10-14. Welding Process

Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
TWI
CSWIP 3.2
WIS 10
SENIOR WELDING INSPECTION

WELDING PROCESS
Welding process chart
Fusion welding
Pressure
welding
MMA TIG MIG/MAG
/FCAW
SAW
EBW LBW
Arc
welding
Power
beam
welding
Oxy fuel
welding
Electroslag
welding
Thermit
welding
Resistance
welding
Solid state
welding
PAW
MMA - Principle of operation
ARC CHARACTERISTICS
Volts
Amps
OCV
Constant Current/Amperage Characteristic
Large change in voltage =
Smaller change in amperage
Welding Voltage
Large arc gap
Small arc
gap
MMA welding
Shielding provided by decomposition of flux
covering
Electrode consumable
Manual process
Welder controls
Main features
Arc length
Angle of electrode
Speed of travel
Amperage settings
MMA welding power source
Transformers AC only
Transformer/Rectifiers AC and DC
Petrol or Diesel driven Generators Site work DC
Inverters AC and DC
TYPES:-
Input 240v (single phase) or
415v ( 2 live phases of 3 phase supply)

Output AC (O.C.V. 80v) or DC (O.C.V. 50v) or both.
AC for Shop

DC for site work as it is SAFER (lower OCV). Also for
shop work..

Current adjustment control

POWER
SOURCE:-
Equipment for MMA welding
Safety visor
(with dark lens)
Electrode oven
Power return
cable
Power source.
Transformer/
Rectifier
Heated quiver
Inverter
power source
Power cable
Power control
panel
Electrodes
Electrode
holder
MMA electrodes - type of covering
Acid
covering
Cellulosic
covering
contains oxides and silicates high O
2

content low UTS weld
smooth profile with tendency to
concavity
slag easy to detach
limited usability
contains organic material no
backing/drying allowed
generates high level of fumes and H
2

cold cracking
thin slag layer, poor appearance
increased penetration

MMA electrodes - type of covering
Rutile
covering
Basic
covering
contains TiO
2

stable, easy-to-use arc can operate in
both DC and AC
slag easy to detach, smooth profile
good strength weld metal
can be dried to lower H
2
content
contains CaF
2
and CaCO
3

requires backing to keep H
2
low
very good mechanical properties
difficult to detach slag
produce convex weld profile

3) Porosity
1) Slag inclusions
2) Arc strikes
4) Undercut
Most welding defects in MMA are caused by a lack
of welder skill (not an easily controlled process),
the incorrect settings of the equipment, or the
incorrect use, and treatment of electrodes
5) Shape defects (overlap, excessive root
penetration, etc.)
MMA welding typical defects
Advantages:
1) Field or shop use
2) Range of consumables
3) All positional
4) Very portable
5) Simple equipment
Disadvantages:
1) High skill factor
2) Slag inclusions
3) Low operating factor
4) High level of fume
5) Hydrogen control
MMA advantages/disadvantages
TIG - Principle of operation
Sizes/types vary depending on current/application TORCH
To deliver correct gas flow (velocity) depending on
welding position and joint configuration.
FLOWMETER
(graduated in ltr/min)
Correct type for application.(ar, he, ar/he mixture)
Argon/hydrogen for austenitic stainless steel
INERT GAS SUPPLY
(Cylinder & regulator)
Note that current actually flows from this lead RETURN LEAD
Flexible may carry current, gas, cooling water. TORCH HOSE
Transformers for AC aluminium alloys
Rectifiers for DC - steels
Transformer/rectifier for AC/DC
Inverters for AC/DC more portable - expensive
POWER SOURCE
440v 50Hz 3 phase or
240v single phase
input
TIG power source
Inverter
power source
Power cable
Flow-meter
Power
control panel
Transformer
/ Rectifier
Power
control panel
Power return
cable
Torch
assemblies
Tungsten
electrodes
Equipment for TIG
TIG torch
Ceramic
shield cup
Gas lens
Torch body
Tungsten
electrodes
Spare ceramic
shielding cup
Gas diffuser
Split collet
Fitted ceramic
shielding cup
Tungsten
housing
On/Off switch
Most welding defects with TIG are caused by a lack of
welder skill, or incorrect setting of the equipment. i.e.
current, torch manipulation, welding speed, gas flow
rate, etc.
1) Tungsten inclusions (low skill or wrong vertex angle)
2) Surface porosity (loss of gas shield mainly on site)
3) Crater pipes (bad weld finish technique i.e. slope out)
4) Oxidation of S/S weld bead, or root by poor gas cover
5) Root concavity (excess purge pressure in pipe)
6) Lack of penetration/fusion (widely on root runs)
TIG typical defects
Advantages:
1) High quality
2) Good control
3) All positional
4) Lowest H
2
arc
process
5) No slag
Disadvantages:
1) Very high skill factor
2) Range of consumable
3) Loss of gas shield/site
4) Complex equipment
5) High ozone levels
TIG advantages/disadvantages
6) Low Output
MIG/MAG - Principle of operation
ARC CHARACTERISTICS
Volts
Amps
OCV
Constant Voltage Characteristic
Small change in voltage =
large change in amperage
The self
adjusting arc.
Large arc gap
Small arc gap
Power return
cable
Transformer
/ Rectifier
Power cable
& hose
assembly
Liner for wire
Welding gun
assembly
External wire
feed unit
Power control
panel
Internal wire
feed system
15kg wire spool
Equipment for MIG/MAG
Plain top roller
Half grooved
bottom roller
Wire guide
Internal wire
drive system
MIG/MAG wire drive system
Torch body
Contact tips
Spot welding
spacer
Gas diffuser
Nozzles or
shrouds
Torch head assembly
(less nozzle)
On/Off switch
Hose
port
MIG/MAG torch head assembly
MIG/MAG-methods of metal transfer
Dip transfer
Transfer occur due to short circuits
between wire and weld pool, high
level of spatter, need inductance
control to limit current raise
Can use pure CO
2
or Ar- CO
2

mixtures as shielding gas
Metal transfer occur when arc is
extinguished
Requires low welding current/arc voltage, a low
heat input process. Resulting in low residual
stress and distortion
Used for thin materials and all position welds
Spray transfer
Transfer occur due to pinch effect
NO contact between wire and weld
pool!
Requires argon-rich shielding gas
Metal transfer occur in small
droplets, a large volume weld pool
Requires high welding current/arc voltage, a
high heat input process. Resulting in high
residual stress and distortion
Used for thick materials and flat/horizontal
position welds
Globular transfer
Transfer occur due to gravity or
short circuits between drops and
weld pool
Requires CO
2
shielding gas
Metal transfer occur in large drops
(diameter larger than that of
electrode) hence severe spatter
Requires high welding current/arc voltage, a
high heat input process. Resulting in high
residual stress and distortion
Non desired mode of transfer!
Pulsed transfer
Controlled metal transfer, one
droplet per pulse, NO transfer
between droplet and weld pool!
Requires special power sources
Metal transfer occur in small
droplets (diameter equal to that
of electrode)
Requires moderate welding current/arc voltage, a
reduced heat input . Resulting in smaller residual
stress and distortion compared to spray transfer
Pulse frequency controls the volume of weld pool,
used for root runs and out of position welds
3) Porosity (from loss of gas shield on site etc)
1) Silica inclusions (in Fe steels) due to poor
inter-run cleaning
2) Lack of fusion (primarily with dip transfer)
Most welding imperfections in MIG/MAG are caused by lack of
welder skill, or incorrect settings of the equipment
The use of low quality wires will cause wire feed problems
Worn contact tips will cause poor power pick up, or transfer
Bad power connections will cause a loss of voltage in the arc
4) Solidification problems (cracking, centerline
pipes, crater pipes) especially on deep
narrow welds
MIG/MAG typical defects
Disadvantages:
Advantages:
1) Lower skill required
2) Easily automated
3) All positional Dip &
Pulse
4) Thick/thin materials
5) Continuous electrode
1) Lack of sidewall fusion
2) Range of consumables
3) Loss of gas shield/site
4) Complex equipment
5) High ozone levels
MIG/MAG advantages/disadvantages
Flux cored arc welding
FCAW
methods
With gas
shielding -
Outershield
Without gas
shielding -
Innershield
With metal
powder -
Metal core
Outershield - principle of operation
Innershield - principle of operation
FCAW - differences from MIG/MAG
usually operates
in DCEP but some
Innershield
wires operates in
DCEN
doesn't work in
dip transfer mode
require knurled
feed rolls
Advantages:
1) Field or shop use
2) High productivity
3) All positional
4) Slag supports and
shapes the weld Bead
5) No need for shielding
gas
Disadvantages:
2) Slag inclusions
3) Cored wire is
Expensive
4) High level of fume
(Innershield)
5) Limited to steels and
nickel alloys
FCAW advantages/disadvantages
SAW - Principle of operation
SAW
SAW
Principles of operation
Factors that determine whether to use SAW
chemical composition and mechanical
properties required for the weld deposit
thickness of base metal to be welded
joint accessibility
position in which the weld is to be made
frequency or volume of welding to be
performed
Principles of operation
SAW methods
semiautomatic - for relatively small
diameter electrodes and moderate travel
speed
mechanised - the majority of applications
automatic - for mass production (e.g.
pipes)
Advantages of SAW
high current density, high deposition rates (up to 10 times
those for MMA), high productivity
deep penetration allowing the use of small welding grooves
fast travel speed, less distortion
deslagging is easier
uniform bead appearance with good surface finish and good
fatigue properties
can be easily performed mechanised, giving a higher duty cycle
and low skill level required
provide consistent quality when performed automatic or
mechanised
Virtually assured radiographically sound welds
arc is not visible
little smoke/fumes are developed
Disadvantages of SAW
limited mainly to flat/horizontal position
limited to carbon, low alloy, creep resisting, stainless steels
and nickel alloys
due to the high heat input, impact strength of weld metal/HAZ
may be low; also high dilution
slag must be cleared away after welding due to the danger of
slag inclusions
need flux storage, handling and recirculation control
difficult to apply on-site due to complicated equipment
high capital costs
weld line must be regular (straight or circumferential seams
only) with accurate fit-up
SAW filler material
Welding wires can be used to weld:
carbon steels
low alloy steels
creep resisting steels
stainless steels
nickel-base alloys
special alloys for surfacing applications
Welding wires can be:
solid wires
metal-cored wires
SAW FLUXES
Fused:
Baked at high temperature, glossy,hard and
black in colour, cannot add ferro-manganese,
non moisture absorbent and tends to be of the
acidic type

Agglomerated:
Baked at a lower temperature, dull, irregularly
shaped, friable, (easily crushed) can easily add
alloying elements, moisture absorbent and tend
to be of the basic type

SAW FLUXES
Agglomerated SAW Flux
SAW FLUXES
Fused SAW Flux
SAW
SAW
SAW
SAW
SAW
Which settings do you think are incorrect
PAW - Principle of operation
PAW features
operates on DCEN
can be used for welding, spraying and
cutting
Modes of
operation
Microplasma Plasma Microplasma
Plasma arc
modes
Non-
transferred arc
Transferred arc
Advantages:
1) High energy
concentration
2) High arc stability
3) Can cut stainless
steels & aluminum
PAW advantages/disadvantages
Disadvantages:
2) Little tolerance for
joint misalignment
4) High level of UV/IR
radiation, fumes
5) Torch is heavy and
bulky
3) Expensive equipment
4) Wide range of
materials/thickness
5) No danger of
tungsten inclusions
OAW - Principle of operation
Welding flame types
Carburising flame
Neutral flame
Oxidising flame
welding of Al and
high C steels
hardfacing with
Cr and W carbide
welding of most
materials
brazing
welding of bronze
and brasses
OAW advantages/disadvantages
Advantages:
1) No need for power
supply
2) Low equipment cost
3) Can cut carbon and
low alloy steels
Disadvantages:
2) Wide HAZ
4) Slow process
5) Limited range of
consumables
3) Safety issues
4) Good on thin
materials
Choosing welding process
Application characteristics:
Other factors to be considered:
Availability and fitness for service
Skill requirements
Parent material(s) weldability
Availability of consumables
Joint design and welding position
Heat input requirements
Quality requirements
Productivity
Health and safety issues

10-14. Welding Process

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

10-14. Welding Process

Загружено:

Авторское право:

Доступные форматы

Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

Вам также может понравиться