Welding Processes: Nur Syahroni, ST., MT., PH.D

DEPT.
OF OCEAN ENGINEERING-ITS
Welding Processes
Nur Syahroni, ST., MT., Ph.D.
Welding Technology & Inspection (MO-141323)

• Definition of Welding Process
• Classification of Welding Processes
based on AWS terms
• SMAW / MMAW
• GTAW / TIG
• GMAW / MIG / MAG
• FCAW
• SAW
Outline
Teknologi dan Inspeksi Las (MO-141323) 2
The American Welding Society (AWS) defines a
welding process as:
• a joining process that produces coallescence of
materials
• by heating them to the welding temperature
• with or without the application of pressure or
by the application of pressure alone, and
• with or without the use of filler materials
Definition
Classification of Welding Processes (AWS)
Welder & Welding Operator:
• Welder is: a person who performs a manual or a
semiautomatic welding
• Welding operator is: a person who performs a
mechanized or an automatic welding
Methods of Application
Methods of Application
1. Shielded Metal Arc Welding (SMAW)
The Shielded Metal Arc Welding (SMAW) is also known as
the Manual Metal Arc Welding (MMAW) or sometimes
informally termed as the Stick Welding
• The SMA welding Process was first developed in the late
19th century using bare wire consumables.
• SMAW is a simple process in terms of equipment
• The process can by used in AC, DC+ or DC-
• The process is a manual process and demands a high skill
from the welder.
• The process is the most widely used throughout the
welding industry both for shop and site working
conditions
Introduction
Principle of Operation
Basic Equipments
“Tongs” type with spring-

Collet or twist type
loaded jaws
Electrode Holder
Welding Positions & Weldable Metals

Ranges of Metal Thickness

SMAW - Electrodes
Electrode Designation (AWS)

• To facilitate arc ignition and give arc stability
• To generate gas for shielding the arc & molten metal from
air contamination
• To de-oxidise the weld metal and flux impurities into the
slag
• To form a protective slag blanket over the solidifying and
cooling weld metal
• To provide alloying elements to give the required weld
metal properties
• To aid positional welding (slag design to have suitable
freezing temperature to support the molten weld metal)
• To control hydrogen contents in the weld (basic type)
Electrode Functions
SMAW quality (left to right)

• current, arc length and travel speed normal;
• current too low;
• current too high;
• arc length too short;
• arc length too long;
• travel speed too slow;
• travel speed too high
SMAW - Troubleshooting
Advantages:
• Field or shop use
• Range of consumables
• All positions
• Portable
• Simple equipment
Disadvantages:
• High welder skill required
• High levels of fume
• Hydrogen control (flux)
• Stop/start problems
• Comparatively uneconomic when compared with some other
processes i.e MAG, SAW and FCAW
Advantages & Disadvantages

2. Gas Tungsten Arc Welding (GTAW)
• The GTAW, also known as Tungsten Inert Gas (TIG) welding
process was first developed in the USA during the 2nd
world war for the welding of aluminum alloys
• The process uses a non-consumable tungsten electrode
• The process requires a high level of welder skill
• The process produces very high quality welds.
• The TIG process is considered as a slow process
compared to other arc welding processes
• The arc may be initiated by a high frequency to avoid
scratch starting, which could cause contamination of the
tungsten and weld
Introduction
Basic Equipments

Ranges of Metal Thickness

Welding Technology & Inspection (MO-091333) 22
Gas type and flow rate
Generally two types of gases are used in GTAW, argon and helium,
though nitrogen may be considered for welding copper and hydrogen
may be added for the welding of austenitic stainless steels.
The gas flow rate is also important.
Argon (Ar) Inert Helium Argon mixes

• Suitable for welding carbon • Suitable for welding carbon
steel,stainless steel, aluminium steel, stainless steel, copper,
and magnesium aluminium and magnesium
• Lower cost, lower flow rates • High cost, high flow rates
• More suitable for thinner • More suitable for thicker
materials and positional materials and materials of
welding high thermal conductivity.
Welding Variables
Voltage
The voltage of the TIG welding process is variable only by the type of
gas being used, and changes in the arc length
Current
The current is adjusted proportionally to the tungsten electrodes
diameter being used. The higher the current the deeper the
penetration and fusion
Polarity
The polarity used for steels is always DC –ve as most of the heat is
concentrated at the +ve pole, this is required to keep the tungsten
electrode at the cool end of the arc. When welding aluminium and its
alloys AC current is used
Welding Variables
DC • can be DCEN or DCEP
• DCEN gives deep penetration
• can be sine or square wave

AC
Type of • requires a HF current (continuos or
welding periodical)
current • provide cleaning action
Pulsed • requires special power source

current • low frequency - up to 20 pulses/sec (thermal
pulsing)
• better weld pool control
• weld pool partially solidifies between pulses
Types of current
+ - + - + -
+ - + - + -
+ - + - + -
Current type & polarity DCEN AC (balanced) DCEP
Heat balance 70% at work 30% 50% at work 50% 35% at work 65%
at electrode at electrode at electrode
Penetration Deep, narrow Medium Shallow, wide
Oxide cleaning action No Yes - every half cycle Yes
Electrode capacity Excellent (e.g. Good (e.g. Poor (e.g.
3,2 mm/400A) 3,2 mm/225A) 6,4 mm/120A)
Effect of Current type

Polarity Influence – cathodic cleaning effect

Penetration
increase
2-2,5 times electrode
Increase
Vertex
diameter
angle
Decrease
Bead width
increase
Electrode tip prepared for low Electrode tip prepared for high
current welding current welding
Electrode tip for DCEN
DC -ve AC
Electrode tip ground and then

Electrode tip ground
conditioned
Electrode tip for AC
Advantages:
• High quality of weld
• Post cleaning not required
• All positions
• No slag
• Little or no spatter
Disadvantages:
• High welder skill required
• Low productivity

3. Gas Metal Arc Welding (GMAW)
• The GMAW which also known the Metal Inert/Active Gas
(MIG/MAG) welding process was initially developed in the
USA in the late 1940s for the welding of aluminum alloys.
• The latest EN Welding Standards now refer the process by
the American term GMAW
• The process uses a continuously fed wire electrode
• The weld pool is protected by a separately supplied
shielding gas
• The process is classified as a semi-automatic welding
process but may be fully automated
• The wire electrode can be either bare/solid wire or flux
cored hollow wire
Introduction
Basic Equipments
Electrode
Dip Transfer (Short-circuit): (Voltage < 22) / (Amperage < 200)
Voltage
• Thin materials positional welding
Globular Transfer: Between Dip & Spray Transfer

• Limited commercial, Used only in some mechanized MAG
process using CO2 shielding gas
Globular Spray transfer
Spray Transfer: transfer
(Voltage > 27) / (Amperage > 220)
• Thicker materials, limited to flat welding positions, high
deposition
Pulse Transfer: Both spray and dip transfer in
• one mode of operation, frequency range 50-300 pulses/second
Dip transfer
Current
• Positional welding and root runs
Metal Transfer Modes


Welding Process Variations

• Welding current
•Increasing welding current

•Increase in depth and width
•Increase in deposition rate
• Polarity
Process Variables
• Arc voltage
•Increasing arc voltage

•Reduced penetration, increased width
•Excessive voltage can cause porosity,
spatter and undercut
• Travel speed
•Increasing travel speed
•Reduced penetration and width, undercut
Process Variables
Advantages Disadvantages
 High productivity  Lack of fusion (dip)
 Easily automated  Small range of consumables
 All positional (dip & pulse)  Protection on site
 Material thickness  Complex equipment
range  Not so portable
 Continuous electrode
Wide range of application

4. Flux-Cored Arc Welding (FCAW)
Flux core Insulated extension nozzle
Current carrying guild tube

Wire joint
Flux cored hollow wire
Flux powder
Arc shield composed of
vaporized and slag forming
Flux core compounds
wires
Molten
weld Metal droplets covered with
Solidified weld pool
thin slag coating
metal and slag
Principle of Operation (Outershield)

Principle of Operation (Innershield)

Basic Equipments
Flux Metal wire
Electrode
Electrode
Advantages Disadvantages
Field or shop use High skill factor
High productivity Slag inclusions
All positional Cored wire is Expensive
Slag supports and shapes High level of fume (Inner-
the weld Bead shield)
No need for shielding gas Limited to steels and nickel
alloys

5. Submerged Arc Welding (SAW)
• Submerged arc welding was developed in the Soviet Union
during the 2nd world war for the welding of thick section steel.
• The process is normally mechanized.
• The process uses amps in the range of 100 to over 2000, which
gives a very high current density in the wire producing deep
penetration and high dilution welds.
• A flux is supplied separately via a flux hopper in the form of either
fused or agglomerated.
• The arc is not visible as it is submerged beneath the flux layer
and no eye protection is required.
Introduction
Filler wire spool
Flux hopper
Power
supply
- +
Slide rail
Wire electrode
Flux
Basic Equipments
Courtesy of ESAB AB
Courtesy of ESAB AB
Basic Equipments
Electrode & Flux


Welding Processes: Nur Syahroni, ST., MT., PH.D

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DEPT.

Welding Technology & Inspection (MO-141323)

“Tongs” type with spring-

Welding Positions & Weldable Metals

Ranges of Metal Thickness

Electrode Designation (AWS)

SMAW quality (left to right)

Advantages & Disadvantages

Welding Positions & Weldable Metals

Ranges of Metal Thickness

Argon (Ar) Inert Helium Argon mixes

• can be sine or square wave

Pulsed • requires special power source

Current type & polarity DCEN AC (balanced) DCEP

Effect of Current type

Polarity Influence – cathodic cleaning effect

Electrode tip ground and then

Advantages & Disadvantages

Globular Transfer: Between Dip & Spray Transfer

Metal Transfer Modes

Welding Positions & Weldable Metals

Welding Process Variations

•Increasing welding current

•Increasing arc voltage

Advantages & Disadvantages

Current carrying guild tube

Principle of Operation (Outershield)

Principle of Operation (Innershield)

Advantages & Disadvantages

Electrode & Flux

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