WELDING

Q5 HL
 1. Electric Arc Welding

Electricity is passed through an electrode which

jumps between the electrode and the work piece.

This causes an arc which produces great heat

melting the electrode and the work piece causing
the edges to fuse together. (consumable
electrode.)
Draw diagram, exam answer
Manual Metal Arc Welding.
 Operation of the electrode
The weld pool is protected from oxidation by the gasses

produced by melting the chemicals on the electrode

coating.

This wire electrode also acts as a filler material to fill the

gap between the two parts being joined.

Its third function is to form a slag which protects the weld

area from cracking as it allows the joint cool slowly and

protect it from oxidation.

Uses

This has many operational uses such

as repair work to constructional steel.
It is ideal for outdoor uses as the
gasses needed to form the shield are
not blown away.
The Transformer.
This is a device used to change the
voltage of A.C. current.
It can either step up (increase) or step
down (decrease) the voltage.
It is necessary to change the voltage when
welding thicker or different types of steel.
Transformer-rectifier circuit - A.C. to D.C.
1. The transformer circuit element of the circuit take AC current
and pass it through a step down transformer reducing the
voltage, the current is increased.

2. The low voltage AC is then passed through a series of diodes

which only allow current flow in one direction causing it to be
changed into Direct Current, this is called a bridge rectifier.

3. Finally the DC current is passed through a smoothing

capacitor which causes the current flow more evenly.
Transformer-rectifier circuit
Electric Arc Welding Safety
Pg 370
2.Metal Arc Gas Shielded Welding.
(MAGS/MIG)
 MIG (Metal Inert Gas) welding
Also called MAGS (Metal Arc Gas Shielded)
welding
It uses an inert gas such as Argon or CO2 to
shield the weld
The bare wire electrode is fed continuously to
the weld - semi-automatic process
Can be used on light and heavy plate.
Does not produce a slag and can be used for
multi run welds and by robots.
Metal Arc Gas Shielded Welding.
(MAGS/MIG)
 Metal Arc Gas Shielded Welding.
(MAGS/MIG)
Electricity is passed through an electrode which jumps
between the electrode and the work piece. The
electrode is touched briefly against the work, this
causes an arc which produces great heat melting
the electrode and the work piece causing the edges
to fuse together.
 Metal Arc Gas Shielded Welding.
(MAGS/MIG)
Uses.

This is one of the most common ways of welding.

It can be used to weld sheet metal as well as
heavy plates.
As the electrode is fed automatically and no slag
is formed it is ideal for robotic welding for
example car production.
3.Tungsten Arc Gas Shielded Welding.
(TAGS/TIG)
 Tungsten Arc Gas Shielded
Welding. (TAGS/TIG)
Principle.

Two separate current flow in the circuit in this

welding process.
One is for the arc and is similar to MAGS, the
other is a high frequency current used to start
and maintain the arc.
This means an arc is not stuck by touching the
work piece as before.
Tungsten Arc Gas Shielded
Welding. (TAGS/TIG)
 Tungsten Arc Gas Shielded
Welding. (TAGS/TIG)
Operation.

1.The arc melts the two edges to be joined as well as the filler

rod forming the weld pool.

2.Gas is pumped through the nozzle protecting the weld pool

from oxidation.

3.The electrode (non consumable) is only to maintain the arc

supplying the heat. A consumable filler rod fed by the operator

gives the extra metal necessary for the weld pool.

 Tungsten Arc Gas Shielded
Welding. (TAGS/TIG)
Uses.

This is suitable for welding most metals and generally uses

DC current for the power source.

When welding aluminum AC is used. This is necessary to

breakdown the oxide layer on the outside of the aluminum

which has a high melting point.

It is also suitable for stainless steel.