Chapter WP

The Japan Welding Engineering Society
Lecture for SWE / WE
Welding Processes and Equipment
J i i
Joining and
d Welding
W ldi Research
R h Institute
I tit t
Osaka University
Manabu TANAKA
A brief introduction of JWRI
Manabu TANAKA
Joining and Welding Research Institute

Osaka University
Osaka, Japan
1
Firstly, about
Do you know Osaka in Japan?

Osaka University
Nagoya
Kyoto
Tokyo
Osaka
2
History of Osaka University
Kaitokudo Tekijuku
(School of General Education) (School of Dutch Studies)
1724 1838
Osaka Pref.
K. Ogata
Medical School
Osaka 1880
Industrial School
1896
Osaka Imperial University
1931
Osaka University First President

1949 H. Nagaoka
Organization of Osaka University
JWRI
3
Staffs and Students
Teaching staff: 2,546

Staffs Other staff: 2,072
Temporary staff: 2,753
Total: 7,321
Undergraduate: 12,018
Students Graduate: 7 924
7,924
Total: 19,942
And, about JWRI
4
Organization of JWRI
My laboratory
School of IWE
(from 2008)
Staffs and Students in JWRI
Professor: 12 Annual expenditure

(2005)
Associate Professor: 9
A i t t Professor:
Assistant P f 9 Personnel
Staffs
Post Dr Res Fellow: 15 5.0 million US$
Others: 50 Research
Total: 95 3.2 million US$
+
8.1 million US$
Total
Graduate (Mr
(Mr’s):
s): 56
16.3 million US$
Students Graduate (Dr’s): 25
Total: 81
5
History of JWRI
Department of Welding Eng.
(School of Engineering)
1944
Welding Research Center
1969
Welding Research Institute

1972
Department of Manufacturing Sci.

1987
Department of Joining & Welding Research Institute

Materials & Manufacturing Sci. 1996
2004
JWRI is approved as an ATB for IWE by the IIW

Graduate students (Mr’s) can choose subjects among 45 subjects
which include 19 subjects for IWE.
Mr’s course Credit transfer system IWE course

between Mr’s course
& IWE course All IWE subjects (438 hrs.)
15 subjects at the least +
Examination by J-ANB
Mr’s degree Mr’s degree & IWE
After two years…
6
Please ask me, If you are interested
in academic education on science &
technology of joining & welding!
tanaka@jwri.osaka-u.ac.jp
Shall we start Chapter 1?
7
Welding Processes
Principles of typical welding processes Fig. 1.2
Fusion welding
Groove face Weld metal
(Molted part) Filler metal
Brazing
g
Base metal
Base metal
Base metal Heating
Melting point: filler metal < base metal
Pressure-welded
Flash
i t f
interface
Pressure Base metal Pressure
Base metal Heating
Pressure welding
8
Classification of joining methods Fig. 1.1
Ex. Arrange following welding processes in the below table.
a. Arc welding b. Brazing c. Cold pressure welding

d. Electron beam welding e. Explosion welding f. Flash welding
g. Friction
F i ti welding
ldi h.
h Gas
G welding
ldi i.
i Laser
L welding
ldi
j. Resistance welding k. Riveting l. Soldering
m. Thermit welding
Joining energy
Chemical reaction Mechanical
Electrical energy Light energy
energy energy
Joining Mechanism
Mechanical joining
Fusion welding
Welding Pressure
welding
Brazing/
Soldering
Classification of joining methods Fig. 1.1
Joining energy
Chemical Mechanical
Electrical energy Light energy
reaction energy energy
Joining Mechanism
Riveting,
Mechanical joining
Bolt, Folding
Arc welding
Gas welding
Fusion welding Electron beam Laser welding
Thermit welding
welding
Friction
Welding Resistance welding welding
Pressure Explosion
Cold
welding Fl h welding
Flash ldi welding
pressure
welding
Brazing/ Soldering
Flame brazing Laser brazing
Soldering Induction brazing
9
Advantages & disadvantages of welding
Advantages
① Simple joint configuration
② Economical due to p possible material saving g
③ High joint efficiency & excellent leak tightness
④ Almost unlimited thickness for joining
⑤ Less noise during welding work
Disadvantages
① Distortion due to local heating & cooling
② Residual stress
③ To degrade characteristics of base metal being affected by
welding heat
④ Higher possibility of brittle fracture of the whole structure
⑤ Weld metal which has different properties from base metal
⑥ Dependence on skill of welding personnel
Categories of a weld
Reinforcement
Toe
10
Arc phenomena
Electric circuit & discharge

R
A few electrons exist in the air at room
temperature.
I 1~100 electrons/cm3
V IR
V A large
g electric field is applied.
pp
(5~10 kV/cm)
Electrons are heated by the electric

field and then are able to create a large
If a resistance is replaced by a gas…
number of ions through collisions with
Anode
陽極 Cathode
陰極
molecules in the gas.
Glass
ガラス管tube electron
Gas
ガス
ion
A
V
電流
i
From insulators to conductors
Battery
電源 (Breakdown)
It’s discharge!
11
Generation of arc Fig. 1.7
Electrode Electrod
e 架線
Power line
Current
Short-
circuited
Separation パンタグラフ
Pantograph
Arc
Generation of arc
1801: Discovery by H. Davy (UK)
【 Arcs in daily experience 】

◎ Spark between train’s pantograph & power line.
◎ Spark between plug & wall socket.
What is the physical state

of the arc discharge?
12
Plasma
Plasma
If water is heated gradually
gradually…
(at atmospheric pressure)
Gas
Plasma
is Liquid
the fourth state of matter
(ionized gas)
due to Solid
electric conductor of gas.
Arc plasma & ohmic heating
Ar He N2
Arc plasma Arc current (A) Arc voltage (V) Power (kW)
Ar 100 12 1.2
He 100 25 2.5
N2 100 28 2.8
Arc gap: 5 mm
13
Temperature of arcs Fig. 1.7
TIG arc Surface

表面１６，０００，０００Ｋ
１００，０００Ｋ
６，０００Ｋ
４，０００Ｋ
中心
Center Temperature of sun
Electrode
１６，０００Ｋ 8
紫外域
UV
赤外域
IR
１５，０００Ｋ相対強度
sity
Intens 6
１３，０００Ｋ Arc 4 Arc
１０，０００Ｋ 2
Sun
可視域
Visible
0
500 1,000 1,500
Base metal
波Wavelength
長（μｍ）(m)
Temperature of TIG arc Lights of arc & sun
Transport properties of arc plasma
14
Ionization energy & dissociation energy
25
e- He
Ne
20
energy (eV)
電圧（eV）
Hydrogen atom 15 Ar
Kr
電離電
X
Xe
e
10
Ionization
5
Ionization energy of molecules
0
第一イオン化エネルギー 0 10 20 30 40 50 60
分子　　　　（eV） Atomic
原子番号number
H 13.6
He 24.59
Ionization energy at each atomic number
C 11.27
N 14.53
O 13.62
Ne 21 57
21.57 Dissociation energy of molecules
Na 5.14
Mg 7.64
Al 5.99 熱解離エネルギー　電子衝突による
分子　　（eV）解離エネルギー（eV）
Ar 15.76
Fe 7.87 H2 4.476 8.8
H2 15.427 N2 9.760 24.3
N2 15.576 O2 5.080 7
O2 12.063 Cl2 2.475 3.7
Cl2 11.48 NO 6.48 >10
NO 9.250 OH 4.40 -
H 2O 12.614 HCl 4.48 -
CO2 13.769
CH4 12.704
Plasma in arc discharge

25
Helium, Pressure: 100 kPa Argon, Pressure: 100 kPa He
1025 1025 Ar
He Ne
20
V)
energy (eV
e-
電離電圧（eV）
1023 1023 15 Ar
Ar+
Kr
Number density (m-3)
Ar+, e- 10 Xe
Ionization
1021 1021
He+, e- 5
Ar2+
1019 1019
0
Ar3+ 0 10 20 30 40 50 60
1017 1017 Atomic number
原子番号
1015 1015
He: 24.6
24 6 eV
0 5 10 15 20 25 0 5 10 15 20 25
Temperature (103 K) Temperature (103 K) Ar : 15.8 eV
Helium Argon Ionization energy
15
104
Helium, Pressure: 100 kPa Argon, Pressure: 100 kPa
1025 1025 Ar
He
e-
Ar
Electrical conductivity (1/m)

1023 1023
Ar+
103

Ar+, e-
1021 1021
He+, e- He
Ar2+
1019 1019
102
Ar3+
1017 1017
Pressure: 100 kPa

1015 1015
0 5 10 15 20 25 0 5 10 15 20 25 10
Temperature (103 K) Temperature (103 K) 0 10 20 30
Temperature (103 K)
Helium Argon Electrical conductivity

1000
H2
100
He
Specific heat (J/gK)
O2
N2
10 CO2
1
Ar
0.1
4000 8000 1 2 104
1.2 1 6 104
1.6 2 104
Temperature (K)
Specific heat at atmospheric pressure

Energies for vibration & rotation of molecules
are also important to specific heat.
16
Arc plasma & ohmic heating
Ar He N2
Arc plasma Arc current (A) Arc voltage (V) Power (kW)
Ar 100 12 1.2
He 100 25 2.5
N2 100 28 2.8
Arc gap: 5 mm
Voltage-current characteristics in TIG arc Fig. 1.8
16 TIG arc in argon

104
アーク電圧（Ｖ）
Ar
Arc voltage (V)
Arc length: 10mm

Electrical conductivity (1/m)
14
103
He
12 Arc length: 5mm
102
10
Arc length: 2.5mm
2 5mm Pressure: 100 kPa
10
0 10 20 30
0 100 200 300 400 Temperature (103 K)
溶接 current
Arc 電流（A） (A)
Electrical conductivity
17
Structure of arc Fig. 1.7
－
距離 Cathode
C th d drop
d region
i
Cathode Arc length

Anode voltage drop Arc column
voltage
drop
電圧 Arc column 0
voltage drop
Anode drop
Arc voltage
region ＋
Voltage & current waveforms of AC arc Fig. 1.9
Re-ignition voltage
Transformer
変圧器＋ No-load voltage
リアクトル
Reactor P0
交
流 Current : i
電アーク
Arc
源
P
Power source for AC arc Q

Current / Voltage
R S
０
Time
Arc voltage: v
The phase of welding current must be later than the phase of

no-load voltage of the power source (Low power factor)
P  V I cos 
Power factor
18
Electromagnetic pinch effect & plasma jet
Figs. 1.10 & 1.11
Current
Electromagnetic force
Electrode
Current
Current Induced
magnetic field
Electromagnetic
Pinching force
force
Wire
electrode
Plasma jet
C
Current
t
Molten
metal Base metal
Plasma jet
Electromagnetic pinching force
Velocity: 100-300 m/sec.
Electromagnetic pinch effect & plasma jet

Figs. 1.10 & 1.11
Current
Electromagnetic force
プラズマ気流
Current 電極
電流
Current 電磁力電磁力
Pinching force
磁界
Wire
electrode アーク力
溶融池
Molten
metal
Plasma jet
Electromagnetic pinching force
19
Stiffness of arc due to plasma jet
TIG arc
Stiffness of arc
The arc tends to direct along the

extended path of electrode due to the
effect of the plasma jet.
Faltering arc at
lower arc current
Arc blow phenomenon Fig. 1.12
B = H Current
Torch magnetic permeability
High Low
Loop of current
magnetic magnetic Arc
flux density flux density
Base metal
Effect of work lead connection
Welding
direction
Arc Weld bead
End of base metal
Effect of work end
20
Classification of gas shielded arc welding
Nozzle Nozzle
Tungsten electrode
Arc Wire electrode
Filler metal Arc Shielding gas

Shielding gas
Weld metal Weld metal

溶融池
Base metal Weld pool Base metal Weld pool
Non-consumable electrode welding Consumable electrode welding
Melting of consumable electrode
Melting rate of welding wire

Nozzle
= arc heat to wire tip
+ Joule heat in wire extension
= a X I + b X R X I2
Wire extension
a, b: Constants, I: Welding current, Arc
R: Resistance of welding wire,
(which is dependence on a wire diameter & a length of extension)
Weld metal
Base metal Weld pool
Consumable electrode welding
21
Molten metal transfer modes Table 1.1
Welding Low current Middle current High current

processes
Φ1.2・Ｆｅ
Wire （≒100～
100～180Ａ
180Ａ）（≒180～
180～280Ａ
280Ａ）（≒280～
280～350Ａ
350Ａ）
CO2 contents is Globular transfer

more than 30% (Drop / Repelled)
MAG welding
Short-circuit
transfer
Spray transfer
CO2 contents is
less than 25%
MIG welding
Typical types of metal transfer

- Metal is transferred from the wire electrode to the work -
Short circuit Globular Spray
Low current High current
22
Effects of shielding gas on metal transfer
CO2 system Argon system
CO2→ R: R:
CO + O repelled force Ar ((inert)) repelled force
Thermal - 283kJ
Molten metal Molten metal Small
pinch Large heat loss
effect Ｒ heat loss Ｒ
magnetic
g force
agnetic
pinching force
orce
pinching fo
Drag
Electrom
Electroma
Plasma jett
Metal
transfer
(Repelled) (Drop / Spray)
Effects of shielding gas on metal transfer
Globular (Repelled)
23
Condition of spray transfer
400
Wire：steel
Wire： steel（（φ1.2mm）
mm）
Wire Ｅxt
xt..：15
15mm
mm
350
Critical current
Welding current (A)
300 Spray transfer
No-spray transfer
250
Transition region
200
Globular transfer
150
100
0 10 20 30
CO2 content in argon (%)
Penetration shapes in MIG/MAG welding Fig. 1.18
Dependence on welding current Base metal：

metal：SS400・
SS400・9mmt Wire：
Wire：YGW12・
YGW12・φ1.2
Shielding gas：
gas：Ar+20%CO2 Welding speed
speed：：200mm/min
150A・
150A ・21V 200A・
200A ・24V 250A・
250A ・27V
WF：3.3m/min
WF： WF：4.8m/min
WF： WF：6.3m/min
WF：
Penetration shape versus shielding gas
Ar + 2%CO2 Ar + 10
10%%CO2 Ar + 20
20%%CO2 Ar + 50
50%%CO2 100%
100 %CO2
Shielding gas contents
24
Penetration shapes in MIG/MAG welding Fig. 1.17
(a)Vertical up (b)Flat (c)Vertical down
Bead shape
p versus welding
gppositions
Welding positions Fig. 1.5
Welding Vertical up
direction
Welding
direction
Welding
direction
Flat
Vertical down
Welding
Welding
direction
direction
Overhead
Horizontal
25
Effects of welding conditions on penetrations
U d
Undercut
t / humping
h i bead
b d
Lack of penetration
Welding speed
Good penetration
Burn through
Welding current
Output characteristics of power source Fig. 1.20
Drooping characteristics power source

Ｅ0：No-
No-load voltage
External characteristics of power source
⊿Ⅰ＜
⊿Ⅰ ＜ ⊿V
Voltage
Arc characteristics curve
⊿V
Operation point
Ｌ０＜Ｌ1 ⊿Ⅰ
Shielded metal arc welding
Welding current Submerged arc welding
26
Output characteristics of power source
Figs. 1.20 & 1.21
Constant--current character. power source
Constant
Ｅ0 External character. of power source MIG welding

MAG welding
Constant-voltage character. power source

Voltage
⊿V ⊿Ⅰ≫ ⊿V
Ｅ0
Ｌ０＜Ｌ1
⊿Ⅰ
age
Volta
Current ⊿V
⊿Ⅰ≪ ⊿V ⊿Ⅰ
Ｌ０＜Ｌ1
TIG welding
Plasma arc welding Current
Self-correction mechanism of power source

for automatic regulation of arc length Fig. 1.21
Reduced MR with reduced I ＷＦ＝ＭＲ０ Increased MR with increased I
ＷＦ： Constant
ＷＦＩ1＜Ｉ0＜Ｉ2
ＷＦＩ0 Ｉ2
ＭＲ1 ＷＦ
Ｌ1 Ｌ０
Ｉ1 ＭＲ0 Ｌ2
ＭＲ2
Constant-voltage character. power source

Ｌ1
Ｌ０
Arc character.
Voltage
Ｌ2
External character.
of power source
Ｉ1 Ｉ0 Ｉ2
Current
27
Question and Answer for Exercise
[WE Q1.2-3]
Regarding the arc physics, choose the correct one from among the words in each
parenthesis and encircle its alphabetic symbol.
(1) The arc re-ignition voltage in shielded metal arc welding with a alternating current
power source should be [(a) higher than; (b) the same as; (c) lower than; (d) set
regardless of] the no-load voltage of the power source.
(2) The nature of an arc that tends to generate straight in the electrode axis direction is
called [(a) the linearity of an arc; (b) the arc stiffness; (c) arc blow; (d) the straight
directivity of an arc].
(3) As the thermal pinch effect becomes larger, the arc is [(a) expanded; (b) contracted;
(c) reduced in temperature; (d) rotated].
(4) Regarding the current-voltage phase relationship of alternating current power
sources the phase of welding current should be [(a) delayed; (b) matched; (c)
sources,
advanced; (d) paralleled] the phase of no-load voltage.
(5) With an increase in welding current, the electromagnetic pinch effect [(a) becomes
larger; (b) does not change; (c) becomes smaller; (d) acts repulsively].

[WE Q1.2-3]
Regarding the arc physics, choose the correct one from among the words in each
parenthesis and encircle its alphabetic symbol.
(1) The arc re-ignition voltage in shielded metal arc welding with a alternating current
power source should be [(a) higher than; (b) the same as; (c) lower than; (d) set
regardless of] the no-load voltage of the power source.
(2) The nature of an arc that tends to generate straight in the electrode axis direction is
called [(a) the linearity of an arc; (b) the arc stiffness; (c) arc blow; (d) the straight
directivity of an arc].
(3) As the thermal pinch effect becomes larger, the arc is [(a) expanded; (b) contracted;
(c) reduced in temperature; (d) rotated].
(4) Regarding the current-voltage phase relationship of alternating current power
sources the phase of welding current should be [(a) delayed; (b) matched; (c)
sources,
advanced; (d) paralleled] the phase of no-load voltage.
(5) With an increase in welding current, the electromagnetic pinch effect [(a) becomes
larger; (b) does not change; (c) becomes smaller; (d) acts repulsively].
28
[WE Q1.2-4]
In case of using 100% CO2 gas as shielding, droplet size is becoming larger than that in
case of using CO2 – Argon gas mixture. Explain the reasons.

[WE Q1.2-4]
In case of using 100% CO2 gas as shielding, droplet size is becoming larger than that in
case of using CO2 – Argon gas mixture. Explain the reasons.
The arcs in CO2 gas tends to concentrate and shrink at the bottom of droplet, because
CO2 gas has lower electric conductivity (or CO2 gas gives thermal pinch effect to the
arc due to higher specific heat).
The force of this arc acts to push the droplet up and to prevent detachment of the
droplet. The metal transfer mode in CO2 gas arc is defined as “repelled transfer”
according to IIW classification and the size of droplet becomes larger.
29
[WE Q1.2-6]
Regarding the metal transfer modes, choose the relevant one in the word group and
enter its alphabet into each parenthesis.
(1) CO2-shielded arc welding with low currents.
( )
(2) Pulsed MAG welding with low average currents.
( )
(3) CO2-shielded arc welding with medium currents.
( )
(4) MAG welding with high currents and a mixed shielding gas of 80%Ar＋20%CO2.
( )
(5) MIG welding with high currents.
( )
[Word group]
(a) short-circuiting transfer
(b) globular transfer
(c) spray transfer
(d) explosive transfer

[WE Q1.2-6]
Regarding the metal transfer modes, choose the relevant one in the word group and
enter its alphabet into each parenthesis.
(1) CO2-shielded arc welding with low currents.
( a )
(2) Pulsed MAG welding with low average currents.
( c )
(3) CO2-shielded arc welding with medium currents.
( b )
(4) MAG welding with high currents and a mixed shielding gas of 80%Ar＋20%CO2.
( c )
(5) MIG welding with high currents.
( c )
[Word group]
(a) short-circuiting transfer
(b) globular transfer
(c) spray transfer
(d) explosive transfer
30
[WE Q1.3-1]
Describe control system of the welding wire feeding for automatic welding using the
power source having drooping characteristic.

[WE Q1.3-1]
Describe control system of the welding wire feeding for automatic welding using the
power source having drooping characteristic.
Since the area at the proximity of the working point (or

operation point) of the power source with drooping
characteristic has almost the constant current
characteristic as shown in the Figure, the welding current
i.e. the wire melting rate hardly varies due to the variation
in the arc length. However, the wire melting rate must be
equivalent to the feeding speed of the feed motor in order
to keep the arc length constant during welding.
Therefore, the arc voltage in an automatic welding
equipment with the power source having drooping
characteristic is fed back to control the feed speed of
the feed motor.
For example, when the arc voltage becomes high due to
the elongation of arc, the voltage is conveyed to the feed
motor, resulting in the faster wire feed speed. On the
contrary, if the arc length gets shorter, the wire feed speed
gets slower, so that the arc length is kept constant,
providing favorable welding condition
31
[WE Q1.3-2]
In the case of automatic arc welding using the DC power source with constant potential
characteristic, constant speed wire feeding system is generally used. Give the reason.

[WE Q1.3-2]
In the case of automatic arc welding using the DC power source with constant potential
characteristic, constant speed wire feeding system is generally used. Give the reason.
In case the wire is fed at a high speed, it is difficult to make the speed control
because of the feed mortar inertia. However, in the case of the power source
with constant voltage (potential) characteristic, the self-regulation characteristic
of the power source (self-correction mechanism of power source for automatic
regulation of arc length) can be utilized, so that the suitable arc can be obtained
even at constant rate of wire feed. (See Figure)
32
[WE Q1.3-3]
Welding processes are given in the column A in the following table.
The external characteristics of the power sources and the wire (including rod) feeding
systems or electrode adjusting systems are given in Group B and Group C below.
Select and put a mark of the appropriate word in the column B and C respectively.
[Group B] Power source

(a) Drooping (or constant current) characteristics
(b) Constant potential characteristics
[Group C] Wire feeding system or electrode adjusting system
(1) Manually feeding or adjusting
(2) Voltage feed-back control feeding or adjusting
(3) Constant speed feeding or adjusting
Column A Column B Column C
Welding process Power source Wire feeding system
MMA welding (SMAW)
[manual]
TIG welding (GTAW)

[manual]
MIG welding
[automatic]
MAG welding
[semi-automatic]
Submerged arc welding

[automatic]

[WE Q1.3-3]
Welding processes are given in the column A in the following table.
The external characteristics of the power sources and the wire (including rod) feeding
systems or electrode adjusting systems are given in Group B and Group C below.
Select and put a mark of the appropriate word in the column B and C respectively.
[Group B] Power source

(a) Drooping (or constant current) characteristics
(b) Constant potential characteristics
[Group C] Wire feeding system or electrode adjusting system
(1) Manually feeding or adjusting
(2) Voltage feed-back control feeding or adjusting
(3) Constant speed feeding or adjusting
Column A Column B Column C
Welding process Power source Wire feeding system
MMA welding (SMAW)
[manual]
a 1
TIG welding (GTAW)
[manual]
a 1
MIG welding
[automatic]
b 3
MAG welding
[semi-automatic]
b 3
Submerged arc welding
[automatic]
a 2
33
Arc welding equipment
AC arc welding power source
34
Movable-shunt type Figs. 1.22 & 1.23
Primary coil Secondary coil
Core
Core
Little leaked
magnetic flux
Shunt
Movable iron shunt Primary coil Secondary coil
Main iron core

Secondary
Core
Core
Ｅ０
coil
Shunt
ＡＣ
200V
200 V
Arc voltage
Much leaked
g
magnetic flux
Primary
coil Moving
direction Arc character.
Electrode holder
Low I High I
Base metal
Welding current
Output control with voltage reducing device Fig. 1.26
 Voltage reducing device for AC arc welding machines (JIS C 9311)

 This device reduces, when the arc is halted, the voltage between the
electrode holder and base metal to be 25V or less.
 The purpose of equipping this device is for the safety of welders to
prevent an electric shock.
( < 95V)
35
Frequency of electric power supply
Frequency
 Ohm’s law; V(V) ( ) V  ZI
( ) and I(A);
 Z (W); impedance
• Resistance ZR
• Reactance Z  L
where  is the angular frequency.
When  decrease, the reactance decreases.
Overheat
Ex.
A welding power source has a reactance.
The power source is for 60 Hz. However it is used at 50 Hz, what will happen ?
Reversely, a source for 50 Hz is used at 60 Hz, what will happen ?
Full fill the ( ) with a or b.
The power source for 60 Hz is used at 50 Hz ( )

a. the coil may overheat and be destroyed.

b. The welding current may not rise to the rated secondary current.
36
Ex.
A welding power source has a reactance.
The power source is for 60 Hz. However it is used at 50 Hz, what will happen ?
Reversely, a source for 50 Hz is used at 60 Hz, what will happen ?
Full fill the ( ) with a or b.

a. the coil may overheat and be destroyed.

b. The welding current may not rise to the rated secondary current.
Ans.
In the Ohm’s law V  ZI , the reactance is Z  L
The power source for 60 Hz is used at 50 Hz (a)
The power source for 50 Hz is used at 60 Hz ( b )
DC arc welding power source
37
DC welding power source
Transformer
変圧器
Resistance
抵抗
交
Commercial
流リアクトル
Reactor
power
電
supply
源
Arc
アーク
Rectifier
整流器
（ダイオード）
(Diode)
Rectification Reactor (Smoothing of ripples)

Current
Current
電流電流
時間時間
Time Time
Thyristor-type DC welding power source Fig. 1.24
Thyristor
Reactor
Transformer
Torch
Base metal
for MIG/MAG
Output: low
Output: high
DC
(Smoothing of ripples)
50/60 Hz Ton
DC
(Rectification)
for TIG
38
Inverter-type DC welding power source Fig. 1.25
Inverter
Reactor
Transformer
Primary
rectifier
Torch
Digital inverter-
inverter-type
Secondary Base metal
rectifier
DC Ton DC DC
(Smoothing of ripples)
50/60 Hz AC
(Converting to high
frequency AC) Inverter type
~ 100k HZ
Advantage of inverter-type arc welding power source
Advantage
High frequency control by inverter

Fast-speed response Type Control frequency
& precise control
Thyristor 100 to 300 Hz
Inverter 20k to 100k Hz
Small transformer due to high frequency

AC by inverter
Ｅ ≒ Ｂ×Ａ×ｎ×ｆ
Smaller & lighter (Output) (Volume of transformer)
Ｂ：Magnetic flux density,, Ａ：Cross-section of iron core,

ｎ：Roll number of coil, ｆ：Frequency
39
Current form at arc ignition
Fast-speed response & precise control
10ms 10ms
35
35ms A ffew μs
Welding current (A)
Welding current (A)

溶接電流（）
溶接電流（）
200 200
100 100
A
A
0 0
Thyristor type Inverter type
TIG welding power source
Appearance & weight of welding power source

Smaller & lighter
Thyristor type Inverter type Digital inverter type
MGA/MIG MGA/MIG MGA/MIG
Appearance
AC/DC AC/DC AC/DC

TIG TIG TIG
Type Thyristor Inverter

Control Analog Digital
Frequency 100//120
100 120～～
300//360
300 360Hz
Hz 15～
15 ～40kHz
40kHz 80～
80 ～100kHz
100kHz
Weight 103 kg / 161 kg 47 kg / 55 kg 25kg
25 kg / 44 kg
40
Wire feeders Fig. 1.28
Wire reel
Torch
Flexible conduit
Wire feeder Push-type
Wire reel Wire reel

Flexible conduit Flexible conduit
T h
Torch
Torch
Wire feeder Wire feeder

Wire feeder
Pull-type Push-Pull type
For thin wires and soft wires which are easy to buckle.
Duty cycle of welding power sources

Working
Loading
Load Load Load Loading time

Duty cycle =
Working time
t min. t min. t min.
10 min. 10 min. 10 min.

（JIS C 9300）
Loading time at Rated Secondary Welding Current

Rated duty cycle (%) =
10 min.
min
41
[WE Q1.3-7]
There is an AC arc welding power source of rated secondary current=300 Amp and
rated duty cycle-=40%. Evaluate through calculation on the possibility of burning when
this power source is used for welding with current of 200 Amp and duty cycle of 60%.

[WE Q1.3-7]
There is an AC arc welding power source of rated secondary current=300 Amp and
rated duty cycle-=40%. Evaluate through calculation on the possibility of burning when
this power source is used for welding with current of 200 Amp and duty cycle of 60%.
When the welding power source with rated secondary current = Ir and rated duty cycle
= α is given, the permissible duty cycle β at welding current I can be calculated by the
following equation.
β ＝ ( Ir2 / I2 ) X α.
Hence, in this case,
β ＝ 3002 / 2002 X 40 = 90 (%),
In other words, the power source can be used up to 90% of duty cycle at 200 Amp, so
that when used at the duty cycle of 60%,
60% the power source can be safely used without
burning.
42
[WE Q1.3-10]
Regarding the inverter controlled arc welding power sources, choose the relevant one
and circle its alphabet.
(1) The control frequency of inverter type welding power sources is approximately;
(a) a few Hz , (b) 50
50-60
60 Hz, (c) 100
100-500
500 Hz, (d) a few kHz to a few ten kHz
(2) The control response of the inverter type welding power sources is;
(a) superior to, (b) the same as, (c) inferior to, (d) similar to, that of the Thyristor type
welding power sources.
(3) One of the features of the inverter type welding power sources is that the output of
the welding current waveform can be controlled to the changes in the arc condition.
How is the control speed?
(a) the low speed, (b) the medium speed, (c) the high speed, (d) the delayed speed
(4) The size of the inverter type welding power sources;

(a) is proportional to, (b) is inversely proportional to, (c) has nothing to do with, (d) is not
changed according to, the control frequency.
(5) The size of the inverter type welding power sources is;
(a) larger than, (b) smaller than , (c) similar to, (d) the same as , that of the Thyristor
type welding power sources.

[WE Q1.3-10]
Regarding the inverter controlled arc welding power sources, choose the relevant one
and circle its alphabet.
(1) The control frequency of inverter type welding power sources is approximately;
(a) a few Hz , (b) 50
50-60
60 Hz, (c) 100
100-500
500 Hz, (d) a few kHz to a few ten kHz
(2) The control response of the inverter type welding power sources is;
(a) superior to, (b) the same as, (c) inferior to, (d) similar to, that of the Thyristor type
welding power sources.
(3) One of the features of the inverter type welding power sources is that the output of
the welding current waveform can be controlled to the changes in the arc condition.
How is the control speed?
(a) the low speed, (b) the medium speed, (c) the high speed, (d) the delayed speed
(4) The size of the inverter type welding power sources;

(a) is proportional to, (b) is inversely proportional to, (c) has nothing to do with, (d) is not
changed according to, the control frequency.
(5) The size of the inverter type welding power sources is;
(a) larger than, (b) smaller than , (c) similar to, (d) the same as , that of the Thyristor
type welding power sources.
43
Various arc welding processes
Arc welding
 Shielded metal arc welding

 TIG welding
 Plasma arc welding
 MAG, MIG welding
 Self-shielded arc welding
 Submerged arc welding
 Electro-gas arc welding
44
Arc welding

 TIG welding
Shielded metal arc welding (SMAW)
SMAW was developed

d l d in
i
1904 by Oskar Kjellberg
(ESAB, Sweden).
45
Shielded metal arc welding: SMAW
Manual metal arc welding: MMAW
 Several type of covered (stick) electrodes
 Coated flux dissolved to
• Generate gasses -> stable arc
• M k slag
Make l -> de-oxidation
d id ti and d shield
hi ld weld
ld metal
t l
Fig. 1.4
Arc welding

 TIG welding
46
TIG welding Fig. 1.31
TIG: Tungsten Inert Gas
(Ar, He, or their mixture gases)

－
An example of weld bead appearance

(Aluminum alloy)
Effects of polarity in TIG welding

Fig. 1.32
Arc Penetr Bead W Clean
Polarity stiffness ation width loss ing
DCEN Good Dee Narrow Good No
DCEP Bad Shallow Wide Bad Yes
Weld pool
Cathode
－＋ spots
Cleaning zone
Cleaning action in aluminum
アークwelding
＋－－
－－ O id film
Oxide fil fil ＋
O id film
Oxide ＋
＋＋ Melt. Point
－ (deg)
＋－ Al 660
Al2O3 2049
Fe 1536
DCEN DCEP Fe2O3 1562
47
Effects of polarity in TIG welding
Fig. 1.32
Arc Penetr Bead W Clean
Polarity stiffness ation width loss ing
DCEN Good Dee Narrow Good No
DCEP Bad Shallow Wide Bad Yes
Weld pool
Cathode
spots
Cleaning zone
Cleaning action in aluminum
welding
Melt. Point
(deg)
Al 660
Al2O3 2049
TIG arc with AC features the characteristics of Fe 1536
the two polarities in DC, which is suitable for Fe2O3 1562
welding aluminum alloys.
Pulsed TIG welding Fig. 1.34

Welding
溶接方向direction
Arc Weld bead
Ｉp No
溶接電流
pulse
Welding current
Ｉav
Ｔp 50 Hz
Ｉb
Ｔｂ
Ｔ
250 Hz
Av. Welding current : 10 A, Peak current: 50 A, Base current: 5 A
48
Arc welding

 TIG welding
Plasma arc welding
Shielding gas Tungsten electrode Tungsten electrode
Orifice gas Constricting

nozzle
Shielding gas
Nozzle
N
Nozzle
l
TIG Plasma arc
49
Plasma arc welding Fig. 1.35
W electrode
－
Transferred plasma arc
Constricting
nozzle
－－ (plasma arc)
＋
ma P.S.
Pilot arc
P.S.
or
Plasm
H.F. generato
＋
＋
＋
Non-transferred plasma arc
(plasma jet)
W electrode
－
Constricting Constricting
nozzle nozzle －
＋
Plasma P.S.
H.F. generator
Pilot arc
Keyhole technique in plasma arc welding Fig. 1.37
Cross-section
Keyhole
Plasma arc
Weld bead (surface)
Weld bead (back side)

Plasma arc
Keyhole
50
Series arc (or Double arc)
Normal arc
W electrode Constrictin
g nozzle
Nozzle before use
Series arc
Arc Series arc
Base metal ＋
Damaged nozzle due

to series arc
Arc welding

 TIG welding
51
MIG / MAG welding Figs. 1.6 & 1.38
100%CO2
MAG：
MAG ：Metal Active Gas
as（（Ar+CO2 , Ar+O2 , CO2 etc.
etc.））
MIG ：Metal Inert Gas
as（（Ar , Ar+数
Ar+数%O2 etc.
etc.））
Ar+20%CO
Ar 20%CO2
100%Ar
Spatter generation (p. 1-

1-9)
Short-circuit & Arc recovery
MAG（
MAG （280 A, YGW16
YGW16））
52
Pulsed MIG / MAG welding Fig. 1.41
Wire
Arc
Peak current
Ｉｐ Peak current
current
Critical current
Welding c
A current
Av.
Base current
Ｉｂ Base current
Base Base
Pulse Tb Pulse Pulse

Ｔｐ
Arc welding

 TIG welding
53
Self-shielded arc welding Fig. 1.42
Wire feed motor

Wire feed rollers
Welding wire
Contact tip
Protective tube
Welding Fume, gas, vapor

power source
Molten slag
Welding arc
Solidified slag
Weld metal
Base metal Weld pool
Arc welding

 TIG welding
54
Submerged arc welding Fig. 1.43
Solid slag
Weld bead
Welding wire
Granular Wire feed roller
flux
Welding direction
Flux Granular flux

Contact tip
feed (current supply part)
tube
Cavity
Solid slag
Base
metal
Backing metal Weld pool Weld metal Molten slag
Arc welding

 TIG welding
55
Electro-gas arc welding Fig. 1.47
EGW is conducted basically by one-pass welding

using 10-35 mm thick steel plates.
Other welding processes
56
Electro-slag welding Fig. 1.50
Welding wire
Cooling water
Molten slag
Weld pool Retaining copper shoe
Weld bead
Weld direction
Cross-section
The ESW equipment typically has the
mechanism of oscillating the electrode wire,
with which one electrode wire can weld plate
thicknesses of up to 100 mm.
An application example of ESW
Welding wire
Diaphragm
Retaining steel shoe

Skin plate
Molten slag
Weld bead
スキンプレート
Skin plate
Diaphragm
ダイアフラム
Start tab
銅製ｽﾀｰﾄﾀﾌﾞ
water-cooled
（水冷式）
57
Electron beam welding Fig. 1.51
Power source for filament
Bias power source

Filament
(cathode)
High voltage power source
Grid
Anode
Focusing Power source for focusing coil

Turbo molecular
pump coil
Power source for deflection coil
Deflection
Oil rotation pump coil
Electron
beam TIG EBW
Welding
Mechanical booster (for chamber
soft vacuum) or oil diffusion
pump or turbo molecular
pump (for
( hard vacuum))
Workpiece
Oil rotation pump
X-Y table 200A, 30cm/min

Base metal: 6mmt
Fig. 1.51 Schematic of electron beam welding equipment
500kV, 40cm/min
Base metal: 135mmt
Laser beam welding Figs. 1.53 & 1.54
Discharge circuit (for excitation)

Output window
Laser oscillator
Reflector CO2 gas laser
(wavelength：10.6m)
Pressure in the oscillation tube: low (40-120Torr)
100% reflector Transmissive reflector
((resonator)
eso a o ) ((resonator)
eso a o )
Heat Circu- Focusing lens

Gas supply exchanger lation
pump
Partially evacuated gas
Workpiece
Monitor
Fig. 1.53 Basic configuration of2 CO gas laser equipment
TV camera
Laser generator
YAG laser
Guide laser
Laser head (wavelength：1.06m)
resonator
Lamp
Dichroic mirror
Mirror
Focusing lens for wellding
piece
Mirror
Lens protection glasss
Setting point of workp
Focusing lens
Lamp
YAG laser rod
Cooling Driving Work
device power source piece
Optical fiber
input terminal Optical output
system with
optical fiber
Optical
Divergent angle
output terminal
fiber
58
Energy densities of various heat sources Table 1.6
SMAW
Plasma arc W
Table 1.6 Energy densities of various heat sources
Typ e of heat source Energy density (kW/cm2 )

LBW
Oxy-acetylene flame Approx. 1
Gas flame
Oxy-hydrogen flame Approx. 3
Sunlight (1.6-3. 6) ×10-4

EBW
Concen trated sunlight beam
1-2
Light beam (1-100 kW)
Concentrated arc-light beam

1-5
（xenon lamp: up to 10 kW）
Open arc
Approx. 15
( Argon arc, 200A)
Arc
Plasma arc 50-100
Point arc App rox. 1000
Pulsed 1 0,000 or higher

Electron beam
Continuous 1000 or higher
Pulsed 1 0,000 or higher

Laser beam
Continuous 100 or higher
Resistance spot welding (RSW)

Pressure
Electrode
Melting Point
Nugget Temp..
Temp
Current
ＩＲ
Electrode
Ｈ＝ＶＩｔ＝ＲＩ 2ｔＶ
Pressure
【 Weld surface 】【 Cross section】

section】
59
Stationary resistance spot welding equipment
Electromagnetic valve
Compressed air
Pneumatic
cylinder
Upper arm
Welding power source
Electrode holder
Electrode
Lower arm
Projection welding
Pressure
Electrode Example of work
Projection
60
FSW
Rotation Rotation
FSW：
FSW ：Friction Stir Welding
Stir zone Press
Tool Rotating
母材 Travel
Shoulder
Press
Probe
① ② ③
Heat Affected Zone (HAZ)
HAZ
Stir zone
BM
FSW of aluminum alloy
FSW of aluminum alloys
Arc welding (MIG)
FSW
1,300
Weld seam
Weld seam
Rail way car

(Normal type)
A6N01
Floor panel for Shinkansen

Rail way car (Express type)
61
[WE Q1.4-1]
Pick out one welding process in which welding power source with a drooping
characteristic is usually used and explain its welding process briefly

[WE Q1.4-1]
Pick out one welding process in which welding power source with a drooping
characteristic is usually used and explain its welding process briefly
(1) Shielded metal arc welding

An electric arc is ignited between a covered electrode and base material. By utilizing
the arc heat, both electrode and base material are melted. Welding is usually done
by manual operation.
(2) Submerged arc welding with relatively larger diameter wire
Welding joint is covered by powder flux, then wire electrode is inserted in the flux
and arc is ignited between the wire and base material. The arc is submerged in the
flux burden. The electrode wire is usually fed automatically with an arc voltage feed
back control system.
(3) TIG welding process
An arc is ignited between tungsten electrode and base material under shielding of
inert gas such as argon or helium. Usually an filler wire or rod is fed by manually or
automatically. The welding is achieved so that both filler material and base material are
melted by the arc heat and mixed together. Both DC and AC may be used.
62
[WE Q1.4-2]
Pick out one welding process in which welding power source with a constant voltage
(potential) characteristic is usually used and explain its welding process briefly.

[WE Q1.4-2]
Pick out one welding process in which welding power source with a constant voltage
(potential) characteristic is usually used and explain its welding process briefly
(1) MAG welding

Relatively fine diameter wire is fed as an electrode under shielding of 100% of
CO2 gas or mixture gas of CO2 and argon. An arc is ignited between electrode and
base material. The welding is achieved so that both wire electrode and base
material are melted by the arc heat and mixed together. Both solid wire and flux-
cored wire may be used.
(2) MIG welding
Relatively fine diameter wire is fed as an electrode under shielding of inert gas
such as argon or helium. An arc is ignited between electrode and base material. The
welding is achieved so that both wire electrode and base material are melted by the
arc heat and mixed together. Usually a solid wire and DC are used.
63
[WE Q1.4-3]
Pick out one (1) process of gas-shielded metal arc welding using DC power source with
constant voltage characteristics. And then give a kind of shielding gas, the control of
wire feeding and the polarity of wire electrode applied in that welding process.
Welding process ( )
Shielding gas ( )
Wire feeding ( )
Polarity of wire electrode ( )

[WE Q1.4-3]
Pick out one (1) process of gas-shielded metal arc welding using DC power source with
constant voltage characteristics. And then give a kind of shielding gas, the control of
wire feeding and the polarity of wire electrode applied in that welding process.
Welding process ( )
Shielding gas ( )
Wire feeding ( )
Polarity of wire electrode ( )
(Case 1)
Welding process (MAG welding )
Shielding gas (CO2 gas, Ar+ CO2 mixture gas or Ar+ O2 mixture gas )
Wire feeding (Constant speed feeding )
Polarity of wire electrode (Electrode positive )
(Case 2)
Welding process (MIG welding )
Shielding gas (Ar gas or He gas )
Wire feeding (Constant speed feeding )
Polarity of wire electrode (Electrode positive )
64
[WE Q1.4-4]
Pick out a non consumable electrode gas-shielded arc welding process using DC power
source with constant current characteristics. And then give the kind of shielding gas,
the material of electrode and the polarity of electrode, when the process is applied on
welding of stainless steel.
Welding process ( )
Shielding gas ( )
Material of electrode ( )
Polarity of electrode ( )

[WE Q1.4-4]
Pick out a non consumable electrode gas-shielded arc welding process using DC power
source with constant current characteristics. And then give the kind of shielding gas,
the material of electrode and the polarity of electrode, when the process is applied on
welding of stainless steel.
Welding process ( )
Shielding gas ( )
Material of electrode ( )
Polarity of electrode ( )
Welding process ( TIG welding or Plasma welding )

Shielding gas (Ar He or Ar+H2 mixture gas )
(Ar,
Material of electrode (Tungsten or ThO2-Tungsten )
Polarity of wire electrode (Electrode negative )
65
[WE Q1.4-6]
Regarding the electric polarity used in gas shielded arc welding, choose the relevant
one from among the words in the word group below and enter its alphabetic symbol into
each parenthesis.
(1) The electrode polarity used regularly in the TIG welding of stainless steels.
( )
(2) The electrode polarity used regularly in the TIG welding of aluminum alloys.
( )
(3) The electrode polarity used regularly in the CO2-shielded arc welding of mild steels.
( )
(4) The electrode polarity used regularly in the pulsed MAG welding of high strength
steels. ( )
(5) The electrode polarity used regularly in the MIG welding of aluminum alloys.
( )
[Word group]
(a) direct-current, electrode-positive
(b) direct-current, electrode-negative
(c) alternating
(d) every polarity

[WE Q1.4-6]
Regarding the electric polarity used in gas shielded arc welding, choose the relevant
one from among the words in the word group below and enter its alphabetic symbol into
each parenthesis.
(1) The electrode polarity used regularly in the TIG welding of stainless steels.
( b )
(2) The electrode polarity used regularly in the TIG welding of aluminum alloys.
( c )
(3) The electrode polarity used regularly in the CO2-shielded arc welding of mild steels.
( a )
(4) The electrode polarity used regularly in the pulsed MAG welding of high strength
steels. ( a )
(5) The electrode polarity used regularly in the MIG welding of aluminum alloys.
( a )
[Word group]
(a) direct-current, electrode-positive
(b) direct-current, electrode-negative
(c) alternating
(d) every polarity
66
[WE Q1.4-8]
The following sentences are describing MAG welding. Choose the relevant one and circle its
alphabet.
(1) Wire extension is defined as the distance between;
(a) the edge of the nozzle and surface of the plate to be welded, (b) the edge of the contact tip and
the edge of the welding wire where the arc is igniting, (c) cathode and anode, (d) the edge of the
nozzle and the tip of the welding wire where the arc is igniting
(2) Melting rate of the wire is;
(a) proportional to welding current, (b) proportional to arc voltage, (c) determined by the heat
supplied from the arc and joule’s heat of the current in the wire extension, (d) determined by the heat
supplied from the arc.
(3) In case of using 100% CO2 gas as shielding and a solid wire;
(a) arc voltage should be decreased when welding bead become too convex, (b) welding speed
should be increased when undercut is appeared in flat position welding, (c) wire extension should be
increased when welding penetration become too shallow, (d) arc voltage should be increased when
arc varied too deep and arc become unstable
(4) “Heat efficiency” is defined as
(a) the ratio of deposition rate to wire melting rate, (b) the ratio of the heat transferred in the base
metal to welding heat input, (c) the ratio of the heat consumed in melting the wire to welding heat
input, (d) the ratio of deposition rate to welding heat input.
(5) In MAG welding with 100% CO2 gas shielding and smaller diameter wire, usually;
(a) drooping characteristic power source is used, (b) constant potential characteristic power source
is used, (c) pulse arc technique can be used, (d) short circuiting transfer with higher current can be
used

[WE Q1.4-8]
The following sentences are describing MAG welding. Choose the relevant one and circle its
alphabet.
(1) Wire extension is defined as the distance between;
(a) the edge of the nozzle and surface of the plate to be welded, (b) the edge of the contact tip and
the edge of the welding wire where the arc is igniting, (c) cathode and anode, (d) the edge of the
nozzle and the tip of the welding wire where the arc is igniting
(2) Melting rate of the wire is;
(a) proportional to welding current, (b) proportional to arc voltage, (c) determined by the heat
supplied from the arc and joule’s heat of the current in the wire extension, (d) determined by the heat
supplied from the arc.
(3) In case of using 100% CO2 gas as shielding and a solid wire;
(a) arc voltage should be decreased when welding bead become too convex, (b) welding speed
should be increased when undercut is appeared in flat position welding, (c) wire extension should be
increased when welding penetration become too shallow, (d) arc voltage should be increased when
arc varied too deep and arc become unstable
(4) “Heat efficiency” is defined as
(a) the ratio of deposition rate to wire melting rate, (b) the ratio of the heat transferred in the base
metal to welding heat input, (c) the ratio of the heat consumed in melting the wire to welding heat
input, (d) the ratio of deposition rate to welding heat input.
(5) In MAG welding with 100% CO2 gas shielding and smaller diameter wire, usually;
(a) drooping characteristic power source is used, (b) constant potential characteristic power source
is used, (c) pulse arc technique can be used, (d) short circuiting transfer with higher current can be
used
67
[WE Q1.4-9]
Give four (4) advantages and four (4) disadvantages of SAW, comparing with the
SMAW (Manual metal arc welding).

[WE Q1.4-9]
Give four (4) advantages and four (4) disadvantages of SAW, comparing with the
SMAW (Manual metal arc welding).
Advantages:
(1) With higher deposition rate, it has higher efficiency.
(2) Deeper penetration is obtainable due to larger current and current density.
(3) Weld metal deposition is less.
(4) Welding of uniform quality is possible.
(5) Provides beautiful bead appearances.
(6) There is no need filter glasses (goggles).
(7) Very few fumes generation.
Disadvantages:
(1) Equipment is large and complex,complex and hence gives inconveniences in
transportation.
(2) Not suitable for the welding of complicated work (not suitable when unit weld
line is short).
(3) Confined to flat, horizontal fillet and horizontal position welding.
(4) Need edge preparation of higher accuracy.
(5) May be sensitive to cause defect (flaw) due to rust, moisture, paint, etc.
(6) Lower notch toughness in weld and HAZ when the heat input is large.
68
[WE Q1.4-11]
The sentences below, describing MAG welding, have error(s) in the parentheses.
Correct them.
(1) In the case of shielding gas containing argon mixed with 20% of CO2 gas, the metal
transfer mode become spray transfer (when the welding speed is higher than a certain
critical value).
(2) Comparing with 100% CO2 gas shielded arc welding under the same welding
parameters, MAG welding with using mixed gas of 80% argon and 20% of CO2 has
(wider bead, but easily gets more spatter)

[WE Q1.4-11]
The sentences below, describing MAG welding, have error(s) in the parentheses.
Correct them.
(1) In the case of shielding gas containing argon mixed with 20% of CO2 gas, the metal
transfer mode become spray transfer (when the welding speed is higher than a certain
critical value).
(2) Comparing with 100% CO2 gas shielded arc welding under the same welding
parameters, MAG welding with using mixed gas of 80% argon and 20% of CO2 has
(wider bead, but easily gets more spatter)
(1) (when the welding speed is higher than a certain critical value).
speed is wrong. current is correct.
(2) (wider bead, but easily gets more spatter).

easily gets more spatter is wrong. hardly get spatter is correct.
69
[WE Q1.4-12]
Choose the relevant one and circle its alphabet.
(1) AC welding power source for SMAW is a kind of the load with a lower;
(a) power factor, (b) duty cycle, (c) thermal efficiency, (d) Arc efficiency
Therefore, in order to improving it, a;
(a) resistor, (b) reactor, (c) Thyristor, (d) capacitor
is connected in parallel in the primary circuit.
(2) In MAG welding, welding wire with a smaller diameter is fed at a higher constant
speed by utilizing;
(a) drooping characteristic, (b) thermal pinch effect, (c) self-regulation effect,
(d)cleaning action
(3) In MAG welding with 100% CO2 gas shielding, shielding in order to decrease spatter
generation, a technique of
(a) pulse current, (b) buried arc, (c) key-hole arc, (d) open arc
is usually used.

[WE Q1.4-12]
Choose the relevant one and circle its alphabet.
(1) AC welding power source for SMAW is a kind of the load with a lower;
(a) power factor, (b) duty cycle, (c) thermal efficiency, (d) Arc efficiency
Therefore, in order to improving it, a;
(a) resistor, (b) reactor, (c) Thyristor, (d) capacitor
is connected in parallel in the primary circuit.
(2) In MAG welding, welding wire with a smaller diameter is fed at a higher constant
speed by utilizing;
(a) drooping characteristic, (b) thermal pinch effect, (c) self-regulation effect,
(d)cleaning action
(3) In MAG welding with 100% CO2 gas shielding, shielding in order to decrease spatter
generation, a technique of
(a) pulse current, (b) buried arc, (c) key-hole arc, (d) open arc
is usually used.
70
[WE Q1.4-13]
Pick out at least three (3) features of TIG welding (GTAW), comparing with MMA
welding (SMAW).

[WE Q1.4-13]
Pick out at least three (3) features of TIG welding (GTAW), comparing with MMA
welding (SMAW).
(1) Flux is not necessary usually.

(2) Very easy in all position welding.
(3) Good notch toughness and clean micro-structure in weld metal due to low oxygen
content.
(4) Easy to get sound back-side weld bead in one sided welding.
(5) Many kind of metals and their alloys are able to be welded.
(6) Aluminum and its alloy are easy to weld by using AC current.
(7) Stable arc and less spatter.
71
[WE Q1.4-14]
Pick out three (3) advantages and two (2) disadvantages of MAG welding comparing to
SAW (submerged arc welding) respectively.

[WE Q1.4-14]
Pick out three (3) advantages and two (2) disadvantages of MAG welding comparing to
SAW (submerged arc welding) respectively.
Advantages
(1) Applicable in all position welding.
(2) Applicable to thinner base plate.
(3) Operation of welding is easy, because arc and molten pool are visible.
(4) Suitable to shorter weld line.
(5) Suitable to curved weld line.
(6) Easy to apply to robotic welding.
(7) Welding equipment is compact and cheap.
Disadvantages
(1) Deposition rate is low, because applicable welding current is lower.
(2) Magnetic blow of arc is apt to occur.
(3) Penetration depth is shallow, because applicable welding current is lower.
(4) Protection from wind is necessary in outdoor welding.
(5) Protection from arc radiation is necessary.
72
[WE Q1.4-15]
The following sentences describe the power source external characteristics, polarity, and shielding gas. Choose the
relevant one and circle its alphabet.
(1) Power sources that are used generally in shielded metal arc welding are the;
(a) DC type with constant-voltage characteristic
(b) AC type with constant-voltage characteristic
(c) DC type connected with electrode-positive
electrode positive polarity
(d) AC type with drooping characteristic
(2) Power sources that are used generally in TIG welding are the;
(c) DC type connected with electrode-positive polarity
(3) Power sources that are used generally in MAG welding are the;
(b) AC type with constant-amperage characteristic
(c) DC type with drooping characteristic
((4)) Power sources that are used ggenerally
y in submerged
g arc welding
g are the;;
(5) In MAG welding;
(a) argon
(b) a mixture of 80% argon and 20% carbon dioxide
(c) helium
(d) a mixture of argon and helium
is used for the shielding gas.

[WE Q1.4-15]
The following sentences describe the power source external characteristics, polarity, and shielding gas. Choose the
relevant one and circle its alphabet.
(1) Power sources that are used generally in shielded metal arc welding are the;
(c) DC type connected with electrode-positive
electrode positive polarity
(2) Power sources that are used generally in TIG welding are the;
(3) Power sources that are used generally in MAG welding are the;
(b) AC type with constant-amperage characteristic
(c) DC type with drooping characteristic
((4)) Power sources that are used ggenerally
y in submerged
g arc welding
g are the;;
(5) In MAG welding;
(a) argon
(b) a mixture of 80% argon and 20% carbon dioxide
(c) helium
(d) a mixture of argon and helium
is used for the shielding gas.
73
Automatization of arc welding
by welding robot
Arc welding robots Table 1.16
Articulated type
5
Rectangular
coordinated type
3
Twisting
Y 6 4
Z
Bending 2
Controller
74
Teaching operation
Example of teaching operation
The teaching is to teach an arc welding robot how to

operate. With the teaching-playback system, the teaching
of operation sequence is provided directly for a robot.
In this case, welding is intermitted when the teaching

operation is provided for a robot, hence welding work
cannot be performed during the teaching operation.
Off-line teaching system Fig. 1.74
•The off-line-teaching system has solved this problem, with which the teaching
operation is provided for the simulated robot on the CRT of the computer.
•The teaching data input in the computer are transmitted to the actual robot via a
p
LAN to operate the robot according
g to the teaching
g data.
•With this system, the uptime of a robot can be improved greatly.
Work transfer Control panel for

command work transfer
Host computer
equipment Work transfer equipment
system
Name of work,
Name of robot to which
data must be sent Robotic system
control panel
Motion command
Teaching
Off-line Multiplexer
teaching system
Robotic welding system
Fig. 1.74 Conceptual diagram of off-line teaching system
75
Wire-touching sensor Fig. 1.70
•Wire-touching sensors recognize the position of the base metal by detecting a change
in current or voltage when the welding wire tip touches the base metal.
•In the typical sensing procedure, the touching motion is repeated several times to
detect particular positions such as the groove and edge of a wor-kpiece.
Welding torch
No-load
wer source
Voltage
Sensor
A ①
Welding
g wire
pow
Short-circuit
②
③ ④
Touching
Current
B
C D
Base metal
Arc sensor Fig. 1.71
Welding current Welding current

ｉ R1
ｉL0 ｉ R0
ｉL1
Just on the welding seam Deviation from the welding seam

ｉ L 0 = ｉ R0 C2 C1
C0
ｉ L 1 ＜ｉ R1
ｉ R1
ｉL0 ｉ R0 ｉL1
Base metal Base metal
76
[WE Q1.5-1]
Regarding arc welding robots, choose the relevant one and circle its alphabet.
(1)
(a) Submerged arc welding, (b) MAG welding, (c) Plasma arc welding, (d) Laser welding
is widely applied for arc welding robots.
(2)
(a) Weaving, (b) Teaching, (c) Chipping, (d) Gouging
is to input the data of sequential movement and the welding conditions for an arc welding robot in
advance.
(3) When the arc welding robots is performing a welding work, it is obligated;
(a) to equip ventilation equipment, (b) to have an observer attend, (c) to equip a safety fence around
the robot for keeping workers out, (d) to equip an arc voltage reducing device
in accordance with the Industrial Safety and Health Law of Japan.
(4) The function of the arc sensor equipped in an arc welding robot is;
(a) to track the welding seam by utilizing the arc characteristics, (b) to sense the welding start point,
(c) to control a bead width constant, (d) to prevent electric shock
(5) The function of the wire-touch sensor equipped in an arc welding robot is;
(a) to track the welding seam by utilizing the arc characteristics, (b) to control the welding current
constant, (c) to control a bead width constant, (d) to sense the position of the structural member

[WE Q1.5-1]
Regarding arc welding robots, choose the relevant one and circle its alphabet.
(1)
(a) Submerged arc welding, (b) MAG welding, (c) Plasma arc welding, (d) Laser welding
is widely applied for arc welding robots.
(2)
(a) Weaving, (b) Teaching, (c) Chipping, (d) Gouging
is to input the data of sequential movement and the welding conditions for an arc welding robot in
advance.
(3) When the arc welding robots is performing a welding work, it is obligated;
(a) to equip ventilation equipment, (b) to have an observer attend, (c) to equip a safety fence around
the robot for keeping workers out, (d) to equip an arc voltage reducing device
in accordance with the Industrial Safety and Health Law of Japan.
(4) The function of the arc sensor equipped in an arc welding robot is;
(a) to track the welding seam by utilizing the arc characteristics, (b) to sense the welding start point,
(c) to control a bead width constant, (d) to prevent electric shock
(5) The function of the wire-touch sensor equipped in an arc welding robot is;
(a) to track the welding seam by utilizing the arc characteristics, (b) to control the welding current
constant, (c) to control a bead width constant, (d) to sense the position of the structural member
77
Cutting processes
Classification of cutting processes Fig. 1.82
Gas cutting, powder cutting

(Use of thermal energy produced by oxidative reaction)
Plasma cutting
(Use off thermal
(U th l energy produced
d dbby arc di
discharge;
h O
Oxidative
id ti reaction
ti iis also
l accompanied)
i d)
Thermal cutting
Laser cutting
(Use of thermal energy of light; Oxidative reaction is also accompanied)
Cutting processes Wire-cut discharge cutting

(Use of thermal energy of discharge)
Water-jet cutting
Non-thermal (Use of the kinetic energy of water and hard micro-particles)
cutting
Mechanical cutting (e.g. sawing machine)
(Use of mechanical energy)
78
Thermal cutting processes
Gas Plasma Laser
Manual
cutting
Robot system
大型機ガントリ
大型機・ガントリー
Table type
Plasma cutting machine
Gas cutting process Fig. 1.83

Cutting oxygen
Preheating gas
Cutting tip
Cutting direction
Preheating flame
Cutting oxygen stream
Cutting material
Drag line
Preheated zone
Reaction zone
Slag
•Gas cutting is used most broadly for cutting ordinary steels such as carbon steels, because
the cutting device is simple and the cutting cost is low.
•The most significant feature of the gas cutting process is that the thermal energy for melting
the cutting portion is provided by the heat of oxidation reaction of the steel to be cut.
•Gas cutting can be applied to a wide range of mild steel plates with thicknesses ranging
from approximately 5 mm to 100 mm or thicker. Only this method is practical as a thermal
cutting method that can be applied to thick plates of 50 mm or bigger.
79
Gas cutting process Fig. 1.86
Nozzles
 Straight nozzle
• Simple
 Divergent nozzle
• Supersonic jet -> thicker plate at higher speed
• Careful control of nozzle top is important for the quality.
Plasma cutting Fig. 1.87
Electrode
Orifice gas
High
Pla a a
Plasma arcc Pilot arc frequency
Power source power source Liner
generator (gas distributor)
Nozzle (tip)
Arc
Current passage
Cutting workpiece
•In plasma cutting the arc energy constricted by the nozzle is concentrated to melt the
cutting portion of a material, and then the molten part is removed by a high speed gas flow
to cut the material.
•As to the electrode material, tungsten is used when the orifice gas is non-oxygenated, and
zirconium or hafnium embedded water cooled cupper sheath is used when the orifice gas
is oxygenated.
80
Plasma cutting Table 1.21
Table 1.21 Examples of combinations of orifice gas and cutting material in plasma arc cutting
Gas Gas flow rate Cutting material

Ar + H2 Ar: 30 l/min, H2: 10-20 l/min Stainless steel, Aluminum
Ar + N2 Ar: 30 l/min, N2: 5-10 l/min Stainless steel
Ar + H2 + N2 Ar: 30 l/min, H2: 10-20 l/min, N2 : little Stainless steel
N2 80-１00 l/min Stainless steel
Air 35-50 l/min Mild steel
O2 35-50 l/min Mild steel
N2 + H2O N 2: 80-100 l/min, H 2O: 2.0 l/min Stainless steel, Aluminum, Mild steel
•With argon, hydrogen, and nitrogen, only the arc heat is used as a cutting heat
source.
•With oxygen and air, the cutting efficiency can extremely be higher because the
oxidation reaction heat can also be used as a cutting heat source in addition to
the arc heat.
Plasma cutting
0
Cupper sheath Hafnium 500 K,

300 K
Interval 500 K
3500 K
5
33000 K 300 K
400 K,
Interval 100 K
10
1000 K
Axis (mm)
Max. 3029 m/s

15
ND: 3.5 mm
•As to the electrode material, tungsten is TL: 7.5 mm
used when the orifice gas is non- 20

oxygenated and zirconium or hafnium
oxygenated, 2764 m/s
/ 15000 K
embedded water cooled cupper sheath 3000 K,

Interval 3000 K
is used when the orifice gas is
25
oxygenated.
W ：MP 3,410℃ W-Oxide: MP 1,410℃ O2,
Hf：MP 2,231℃ Hf
Hf： Hf--Oxide: MP 2,810℃ 400 A, 35.3 V
30
Zr：
Zr ：MP 1,857℃ Zr
Zr--Oxide: MP 2,700℃
6 4 2 0 2 4 6
Radius (mm) Radius (mm)
81
Laser cutting Fig. 1.88
Reflecting mirror
Cooling water
Beam radius : α
Focusing lens
Assist gas
Kerf width : W
Cutting speed : v
Thickness : t
Cutting workpiece
•When laser beam is focused on the localized area of a cutting workpiece by using lenses
and mirrors, the cutting workpiece absorbs the light energy, and thus the temperature at the
cutting portion increases locally, and thereby the cutting portion is melted.
•And then a jet of high-pressure gas (assist gas) is applied onto the molten part to blow
away the molten substance. Consequently, the cutting portion can be cut with a narrow kerf
width with extremely high accuracy.
Laser cutting
Mild steel 6 mmt
Mild steel 12 mmt

•When laser beam is focused on the localized area of a cutting workpiece by using lenses
and mirrors, the cutting workpiece absorbs the light energy, and thus the temperature at the
cutting portion increases locally, and thereby the cutting portion is melted.
•And then a jet of high-pressure gas (assist gas) is applied onto the molten part to blow
away the molten substance. Consequently, the cutting portion can be cut with a narrow kerf
width with extremely high accuracy.
82
Cutting accuracy
Accuracy of thermal cutting (Mild steel)
Accuracy：Ｌ＞Ｐ≧Ｇ
±0 1
±0.1
Cuttting accuracy (mm)
Laser
±0.3
Plasma
±0.5
±1.0 Gas
0.8 4.5 19 25 50 Thickness (mm)
Cutting cost
Cutting cost
Laser Major
Ｐ<Ｌ<ＧＧ<Ｐ
Ｌ<Ｐ<Ｇ
Gas Major
Plasma Major
4.5～6mm 19mm 28～32mm 50mm

Plate thickness
83
Water jet cutting Fig. 1.89
High pressure water High pressure water
Water nozzle
Water jet
Abrasive
Mixing chamber
Abrasive nozzle
Jet stream
Jet stream with abrasive
(a) Straight water jet method (b) Abrasive-jet method
•Water jet cutting uses a jet of water, which can cut materials under high
pressure of approximately 100-600 MPa.
•Water jet cutting methods can be categorized into straight water jet method
that uses a jet of water only, and abrasive-jet method that uses an abrasive
mixed in water jet stream
Water jet cutting Table 1.21
Table 1.22 Variations of water jet cutting methods and applicable materials
Method Pressure (MPa) Applicab le materials
Straigh
g t water jet
j 200-600 Rubb er,, leather,, plastics,
p , F RPs,, papers,
p p , frozen foods,, lumber
Dry-type abrasive jet 100-300 Metals, ceramics, glass, concrete, rocks, FRMs
Slurry-type abrasive jet 100-300 Thin plates, ductile metals that produce burrs by the dry-type
abrasive-jet cutting
•Water
W t jetj t cutting
tti can be
b used d for
f mostt materials
t i l including
i l di papers, rubbers,
bb
and metals.
•In abrasive-type water jet cutting, the cutting material is abraded by collision
of the abrasive accelerated by water jet stream onto the cutting material; this
method is used for cutting metals.
84
[WE Q1.6-1]
The nozzle for gas cutting is broadly classified into straight nozzle and divergent nozzle.
Explain the features of each nozzle.

[WE Q1.6-1]
The nozzle for gas cutting is broadly classified into straight nozzle and divergent nozzle.
Explain the features of each nozzle.
Straight nozzle
Th straight
The t i ht nozzle
l has
h th shape,
the h shown
h i Figure
in Fi ( ) below.
(a) b l I this
In thi system
t th
the
cutting oxygen jet does not exceed the sound speed, so that it does not suit thicker
plate cutting. However, because of easy maintenance, control and manufacturing, this
nozzle is widely used for manual cutting and for thinner plate cutting.
Divergent nozzle
The divergent nozzle has the shape in Figure (b) below. The nozzle shape is so
designed as to provide supersonic oxygen jet for cutting. The nozzle, therefore, enable
higher speed cutting and suit for thicker plate cutting. This nozzle is used for automatic
cutting and for thicker plate cutting.
cutting It shall be noted here that the oxygen pressure is
fixed, depending on the shape of the nozzle, so that the selection of nozzle as well as
the control of oxygen pressure at the time of cutting is important.
85
[WE Q1.6-3]
Following sentences are describing the various cutting processes. Choose the relevant one and
circle its alphabet.
(1) The water jet cutting process usually uses water pressure of;
(a) 0.1～0.4 Mpa, (b) 1～4 Mpa, (c) 10～40 Mpa, (d) 100～400 Mpa
(2) There are two types of water jet cutting processes. One is the type of using only water as
material. Another is the type of using an abrasive mixed with water. The latter process is usually
used for the cutting of;
(a) woods, (b) concrete, (c) metals, (d) plastics
(3) For cutting of mild steels with the thickness of more than 50mm;
(a) powder cutting, (b) laser cutting, (c) oxy-fuel gas cutting, (d) plasma cutting
process is practically used.
(4) In plasma arc cutting, precaution for;

(a) back firing, (b) disturbance of shielding gas, (c) generation of series arc, (d) explosion of fuel gas
should be taken.
(5) Air arc gouging process uses;

(a) covered steel electrode, (b) carbon electrode with coated cupper, (c) tungsten electrode, (d)
tungsten electrode with Thoria (ThO2)

[WE Q1.6-3]
Following sentences are describing the various cutting processes. Choose the relevant one and
circle its alphabet.
(1) The water jet cutting process usually uses water pressure of;
(a) 0.1～0.4 Mpa, (b) 1～4 Mpa, (c) 10～40 Mpa, (d) 100～400 Mpa
(2) There are two types of water jet cutting processes. One is the type of using only water as
material. Another is the type of using an abrasive mixed with water. The latter process is usually
used for the cutting of;
(a) woods, (b) concrete, (c) metals, (d) plastics
(3) For cutting of mild steels with the thickness of more than 50mm;
(a) powder cutting, (b) laser cutting, (c) oxy-fuel gas cutting, (d) plasma cutting
process is practically used.
(4) In plasma arc cutting, precaution for;

(a) back firing, (b) disturbance of shielding gas, (c) generation of series arc, (d) explosion of fuel gas
should be taken.
(5) Air arc gouging process uses;

(a) covered steel electrode, (b) carbon electrode with coated cupper, (c) tungsten electrode, (d)
tungsten electrode with Thoria (ThO2)
86
Plasma cutting
Electrode
Orifice gas
Nozzle
Arc Series arc
Cutting workpiece
Generation of series arc leads to unstable cutting.

[WE Q1.6-4]
Following sentences are describing the various cutting processes. Choose two appropriate words
for each and circle their alphabet.
(1) Stainless steel plate of 30mm thickness can be cut by;
(a) oxy-fuel gas cutting, (b) powder cutting, (c) plasma arc cutting, (d) diode laser cutting
(2) The following plate materials can be cut by oxy-flame gas cutting.
(a) Low alloy steels, (b) Aluminum alloys, (c) Cupper alloys, (d) Titanium
(3) The following cutting processes can be applied for the cutting of thin concrete plate.
(a) Oxy-fuel gas cutting, (b) Plasma arc cutting of transfer type, (c) Plasma arc cutting of non-
transfer type, (d) Water jet cutting
(4) The following gases can be used as the plasma gas for a plasma arc cutting process.
(a) Air, (b) Oxygen, (c) Acetylene, (d) Propane
(5) The following gases can be used as the assist gas for a laser cutting process.
(a) Air, (b) Argon, (c) Acetylene, (d) Propane
87
[WE Q1.6-4]
Following sentences are describing the various cutting processes. Choose two appropriate words
for each and circle their alphabet.
(1) Stainless steel plate of 30mm thickness can be cut by;
(a) oxy-fuel gas cutting, (b) powder cutting, (c) plasma arc cutting, (d) diode laser cutting
(2) The following plate materials can be cut by oxy-flame gas cutting.
(a) Low alloy steels, (b) Aluminum alloys, (c) Cupper alloys, (d) Titanium
(3) The following cutting processes can be applied for the cutting of thin concrete plate.
(a) Oxy-fuel gas cutting, (b) Plasma arc cutting of transfer type, (c) Plasma arc cutting of non-
transfer type, (d) Water jet cutting
(4) The following gases can be used as the plasma gas for a plasma arc cutting process.
(a) Air, (b) Oxygen, (c) Acetylene, (d) Propane
(5) The following gases can be used as the assist gas for a laser cutting process.
(a) Air, (b) Argon, (c) Acetylene, (d) Propane

[WE Q1.6-7]
Regarding the cutting processes and supplementary materials used, choose the
relevant one from the [Word group] and put its alphabet into each parenthesis.
(1) This cutting process uses an abrasive.
( )
(2) This cutting process uses an assist gas.
( )
(3) This cutting process uses iron powder that is applied into the cutting gas flow.
( )
(4) This cutting process uses a divergent nozzle to cut thick plates.
( )
(5) This cutting process uses a special nozzle that restricts the arc.
( )
[Word group]
(a) Water jet cutting (b) Plasma cutting (c) Laser cutting
(d) Flame (Oxygen) cutting (e) Powder cutting
88
[WE Q1.6-7]
Regarding the cutting processes and supplementary materials used, choose the
relevant one from the [Word group] and put its alphabet into each parenthesis.
(1) This cutting process uses an abrasive.
( a )
(2) This cutting process uses an assist gas.
( c )
(3) This cutting process uses iron powder that is applied into the cutting gas flow.
( e )
(4) This cutting process uses a divergent nozzle to cut thick plates.
( d )
(5) This cutting process uses a special nozzle that restricts the arc.
( b )
[Word group]
(a) Water jet cutting (b) Plasma cutting (c) Laser cutting
(d) Flame (Oxygen) cutting (e) Powder cutting

[WE Q1.6-9]
Regarding the features of the cutting processes, choose the correct one from among the words in
each parenthesis and encircle its alphabetic symbol.
(1) The powder cutting process is a variation of;
(a) the water jet cutting process, (b) the plasma cutting process, (c) the laser cutting process, (d) the
gas cutting process
(2) The;
(a) water jet cutting, (b) plasma cutting, (c) laser cutting, (d) gas cutting
is not included in the thermal cutting processes.
(3) The;
cannot be applied for cutting nonferrous metals such as copper alloys and aluminum alloys.
(4) The;
is most suitable for the precision cutting of sheet metals.
(5)
The;
uses the arc discharge.
89
[WE Q1.6-9]
Regarding the features of the cutting processes, choose the correct one from among the words in
each parenthesis and encircle its alphabetic symbol.
(1) The powder cutting process is a variation of;
(a) the water jet cutting process, (b) the plasma cutting process, (c) the laser cutting process, (d) the
gas cutting process
(2) The;
is not included in the thermal cutting processes.
(3) The;
cannot be applied for cutting nonferrous metals such as copper alloys and aluminum alloys.
(4) The;
is most suitable for the precision cutting of sheet metals.
(5)
The;
uses the arc discharge.
Thank you very much for your attention!
tanaka@jwri.osaka-u.ac.jp
90

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The Japan Welding Engineering Society

Lecture for SWE / WE

Welding Processes and Equipment

A brief introduction of JWRI

Joining and Welding Research Institute

Do you know Osaka in Japan?

Osaka University First President

Organization of Osaka University

Teaching staff: 2,546

And, about JWRI

Staffs and Students in JWRI

Professor: 12 Annual expenditure

Welding Research Institute

Department of Manufacturing Sci.

Department of Joining & Welding Research Institute

JWRI is approved as an ATB for IWE by the IIW

Mr’s course Credit transfer system IWE course

Mr’s degree Mr’s degree & IWE

After two years…

Shall we start Chapter 1?

Principles of typical welding processes Fig. 1.2

Melting point: filler metal < base metal

Base metal Heating

Ex. Arrange following welding processes in the below table.

a. Arc welding b. Brazing c. Cold pressure welding

Classification of joining methods Fig. 1.1

Electric circuit & discharge

Electrons are heated by the electric

1801: Discovery by H. Davy (UK)

【 Arcs in daily experience 】

What is the physical state

Arc plasma & ohmic heating

TIG arc Surface

１３，０００Ｋ Arc 4 Arc

Transport properties of arc plasma

Plasma in arc discharge

Number density (m-3)

Electrical conductivity (1/m)

Number density (m-3)

Pressure: 100 kPa

Helium Argon Electrical conductivity

Plasma in arc discharge

Specific heat at atmospheric pressure

Voltage-current characteristics in TIG arc Fig. 1.8

16 TIG arc in argon

Arc length: 10mm

Cathode Arc length

Voltage & current waveforms of AC arc Fig. 1.9

Power source for AC arc Q

The phase of welding current must be later than the phase of

Electromagnetic pinch effect & plasma jet

The arc tends to direct along the

Arc blow phenomenon Fig. 1.12

Effect of work lead connection

Arc Weld bead

End of base metal

Effect of work end

Filler metal Arc Shielding gas

Weld metal Weld metal

Base metal Weld pool Base metal Weld pool

Non-consumable electrode welding Consumable electrode welding

Melting of consumable electrode

Melting rate of welding wire