2

Submerged arc welding

SAW,
Sub-arc
 3

Submerged arc welding

 4

Submerged arc welding

Submerged arc welding - Features

High productivity
2 to 10 kg/hour
Up to 2m/min
Bulky, expensive and
heavy equipment
Flat and horizontal
positions only
Thicker sections (3mm
and above)
Mostly ferrous materials
(also Ni alloys)
Submerged arc welding - Equipment

Power source
Welding head and
control box
Welding head
travel
Flux recovery
system (optional)
Positioners and
Fixtures
6
 7

Submerged arc welding - Consumables

Solid or cored wires

Granular fluxes
Agglomerated, fused or sintered
Alloying activity
Contribution to weld metal chemistry from flux
Basicity
Acid fluxes made from manganese oxide, silica,
rutile are easy to use
Basic fluxes (MgO, CaO, CaF2, Al2O3) provide
excellent toughness welds
 8

Submerged arc welding - Applications

Long straight welds in heavier material

Vessel longitudinal and circumferential
welds
Flange to web joints of I beams
Flat or horizontal position
Flux has to be supported
Access has to be good
 9

Gas shielded arc process

Tungsten Inert Gas welding (TIG)
Gas tungsten arc welding (GTAW)
Gas Tungsten Arc Welding

Alternative names -
GTAW,TIG (Tungsten Inert
Gas), Argonarc

Heat source is an electric

arc between a non-
consumable electrode and
the workpiece

Filler metal is not added or

is added independently
10
 11

Gas Tungsten arc welding

 12

Gas Tungsten Arc Welding - Process features

Excellent control
Stable arc at low power (80A at 11V)
Independently added filler
Ideal for intricate welds eg root runs in pipe or thin sheet
Low productivity 0.5kg/h manual
High quality
Clean process, no slag
Low oxygen and nitrogen weld metal
Defect free, excellent profile even for single sided welds
Gas Tungsten Arc Welding - Equipment

Welding power source with constant

current characteristic
DC for most metals, AC for Al
Arc starting by high frequency (5000V, 0.05A)
Sequence timers for arc starting, arc finishing &
gas control
Water- or gas-cooled torch with tungsten
electrode
Electrode may contain thoria or zirconia, etc
 14

Gas Tungsten Arc Welding - Shielding gases

Torch is fed with an inert or reducing gas

Pure argon - widespread applications
Argon-helium - Higher arc voltage, inert
Argon-2% hydrogen - Cu alloys & austenitic steel
Torch gas must not contain oxygen or CO 2
Backing (or purge) gas
Used for all single-sided welds except in carbon steel
Argon, nitrogen, formier gas (N2 + H2)
Supplementary shielding
Reactive metals: Ti, etc
Gas filled chambers or additional gas supply devices
 15

Gas Tungsten Arc Welding - Filler metals

Autogenous welding (no filler)

Filler wire or rod of matching composition
C-Mn & low alloy steel
Stainless Steel
Al, Mg, Ti
Cu & Ni
Consumable inserts - filler preplaced in
joint
 16

Gas Tungsten Arc Welding - Automation

 17

Gas Tungsten Arc Welding A TIG

 18

GMAW and FCAW

Gas metal arc welding

(MIG, MAG, CO2 welding)
Flux cored arc welding
Gas metal arc welding

A continuous solid wire, small

diameter
GMAW uses solid wire, no flux
FCAW uses flux-filled wire
Fed through the gun to the arc by
wire feeder.
The weld pool may be protected
from oxidation by shielding gas.
High productivity 3 kg/h or more
Direct current (DCEP mostly)
19
 20

Gas metal arc welding

 21

Gas metal arc welding

MIG Welding
Heat source - arc between parent metal
and consumable electrode wire (0.6 to
1.6mm diameter)
60-500A, DC only
16-40V
1 to 20kW
 22

Gas metal arc welding

Gas metal arc welding - Equipment

Welding power source

Wire feeder mechanism
May be in power source
cabinet
Gun with gas supply &
trigger switch
Manual (semiautomatic) guns
Automatic torches available
Can be fitted to robot etc
23
Gas metal arc welding Metal transfer
Spray
Higher current & voltage, argon-rich gas
Short circuiting (dip)
Low current and voltage, CO2
Globular
Intermediate current
Pulsed current power sources
Adjustable frequency
One droplet per current pulse.
 25

Gas metal arc welding Metal transfer

In gas metal arc welding (GMAW), the many varieties of

shielding gases, welding wires, and power sources
result in three different modes of metal transfer across
the arc. These modes are known as spray, globular, and
short-circuiting. Figure 1 shows differences between the
three metal transfer modes. Each mode of metal
transfer has specific advantages and limitations.
26
 27
As shown in Fig. 2, a spray transfer arc requires relatively high welding currents
(higher than the "transition current" or "critical current" related to the wire
diameter). Argon or argon-rich gas mixtures (e.g. 80%Ar+20%CO2) are necessary
for shielding the spray arc. The spray transfer mode results in a highly directed,
stable stream of discrete drops and is essentially spatter free.
 28

Gas metal arc welding - Consumables

Solid Wires (GMAW)

A wide variety of alloys are available
Flux cored arc welding (FCAW)
Gas shielded flux cored wires
Self-shielded flux cored wires
Used outdoors
Metal cored wires
Light flux cover
 29

Introduction to welding
Gas metal arc welding Wire size
 30

Gas metal arc welding - Gas mixtures

Inert gases (MIG)

Argon or helium or mixtures of these
Active base metals, Al, Mg, Ti

Active gases (MAG and FCAW)

Carbon dioxide
Argon plus oxygen and/or carbon dioxide
Nitrogen, hydrogen
 31

Introduction to welding
Gas metal arc welding - Developments
 32

Gas metal arc welding - Developments

 33

Gas metal arc welding - Developments

 34

Gas metal arc welding - Developments

 35

Plasma Cutting, Welding & Surfacing

 36

Introduction to welding
 37

Oxy-Acetylene Welding
Oxidising Flame

Carburising Flame

Neutral Flame
 38

Thermit welding
 39

Laser Welding

Laser beam welding is a technique in manufacturing whereby two or more

pieces of material (usually metal) are joined by together through use of a laser
beam.
 40

Laser welding
 41

Electron Beam Welding

Electron beam welding (EBW) is a fusion welding process in which a

beam of high-velocity electrons is applied to two materials to be
joined. The workpieces melt and flow together as the kinetic energy
of the electrons is transformed into heat upon impact. EBW is often
performed under vacuum conditions to prevent dissipation of the
electron beam.
 42

Electron Beam Welding

 43

Size of weld beads in

(a) electron-beam or laser-beam welding
(b) conventional arc welding.
 44

Solid-State Welding

Heat
Pressure
Time
NO Melting
NO Filler Material
Intimate Contact
Usually Requires Deformation
Works with Dissimilar Metals
 45

Resistance Welding
 46

Resistance spot welding Robots

 47

Introduction to welding
Flash Butt Welding
 48

Friction Welding
 49

Introduction to welding
Friction Stir Welding
 50

Introduction to welding
Friction Stir Welding
 51

Introduction to welding
Explosive Welding
 52

Introduction to welding
 53

Introduction to welding