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SET - UP
THE MAIN CONSTITUENTS OF SET - UP
:
POWER SOURCE
WIRE FEEDER
GAS CYLINDER
CONTROL
MODULE
TORCH
HOT WIRE
MOLTEN DROPLETS DURING TRANSFER
MOLTEN POOL & SOLIDIFYING METAL
HOT PARENT MATERIAL
METAL TRANSFER
SHORT CIRCUITING TYPE
PROJECTED TYPE
GLOBULAR
STREAMING
SPRAY
INCREASING
CURRENT
HIGH CURRENT
MULTIPLE FINE DROPLETS FORMED
PROJECTED WITH FORCE
THIS MODE SUITABLE FOR OUT OF POSITION WELDIN
PROCESS CONTROL
PROCESS IS STABILISED WHEN THE
WIRE FEED RATE = MELTING RATE
HENCE THERE IS ALWAYS A FEED BACK CONTROL
MANUAL ( SEMI AUTOMATIC ) OPERATION
USE POWER SOURCE WHICH HAS DROOPING I V RELATION .
USE VOLTAGE BASED FEED - BACK
SUITABLE FOR MANUAL OPERATION
AUTOMATIC
OPERATION
CONSUMABLES
GENERALLY 1.2 & 1.6 DIA WIRES ARE USED.
THE WIRES COME IN 12.5 Kg. SPOOLS
THE SPOOLS SHOULD BE SPIRALLY WOUND. ELSE
WIRE FEEDING PROBLEM CAN RESULT.
CONSUMABLES
MATERIAL
GMAW WIRE
CS
ER 70 S 6
LTCS
ER 70 S G
C 0.5 Mo
ER 70 S - A1
C 1.25 Cr 0.5 Mo
ER 80 S - B2
C 2.5 Cr 1 Mo
ER 90 S - B3
C 5 Cr 1 Mo
ER 80 S - B6
C 6-8 Cr 1 Mo
ER 80 S - B6
C 9 Cr 1 Mo
ER 80 S - B8
C 9 Cr 1 Mo Nb
--------------
Austenitic SS
ER3XX
PRAXAIR 99.995%
GUJ I
99.9993 %
GUJ II
99.9978 %
INOX I
99.9978 %
ADVANTAGES OF GMAW
CONTINUOUS PROCESS
DEPOSITION RATE ~ 5 - 6 Kg / Hr
EASILY AUTOMATED
CAN BE USED FOR WIDE VARIETY
OF MATERIALS
OUT OF POSITION WELDING POSSIBLE
DISADVANTAGES OF GMAW
EXPOSED ARC
TRAINED WELDER
NEEDED
VARIANTS OF GMAW
CO2 PROCESS AND FCAW PROCESS
ALSO KNOWN AS MAG PROCESS
SHIELDING GAS IS CO2
CO2 ----->
O
PROVIDES
SHIELDING
CO +
REACTS WITH Si & Mn
IN SOLID WIRE AND
WITH FLUX IN FLUX
CORED WIRES
CHEAP PROCESS
CO2
CARBON STEELS ,
SOME LOW ALLOY STEELS AND
STAINLESS STEELS
Trial 6
600 - 650
Wire Position at
Centre of
Groove
3 mm
2 mm
Second Pass
STUB SIDE
PIPE SIDE
Third Pass
Wire 3 mm from
Centre of Groove
towards stub end
STUB SIDE
PIPE SIDE
STUB SIDE
PIPE SIDE
CONSUMABLES
MATERIAL
FCAW WIRE
CS
E 70 T1
LTCS
E 80 TJ
C 0.5 Mo
E 70 T1-A1
C 1.25 Cr 0.5 Mo
E 80 T1-B2
C 2.5 Cr 1 Mo
E 90 T1-B3
C 5 Cr 1 Mo
E 80 T1-B6
C 6-8 Cr 1 Mo
E 80 T1-B6
C 9 Cr 1 Mo
E 80 T1-B8
C 9 Cr 1 Mo Nb
--------------
Austenitic SS
E3XX LT 1
SYNERGIC MIG
SPECIAL POWER SOURCE -- GIVES PULSED CURRENT.
OVERALL HEAT INPUT IS MAINTAINED LOW.
WIRE MELTING TAKES PLACE IN EACH HIGH PULSE
TIME.
THE CURRENT, WIRE FEED & PULSING ARE
ADJUSTED AUTOMATICALLY.
INDIVIDU
ALEFFECT
S
SYNERGIC
EFFECTS
INITIAL PROCESS
IN PRODUCTION PROCESS
STARTING POINT
TOOLS USED :
-- Factorial Analysis
-- Taquchi Analysis
CURRENT
VOLTAGE
TORCH STANDOFF
SPEED OF ROTATION
TECHNIQUE
WORK ANGLE
LEAD / DRAG ANGLE
UPHILL / DOWNHILL WELDING
mm
A
amps
V
volts
S
mm/min
Auto
1.2
220 - 240
18 - 20
800
0.327
Manual
1.2
180 - 200
18 - 20
200
1.03
Auto
0.8
180 - 200
17 - 18
750
0.266
Manual
0.8
140 - 160
17 - 18
150
1.05
Wire Dia.
Heat Input
KJ/mm
ESSENTIAL VARIABLES
MATERIAL WELDED
MATERIAL THICKNESS
SHIELDING GAS
GAS COMPOSITION
BACKING ?
BACKING TYPE
CONSUMABLE USED
CONSUMABLE TYPE
ADDITIONAL CONSUMABLE
ALLOY ADDITIONS
PREHEAT
POST WELD HEAT TREATMENT
NONESSENTIAL VARIABLES
CURRENT TYPE
GROOVE TYPE
CURRENT VALUE
GROOVE ANGLE
POLARITY
ROOT GAP
PULSING PARAMETERS
ROOT FACE
VOLTAGE
WELDING POSITION
WELDING SPEED
WEAVING / STRINGER
SHIELDING CUP SIZE
SINGLE / MULTIPLE PASS
SINGLE / MULTIPLE ELECTRODE
PEENING / NO PEENING
MANUAL / AUTOMATIC