with or
without filler wire. When welding without filler wire it is called autogenous welding. The
process uses an inert shielding gas for protection. GTAW produces clean and quality welding
and can be used for joining of a wide variety of materials including the reactive materials. It
is quite useful for thin sheet application and root pass welding. But the speed of welding and
the penetration level are comparatively low. TIG power source will have constant current
characteristics. Both DC and AC/DC welding machines are available, and a high frequency
unit will be integrated for smooth contactless arc ignition to avoid tungsten inclusions. TIG
welding of aluminium alloy is done with AC current which will provide the cleaning action
during the positive half cycle for the removal of the oxide layer.Hot Wire GTAW, Pulsed
GTAW, ATIG, FBTIG, KTIG are variants of GTAW to overcome lower penetration and
deposition as in the case of conventional process.

Hot wire process uses an auxiliary AC power source to heat the filler wire to achieve
higher deposition rate. Since the filler wire is heated near to its melting point contrary to cold
wire feeding, heat of the arc is available for proper fusion and penetration resulting in
increased welding travel speed.The advancements in automation gives more scopes for hot
wire GTAW in applications such cladding andoverlays.[3]

Ip – Peak Current
Ib – Background Current
tp – Pulse Current Duration
tb – Background Current Duration

Fig. 2 Pulsed Current Wave Form

In Pulsed GTAW instead of a steady current, current is alternated between a peak and
background current with a frequency, as shown in fig.2.The peak current will control melting
and fusion and background current keep the arc live while the weld pool cools and solidifies.
So, forrequired penetration pulsed GTAW uses lower heat input and results in faster cooling
rate and refined grains in the weld bead.Current pulsing is available in both AC and DC
power sources and the frequency for DC current can be in the range of 0.2-250Hz or
above.Power sources allows shape of the pulsed current wave form, square wave or sine
wave, to be selected depending upon the application.

Activated TIG (ATIG) and Flux Bounded TIG (FBTIG) processes increasing the
penetration almost three times that of the conventional process. The Schematic of both the
process are shown in Fig. 3. These processes use arc constriction and reverse Marangoni
effect for achieving deeper penetration. In ATIG process, flux mixed with acetone is coated
as a thin layer on the plate surface. The coated layer tends to constrict the arc and the
presence of flux reverses the surface tension behaviour of the molten metal. In the presence
of an activating agent surface tension increases as temperature increases. This phenomenon
reverses the molten metal flow increasing penetration. But in ATIG due to slight unevenness
in the layer thickness while coating the arc tends to wander resulting in poor joint strength.
So FBTIG was developed leaving a gap, along the weld joint line when coating the flux,
which is smaller than the width of weld bead in conventional process. So better arc
constriction is achieved and liquation cracking tendencies as in ATIG is avoided [4].

(a) (b)
Schematic Of (a) ATIG (b) FBTIG[4]

3.3 Gas Metal Arc Welding

Gas Metal Arc Welding (GMAW) generally know MIG/MAG (Metal Inert Gas/Metal
Active Gas) welding is widely used in the industry. A wide range of materials can be welded
with higher productivity. GMAW is a semiautomated process where the electrode is fed
continuously with a wire feeding unit and an external shielding gas is supplied during
welding. A power source with constant voltage characteristics is used for the process. Even
though widely used as manual process GMAW lend itself easily for mechanization and
automation.

As the current density of the electrode increasesvarious mode of metal transfer

namely; Short circuit, globular, spray transfers are achieved in GMAW. Shielding gas used
also influences the mode of metal transfer. Short circuit mode of transfer being the lowest in
heat input, low thickness jobs and positional welding can be done. Spray transfer give smooth
weld bead with very little spatter and high deposition, but it is restricted to flat and horizontal
fillet position. Globular transfer mode falls between both these transfer modes where the size
of the detached droplet is higher than the electrode and falls non-axially to the electrode
creating substantial amount of spatter.
 Pulse GMAW, a variant of the process helps in achieving spray transfer even at lower
current levels and a weld with minimal spatter. Current pulsing as in the case of pulsed
GTAW reduces the net heat input in the weld. So many parameters such as peak current,
background current, frequency, pulse timing are involved in pulse welding. Setting up correct
parameters for a job is very difficult. In advanced machines all these parameters are taken
care of the programs or curves installed. Selecting the required wire feed speed sets all other
parameters including the voltage according to the material and consumable combinations
selected. These are called synergic programs. Double pulse GMAW is another variant for
pulse GMAW where there are two levels of pulsing where finer control of the heat input is
possible. The fig.4 (a) represents the variation in current in double pulsing. The mean current,
frequency and the percentage of each current level can be chosen according to the
application. In the fig. 4 (a) percentage of each current level is 50%. A bead in similar
appearance to TIG welding can be achieved by this process. The fig. 4 (b) shows an
aluminium fillet weld by Double Pulse GMAW.

(a) (b)
Fig. 4. (a) Double Pulse Current Wave Form (b) GMAW Weld Bead Using Double Pulsing

Currently new process variants for GMAW are being developed by advanced control
of current wave form. Various manufactures have came with their own modified short arc
welding processes for various applications such as root welding, thin sheet welding, reduced
gap welding etc. WiseRoot+, WiseThin+, CMT, STT, ColdArc are some among them.The
figure shows the welding current trend in Kemppi’sWiseRoot+ process which is a tailored
short arc process for root pass welding.Kemppi’sWiseRoot+ process involves very precise
measurement of voltage, which serves as the input for the current control. Once the power
source has recognised a short circuit, a controlled increase in current triggers the transfer of a
droplet of filler metal from the wire. When the current measurement is exactly right, the
current is dropped, before the filler-metal droplet falls and a short circuit ends. A short circuit
ending at a point of low current produces smooth transfer of filler metal, with no spatter.
After the short circuit is broken, a pulse is created in the current that heats the welding pool,
but it does not cause transfer of filler metal. The process enables positional welding with
improved productivity.

Fig. 5. WiseRoot+ - Welding Current Trend

 Tandem GMAW is a one of the high-performance variants of GMAW. It delivers a
deposition rate more than two time that of normal GMAW and thus extend the productivity.
The wires in tandem GMAW are positioned inline with the joint direction comes out of two
isolated contact tips producing a common weld pool. The wire a separated by about half an
inch. The function of the lead wire is to generate most of the base plate penetration, while the
trail wire performs the function of controlling the weld puddle for bead contour, edge wetting and
adding to the overall weld metal deposit rate. A tandem welding system have two completely
separate welding circuit with its own welding power source and equipment [5].

4. Automation in Welding

Automation in the welding industry is driven by so many factors such as, to improve
productivity, reduce overall cost,restricted availability of skilled welders, maintain joint
integrity and consistency in critical structures, improve occupational health and safety in the
working environment. The labour cost constitute a round 70% to 80% of the total welding
cost and as it is escalating it is difficult to tie down the fabrication cost which will affect total
productivity [6]. The emergence of high-performance process like tandem welding, Hybrid
Laser Arc Welding and arc-based metal deposition additive manufacturing [7]also calls for
automation.

There are different level of automationstarting from simple mechanization to programable

robotic systems.The robotic welding systemwill have the robot and its controller, welding
equipment and communication device. The robotics systems are now affordable, and the user
interface have become much more convenient.Novel techniques are integrated to the robotic
welding system such Through-Arc Seam Tracking (TAST), for accurate welding. Through-
Arc Seam Tracking is used in arc welding for following a welding groove automatically by
weaving the welding head. Due to fit-up variation or some other reason the actual job might
be misaligned form the direction in which the robot was taught to weld. During weaving
TAST measures the arc length variations and generate signals equivalent to
weldingcurrent.The stabilised signal is then given to the robot for maintaining the welding in
the joint line.

5. The New Era: Weld 4.0

We are at the brim of the fourth wave of industrial revolution named industry 4.0.
Automations and computerization that took place in the third industrial revolution gave the
foundation for this new wave. Industry 4.0 instil the industry with the new age technologies
for communication and data exchange. It is a combination of cyber physical system, internet
of things and network, which is fuelled by data and machine learning making systems smarter
and autonomous. The real time data from a process or system are collected and transferredto
the user database. These data with proper analysis will provide insight into the process or the
system for streamlining the operation by taking the corrective action at the earliest possible
time.

Welding involves a number of parameters and variables which will affect the final
quality of the weld and are critical in a production environment. A defective weld may
become detrimental in a structure or product during its course of life. As mentioned earlier
the major parameters during welding can be collected in real time and necessary action can
be taken at the earliest. The stored data will provide traceability at any point of time to
understand what might have went wrong. These system makes the documentation process
easy and simple. In the near future we will see smart welding systems taking autonomous
decision to perform a task in optimized manner.

6. Conclusion

The timeline of arc welding equipment starting with the generator sets reached
microprocessor-controlled inverter technology machines. The digitally controlled and
programmable machines empower the development of application specific process variants
and functions. Machines with multi-process capabilities are being manufactured.
Preprogrammed curves can be installed in current MIG/MAG welding machines to suit the
material and the consumables to provide the best arc characteristics. The ability to precisely
control the welding current wave form give raise to new welding process variants itself.
Advanced controls are now available in SMAW machines for efficient starting and to avoid
sticking of electrode to the work piece which will reflect in the productivity.
Pulsed GMAW and GTAW are processes in which the current is switched between
peak and base levels alternatively resulting in a lower heat input welding process. Multi wire
welding processes are being used in the industry to increase the deposition rate and hence the
productivity. Automation of the welding system brings in consistent quality reduces overall
cost, in some processes automation becomes inevitable.With the integration of automation
with a fully matured industry 4.0 will marks the dawn of a new era in welding.

Acknowledgement

I would like to express my sincere gratitude to my Managing

DirectorMr.Rashmiranjan Mohapatrafor the support and motivation he provided and to my
company and colleagues for sharing their knowledge for completion of this paper

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