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Introduction to Welding Processes
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Introduction to welding
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Overview of joining methods
Mechanical methods Screwed fasteners, rivets,
Adhesive bonding Brazing and Soldering
Base metal does not fuse. Molten filler drawn into close-fit joints by capillary action (surface tension forces). Brazing filler melts >450 C, solder <450 C
Welding
Introduction to welding
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Weld
A joint produced by heat or pressure or both So there is continuity of material.
Filler (if used) has a melting temperature close to the base material
Introduction to welding
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Welding processes
Fusion welding Welding in the liquid state with no pressure Union is by molten metal bridging
Solid phase welding Carried out below the melting point without filler
additions Pressure often used Union is often by plastic flow
Introduction to welding
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Introduction to welding
Basic Requirements of Welding Process
Source of Heat Chemical ReactionElectrical - Arc, Resistance, InductionMechanical
Protection from AtmosphereGas ShieldingFluxMechanical ExpulsionVacuum
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Fusion welding heat sources
Power beams
LaserElectron beam
Spot, seam and projection welding
Electroslag
Electric arcChemical reactionElectric resistance
Oxyfuel gas welding
Thermit welding
MMAWGMAWGTAWFCAWSAW
Introduction to welding
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Solid phase welding
Hot processes Forge welding Friction welding Diffusion bonding
Cold processes Ultrasonic welding Explosive welding
Introduction to welding
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Some arc welding processes
MMAW - manual metal arc welding SAW - submerged arc welding GTAW - gas tungsten arc welding (TIG) GMAW - gas-metal arc welding (MIG, MAG) FCAW - flux cored arc welding
Introduction to welding
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The electric arc Electric discharge between 2
electrodes through ionised gas 10 to 2000 amps at 10 to 500 V arc
voltage Column of ionised gas at high
temperature Forces stiffen the arc column
Transfer of molten metal from electrode to work piece
Can have a cleaning action, breaking up oxides on work piece
+
- Cathode drop zone
Anode drop zone
Peak temperatures
18,000 K
Introduction to welding
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Arc energyQ = arc energy in kJ/mmE = current in ampsI = arc voltageV = travel speed in mm/min
Low arc energy• Small weld pool size• Incomplete fusion• High cooling rate• Unwanted phase transformations• Hydrogen cracking
High arc energy• Large weld pool size• Low cooling rate• Increased solidification cracking risk• Low ductility and strength• Precipitation of unwanted phases (corrosion and ductility)
Introduction to welding
Q = E x I V
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Introduction to welding
• 103 Watts/cm2 melts most metals
• 106 -107 Watts/cm2 vaporizes most metals
• 103 to 106 Watts/cm2 typical for fusion welding
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Manual Metal Arc Welding
MMAW, SMAW, Stick electrode weldingManual welding
Introduction to welding
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Manual Metal Arc WeldingHeat source - arc between metal and a flux coated electrode (1.6- 8 mm diameter)
Current 30-400A (depends on electrode size) AC or DC operation Power 1 to 12 kW
Introduction to welding
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Introduction to welding
Manual Metal Arc Welding
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Manual Metal Arc Welding Minimum equipment
Power source (ac or dc, engine driven or mains transformer)
Electrode holder and leads May carry up to 300 amps
Head shield with lens protects face & eyes Chipping hammer to remove slag Welding gloves protect hands from arc
radiation, hot material and electric shock
Introduction to welding
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Manual Metal Arc Welding Process features
Simple portable equipment Widely practiced skills Applicable to wide range of materials, joints,
positions About 1kg weld deposited per arc-hour Portable and versatile Properties can be excellent Benchmark process
Introduction to welding
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Manual Metal Arc Welding Covered electrodes
Core wire Solid or tubular 2mm to 8mm diameter,
250 to 450mm long Coating
Extruded as paste, dried to strengthen
Dipped into slurry and dried (rare)
Wound with paper or chord (obsolete)
Introduction to welding
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Manual Metal Arc Welding Functions of coating
Slag protects weld pool from oxidation Gas shielding also protects weld pool Surface tension (fluxing) Arc stabilising (ionising) Alloying and deoxidation Some ingredients aid manufacture
(binder and extrusion aids)
Introduction to welding
Manual Metal Arc Welding AWS A5.1 classification
E XXXX - H
Useable positions1=all positions2=flat + horizontal4=vertical down
Tensile Strengthin KPSI
Flux type 20 = Acidic (iron oxide) 10, 11 = Cellulosic12, 13 = Rutile24 = Rutile + iron powder27 = Acidic + iron powder16 = basic18, 28 = basic + iron powder
Hydrogen level (HmR)H = 5 ml / 100g of WMR = low moisture pick-up
Introduction to welding
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Manual Metal Arc Welding Applications
Wide range of welded products: light structure & Heavy steel structures Workshop and site High integrity (nuclear reactors, pressure
equipment) Ideal where access is difficult -
construction site, inside vessels, underwater
Joins a wide range of materials
Introduction to welding
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Manual Metal Arc Welding Limitations
Low productivity Low power Low duty cycle (frequent electrode
changes) Hydrogen from flux coatings Electrode live all the time
Arc strike, stray current and electric shock risks
Introduction to welding
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Submerged arc welding
SAW, Sub-arc
Introduction to welding
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Introduction to weldingSubmerged arc welding
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Introduction to weldingSubmerged 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)
Introduction to welding
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Submerged arc welding - Equipment
Power source Welding head and
control box Welding head travel Flux recovery system
(optional) Positioners and
Fixtures
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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
Introduction to welding
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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
Introduction to welding
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Submerged arc welding Process variations
Surfacing and hardfacing Wire and strip electrodes
Semi-automatic Multiple electrodes
2 (and more) electrode wires From one or more power sources
Iron powder additions to groove
Introduction to welding
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Introduction to welding
Submerged arc welding – Tandem arc
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Gas shielded arc process
Tungsten Inert Gas welding (TIG)Gas tungsten arc welding (GTAW)
Introduction to welding
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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
Introduction to welding
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Introduction to weldingGas Tungsten arc welding
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Gas Tungsten Arc Welding
Heat source - arc between a tungsten tip and the parent metal 30-400A, AC or DC 10-20V 0.3-8kW
Inert gas shielding
Consumable filler rod can be used (1 to 4mm diameter)
Introduction to welding
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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
Introduction to welding
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
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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 CO2
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
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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
Introduction to welding
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Gas Tungsten Arc Welding - Automation
Introduction to welding
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Introduction to weldingGas Tungsten Arc Welding – A TIG
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GMAW and FCAW
Gas metal arc welding (MIG, MAG, CO2 welding)
Flux cored arc welding
Introduction to welding
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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)
Introduction to welding
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Introduction to weldingGas metal arc welding
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MIG WeldingHeat source - arc between parent metal and consumable electrode wire (0.6 to 1.6mm diameter) 60-500A, DC only 16-40V 1 to 20kW
Introduction to weldingGas metal arc welding
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Introduction to weldingGas metal arc welding
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Gas metal arc welding - Equipment
Welding power source Wire feeder mechanism
May be in power source cabinet Gun with gas supply & trigger
switch Manual (semi-automatic) guns Automatic torches available Can be fitted to robot etc.
Introduction to welding
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.
Introduction to welding
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48Current
Voltage
No arc (birds-nesting)
Burn-back and unstable arc Spray
Globular
Short circuiting
Introduction to weldingGas metal arc welding – Metal transfer
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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
Introduction to welding
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Introduction to weldingGas metal arc welding – Wire size
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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
Introduction to welding
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Introduction to weldingGas metal arc welding - Developments
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Introduction to weldingGas metal arc welding - Developments
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Introduction to weldingGas metal arc welding - Developments
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Introduction to weldingGas metal arc welding - Developments
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Introduction to weldingPlasma Cutting, Welding & Surfacing
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Introduction to welding
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Introduction to welding
Neutral Flame
Oxidising Flame
Carburising Flame
Oxy-Acetylene Welding
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Introduction to weldingThermit welding
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Introduction to welding
Laser Welding
• Photons transmit energy and heat
• Energy intensity up to 109 Watts/cm2
• Depth to width of hole up to 50x
• Automatic controllers needed
• 90% efficiency
• Reflectors don’t weld easily
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Introduction to welding
Laser welding
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Introduction to welding
Electron Beam Welding
• Electrons strike surface and generate heat
• Best performed in a vacuum
• Workpiece must be a conductor
• Magnetic fields affect beam
• Current to 1/2 A
• Power to 100 kW
• X-rays produced
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Introduction to weldingElectron Beam Welding
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Introduction to welding
Size of weld beads in
(a) electron-beam or laser-beam welding
(b) conventional arc welding.
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Introduction to welding
Solid-State Welding
Heat Pressure Time NO Melting NO Filler Material Intimate Contact
Usually Requires Deformation Works with Dissimilar Metals
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Introduction to weldingResistance Welding
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Introduction to weldingResistance spot welding Robots
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Introduction to weldingFlash Butt Welding
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Introduction to welding
Friction Welding
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Introduction to weldingFriction Stir Welding
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Introduction to weldingFriction Stir Welding
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Introduction to weldingExplosive Welding
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Introduction to welding
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Introduction to welding
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ANY QUESTIONS
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Introduction to welding
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Introduction to welding
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