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WELDING
AL boils at lower Temperature then its oxide melts. The oxide is also
heavier then AL and when melted tends to be trapped in the molten
aluminum.
When Aluminum Oxide become thicker it will absorbs moisture from air.
Moisture is source of H2 which cause porosity in AL welding. Hydrogen
may also come from oil, paint and Dirt in the weld area. Hydrogen will
enter in weld pool and is soluble in molten aluminum. With a rapid
cooling rate, free hydrogen is retained within the weld and cause porosity.
Porosity will decrease weld strength and ductility.
Some Al alloy exhibit hot short tendencies and are creak sensitive.
These means at the range of temperature where liquid is slushy it has not
quite enough strength to resists the shrinkage stress that are occurring
from cooling and transformation.
GENERAL SETUP:-TIG
The gas begins to flow and starts protecting the weld area from the air. The torch is held
over the weld joint just far enough for the torch not to touch the metal. Then the welder
presses a foot pedal and the TIG torches tungsten electrode starts an arc. Once the arc is
started the two pieces of metal begin to melt by creating a puddle of metal. Once the
puddle is established the welder with the other hand starts filling the joint by manually
dipping a welding wire into the arc to fill the joint. Ultimately this process creates a
single piece of metal.
Because of the intense heat some erosion of the electrode will occur, the electrode may get
consumed quickly if it is allowed to get oxidized, since tungsten oxide has a lower melting
temperature. The oxidation occurs when the electrode is allowed to cool in the atmosphere
after welding. Hence, the shielding gas flow should be maintained for some time after
extinguishing the arc so that the electrode gets sufficiently cooled in a protective
atmosphere rather than in the oxidizing normal atmosphere. These include In the last years
some alloy elements have been incorporated, such as cerium and lanthanum, which also
increase the life of the electrode and tend to decrease the risk of radiation that is produced
when electrodes of high thorium content are employed. Zirconium electrodes are preferred
for AC, because they present a higher melting point than pure tungsten or tungstenthorium. During the welding process, it is assumed that the electrode tip is hemispherical
type. This is a very important aspect, because the arc stability depends in a greater manner
of tip geometry.
Shielding Gas for welding:- Primarily two inert gases are used for shielding
purposes. They are argon, helium, or a mixture of the two. They must be of high purity
for welding applications. The purity is normally held to 99.995%(UHP). Each of these
gases have characteristics which must be understood in making a selection of a shielding
gas for a particular application. The primary function of the gas is to exclude the active
properties in the surrounding air from the weld area. The type of gas also has an influence
on the characteristics and behaviour of the arc and resultant weld. The chief factor
influencing the effectiveness of a shielding gas is the gas density. Argon with an atomic
weight of 40 is about one and one third times as heavy as air and ten times as heavy as
helium with an atomic weight of 4. Argon after leaving the torch nozzle tends to form a
blanket over the weld area whereas helium tends to rise rapidly from the arc area. In order
to obtain equivalent shielding, flow rates for helium are usually two to three times that of
argon. The same is true of helium-argon mixtures, especially those with high helium
content.
Argon shielding gas is supplied in BLUE cylinders. Argon may be obtained in the gaseous
state in cylinders or as a liquid in specially constructed cylinders or bulk tanks. The
ionization potential of argon is 15.7 volts. Ionization potential is the voltage necessary to
remove an electron from the gas atom making it an ion or charged atom. Argon has low
thermal conductivity which means it is not a good conductor of heat. This results in a
higher arc density. Arc density refers to the concentration of energy in the arc. With argon
this energy is confined to a narrow area or "pinpointed" in a small area. With a given arc
length, the arc voltage with argon will be less than with helium. Argon provides excellent
arc stability and cleaning action even at low amperages. The correct flow rate is an
adequate amount to shield the "molten weld pool area" and protect the tungsten electrode.
Any greater flow than this is a waste. The correct flow rate in cubic feet per hour (CFH) is
influenced by many variables that must be considered on each application.
Helium shielding gas is supplied in BROWN cylinders. The ionization potential of helium
is 24.5 volts. Helium has excellent thermal conductivity. The helium arc column will
expand under the heat of the arc reducing the arc density. The arc column is more flared
out than the arc column with argon. The more flared out the arc column the more work
surface area is being heated. The heat at the centre of the arc, therefore, can move more
readily downward towards the colder metal at the bottom of the work piece. This results in
a deeper penetrating arc. With an equivalent arc length helium will produce a higher arc
voltage than will argon. With helium shielding any slight variation of arc length can have
quite an effect on arc voltage and, consequently, total arc power. For this reason helium is
not as desirable as argon for manual operations.
Helium is, therefore, used on applications where the torch is machine guided or held.
Because helium is a light gas, flow rates are usually two or three times that of argon for
equivalent shielding. With the increased flow rate, total cost of shielding goes up sharply.
The cost must be weighed against increased penetration on thick material, and the
increased travel speed attainable.
Helium / argon mixtures are sometimes used for their higher heat characteristics. Gas
mixtures, usually 25% helium and 75% argon are sometimes used and can help to increase
travel speeds when AC - gas tungsten arc welding. Mixtures of more than 25% helium for
AC gas tungsten arc welding are used, but not often, as they can tend to produce
instability, under certain circumstances, in the AC arc.
suit the parent metals being welded. Filler rods should be stored in clean dry conditions to
prevent deterioration. They should be free from rust, scale, oil grease and moisture, which
would contaminate welds, and be cleaned with stainless steel wool or smooth aluminum
oxide cloth immediately before use.
Material of Construction for all Concentrated Nitric Acid Storage Tank (T123, T178 &
T179) at Aniline TDI Complex is ASTM SB209 Al 1060 TEMPER O. For welding of
that material we use AWS/SFA 5.10 ER 1100 (2.50*1000) TIG-400.[Al-99.0%,ZN0.10%,MN-0.05,Cu-0.05to0.20%].
where 5.10- stands for Aluminum alloys.
5.1-for carbon steel
5.4-for stainless steel
5.8-for alloy steel
AWS/SFA
5.10 ER 1100. ER 1100 is designed for welding alloys
1060,1100,1350.welding of al 99.8,al 99.7al 99.5.
DCEN:-In this case, the electrode is connected to the negative pole of the heat source and
the electrons are emitted from the electrode and they are accelerated as they travel through
the arc (plasma). This effect produces a high heat in the work piece and therefore gives a
good penetration and a relatively narrow weld shape.
DCEP:-On the other hand, when reverse polarity is used, the electrode is connected to the
positive pole of the heat source. Now the effect of the heating due to the bombardment of
the electrons is higher in the electrode than that of work piece, which results in a wide
weld bead and shallower than that generated by direct polarity. In this case, due to high
energy concentration in the electrode it is necessary to employ a thicker diameter and a
cooling system to eliminate the electrode tip melting possibility. The bombardment effect
by positive ions of the inert gas removes the oxide film and produces a cleaning effect on
the welding surface. Therefore, reverse polarity can be used to weld materials that are
resistant to oxides such as aluminium, if it is not required a high penetration.
TORCHES:- The water cooled torch is designed so that water is circulated through
the torch cooling it and the power cable. The power cable is contained inside a hose, and
the water returning from the torch flows around the power cable, thereby cooling it.
When you add rod to an aluminum weld, the pool will rise. Take this into account when
you position your tungsten over your part or else your weld will rise up and contaminate
your tungsten electrode.
Rod to torch angle is critical. Heat will reflect off of your part and melt your rod if your
are not aware of it. Slide rod in under heat. Rod needs to be pushed into the pool not
drawn in by the heat of the arc or you will never achieve uniformity. This applies to any
process in which you have to manually feed in a rod with your hand. Rod and torch angle
should never be the same if it can be avoided.
Keep your arc length as short as possible. Arc length is the distance between the tungsten
and the workpiece. The more stable your hand is the closer you can get. Different arc
lengths can be used for different materials.Experiment. Less heat is inputted when your arc
is short, Your arc is concentrated in a smaller areas. Welding with higher amps and shorter
arc will input less heat into part than a long arc and less amperes. The hotter you weld the
faster you can go, within reason.