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Equipment
✓ Check that the power source
functions correctly, is correctly
connected to mains, and that you
are familiar with its operation.
✓ Ensure that gas cylinders are
Keep your welding equipment well properly secured, in upright
maintained. position, and fitted with correct
and properly functioning
regulators for the gas. Acetylene
and oxygen regulators shall be
fitted with flashback arrestors.
Protect cylinders against heat and
mechanical damage.
✓ The valve opening of the acetylene
cylinder shall point away from
other compressed gas cylinders,
and a heat resistant mitten shall be
available.
✓ Hoses shall be in good condition,
without leaks or damage, and with
correct colour coding for the gas.
(Red for acetylene, blue for oxygen,
black for shielding gases and filt
ered air). Use correct hose conn
ectors and hose clamps. Pieces of
Never use defective welding cables. pipe and twisted wire must never
be used. Never use oil or grease in
connection with welding gases and
never use copper in connection
with acetylene.
✓ Cables shall be of oil resistant
type with undamaged insulation
and properly mounted cable
connectors. Use safety cable
connectors where both halves are
protected to prevent contact with
deck when disconnected.
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SAFETY IN WELDING
Work place
Tidy up the work place and remove any flammable
materials, liquids and gases from workplace and adja-
cent spaces including spaces above/below decks,
behind bulkheads and inside pipes or containers. Cover
any openings through which sparks may be led to other
areas onboard which have not been prepared for hot
work.
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SAFETY IN WELDING
1.00
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SAFETY IN WELDING
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ELECTRODE WELDING AND GOUGING
Introduction
The principle of Manual Metal Arc Welding (MMAW) commonly called “stick
electrode” welding is, as for all arc welding processes, based on the electric
circuit. The electric arc formed between electrode and workpiece has two
objectives, to melt the edges of the joint forming a melt pool on the workpiece,
and to melt the tip of the coated electrode. The electrode is consumed and acts
as a filler material mixing with the melted base material to fill up the joint.
Initially manual metal arc welding was done with bare metal electrodes without
any coating, a process that was first introduced in 1888 in Russia.
The first coated electrode was patented by the Swedish engineer Oskar
Kjellsberg in 1905, but it took some years of refining coatings and testing the
reliability of welded joints before the process was accepted in the fabrication
of steel constructions. In 1938, however, the world’s first wholly welded
oceangoing ship was launched in Malmø, thereby introducing MMA welding as
a production process for the maritime market.
The popularity of the Manual Metal Arc Welding process is to a large degree
based on its versatility in addition to its modest requirements for equipment.
Even quite unsophisticated welding machines like a step-down transformer
may be used as power supply, at least for the less demanding electrodes,
and the only welding equipment required in addition to the power supply is a
suitable electrode holder.
By selecting the correct electrode, most metallic material may be arc welded
in any position and in any thickness down to approximately 2 mm.
Different electrode holders are required depending on the type of welding
work. In this chapter the following will be described:
• Normal welding/gouging with coated electrodes
• Air-Carbon-Arc gouging with copper coated carbon electrodes
Each of these areas require their special electrode holder.
4.01
Arc processes require a complete electric circuit. Always remember proper grounding.
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ELECTRODE WELDING AND GOUGING
Practical setup
Welding machine
Welding cable
Return cable
Electrode
holder
Electrode
Ground clamp
Arc
Workpiece
4.01
Welding current
The arc properties are dependent on the current supplied to it. Basically there
are two different types of electric current; alternating current (AC) and direct
current (DC). DC is a stream of negatively charged electrons flowing through
the cable, moving from the negative pole (-) to the positive pole (+). AC is
achieved when the power supply switches positive and negative polarity at
a frequency which normally is 50 or 60 times per second (50 or 60 Hz). The
electrons will then no longer flow in a steady stream but flow back and forth in
the cable, and 100 or 120 times a second the current will actually be zero, as
shown in the diagram.
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ELECTRODE WELDING AND GOUGING
AC as welding current
(inverter or rectifier) that rectifies
Mains power will normally be AC, and the AC from the mains supply to a
the simplest form of welding power DC of correct amperage and voltage
sources are transformers that reduce for welding. To avoid the dangers the
the mains voltage and provide means current pulses represent in cases of
for adjusting the amperage (welding electric shock, several countries have
current), still delivering AC to the issued regulations on how smooth
welding arc. As the AC actually is the DC current shall be in order to be
zero each time it changes direction accepted as DC without requirements
only electrodes specially developed for open circuit voltage reducing
for AC will be usable with welding devices. These requirements should
transformers. be observed when installing welding
The pulsating effect of AC has proven equipment on board.
to be especially dangerous to an
operator in case of electric shock.
Where burns are the main danger
from an electric shock from DC, the
AC pulses may in addition cause
cramps and heart failure as the
pulses affect the nervous system.
Authorities in several countries have
therefore issued special regulations
and demands for open circuit voltage
reducing equipment for welding
power sources with AC output.
The only welding application that
requires AC as welding current is TIG
welding of aluminium, as the back
and forth flowing electrons serve the
purpose of tearing up the unmelted
oxide layer that forms on top of an
aluminium melt pool. However, in
onboard repair and maintenance
4.01 welding the Wire Welding Process
Gas Metal Arc Welding (GMAW)
process is an alternative for DC current, constant towards the positive
aluminium welding which offers (+) pole.
several advantages, and is done with
DC. AC current cycling from one direction
through zero to the opposite direction, 50
or 60 complete cycles per second.
DC as welding current
DC is by far the best suited and most
commonly used current for welding
processes. It is normally obtained
through a welding power source
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ELECTRODE WELDING AND GOUGING
+
70 % – 30 % +– 50 %
DC- DC+ AC
Direct current moving from – to + Alternating current
339