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Section 8
Unit 25 & 26
Introduction
Electric arc welding
Introduction-cont.
Process
Heat
Shielding
Filler
Material
SMAW
Electric
Arc
Inert Gas
(Flux)
Stick
Electrode
GMAW
Electric
Arc
Inert Gas
(Cylinder)
Wire
Electrode
In this class you will have the opportunity to use two (2) arc welding
processes:
SMAW
GMAW
4
2. GTAW
3. SAW
4. ESW
Electroslag Welding
5. EGW
Electrogas Welding
6. PAW
7. ASW
Safe Practices
Amperage
Voltage
Polarity
High frequency current
Wave form
GMAW
GTAW
3. Amperage range
9. Available skills
4. Amperage adjustment
10. Safety
mechanism
5. Input power requirements
6. Initial cost and operating cost
1: Amperage Output
10
2: Duty cycle
12
8.
Constant potential
9.
Constant current
10.
Voltage drop
4. Ampere
11.
5. Volt
12.
Arc voltage
6. Resistance
13.
Polarity
7. Ohms Law
13
Electrical Circuit
14
Alternating Current
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Direct Current
Direct current: The type of
current where the flow of
electrons (polarity) is in
one direction.
Controlling the polarity
allows the welder to
influence the location of
the heat.
When the electrode is
positive (+) DCRP or
DCEP it will be slightly
hotter than the base
metal.
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Ampere
Voltage
18
Resistance
19
Ohms Law
20
Constant Current
In the normal operation of a transformer as amperage is
increased, the voltage decreases, and vies versa.
Electrical arc welding power supplies are modified so that either
the voltage or the amperage is relatively constant as the other
factor changes.
This allows two different types of power supplies:
Constant current
Constant potential
Constant Current--cont.
Characteristics of constant current power supply.
The machine provides a high voltage for striking the arc.
Open circuit voltage (OCV)
OCV is not adjustable for most machines
When the arc is struck the voltage drops to the welding voltage.
Arc voltage
Arc voltage varies with the arc length.
As the welding proceeds the current will not vary much as the
arc length changes.
22
Constant Current-cont.
Increasing the voltage from 20
to 25 volts (25%) only
decreases the amperage from
113 to 120 Amp (5.8%).
23
Constant Potential
50
100
150
200
250
Voltage Drop
When extra long welding leads are used, the amperage must be
increased to have the same heat at the weld.
25
Corner
Butt
Lap
Edge
T
26
27
1. Surface Welds
Surface welds are welds were a material has been applied to the surface
of another material.
May or may not be blended with the work piece.
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2. Groove Welds
Groove welds are used to fuse
the sides or ends of two pieces
of metal.
The primary use of groove
welds is to complete butt joints.
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3. Fillet Welds
Fillet welds have a triangular cross section and are used to fuse
two faces of metal that are at a 90 degree angle to each other.
Lap Joint
Outside Corner
T Joint
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4. Plug Welds
Plug welds are used to
attach two surfaces together
when a complete joint is not
required and the design
does not allow for any weld
bead outside the dimensions
of the metal.
31
5. Slot Welds
Slot welds are identical to plug welds except for the shape of the
holes. For slot welds, slots are machined or stamped in the upper
plate.
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Flat
Horizontal
Vertical Up
Vertical Down
Overhead
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Weld Nomenclature
Penetration
Bead
Base metal
Joint Angle
Reinforcement
Bead
Root Face
Root Opening
Excessive
Penetration
34
Weld Nomenclature-cont.
Reinforcement
Toe
Face
Throat
Leg
Toe
Root
Leg
35
Weld Nomenclature-cont.
Cover Pass
Filler Pass
Root Pass
Tack Weld
36
Bead Patterns
Hardsurfacing
Filler pass
Cover pass
Reduce penetration
Common patterns:
Circle
Crescent
Figure 8
37
Weld Defects
38
Cause(s)
Excessive heat
Excessive speed.
Incorrect angle
Incorrect
manipulation
Insufficient heat
Slow speed
39
Small indentions in
the surface of the
weld
Small voids
throughout the weld
material.
Cause(s)
Low heat
Long arc
Incorrect joint design
Accelerated cooling
40
Cause(s)
Accelerated cooling
Constrained joint
Small weld volume
Cracks in the
transition zone
between the weld and
base metal
Induced hydrogen
Incompatible electrode
or wire
Accelerated cooling
Misshapen
and/or uneven
ripples
Inconstant speed
Incorrect manipulation
Incorrect welder settings
41
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