Escolar Documentos
Profissional Documentos
Cultura Documentos
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OBJECTIVES
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INPUT
7.0. INTRODUCTION
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carbon and alloy steels, heat-resistant and stainless steels, cooper and its
alloys, nickel and its alloys, titanium, zirconium and silver.
The arc burns between a tungsten electrode and the work piece within
a shield of the inert gas argon, which excludes the atmosphere and prevents
contamination of electrode and molten metal. The hot tungsten arc ionizes
argon atoms within the shield to form a gas plasma consisting of almost
equal numbers of free electrons and positive ions. Unlike the electrode in the
manual metal arc process, the tungsten is not transferred to the work and
evaporates very slowly, being classed as ‘non-consumable’. Small amount of
other elements are added to the tungsten to improve electron emission.
Gas flow
Torch
Water outlet
Welding
machine
Work piece
Water inlet
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A B B Y Y.c A B B Y Y.c
Electrode
(tungsten)
Inert/noble
gas
Filler rode
Shielded gas
arc
Direction of travel
80 – 90o
20 – 30o
Melting pool
Work piece
Figure 7.2. TIG in progress. The tungsten does not melt into the
puddle for filler. This is a nonconsumable electrode.
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A B B Y Y.c A B B Y Y.c
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A B B Y Y.c A B B Y Y.c
Welding Electrode
machine
Direction of electron
travel
Positive surface
particles travel
Work piece
Deep penetration
Welding
Electrode
machine
Direction of electron
Positive surface travel
particles travel
Work piece
Shallow penetration
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enough to melt, transfer to the weld pool, and contaminate the base
metal. When this happens, the electrode must be removed, its end
broken off, and it must be ground to shape.
Alternating current offers the advantages of both direct current
straight polarity (DCSP) and direct current reverse polarity (DCRP).
Gas tungsten-arc welding of aluminium and magnesium requires an
AC power supply (Fig. 7.5).
Gas tungsten-arc welding is not recommended for metal more
than 20 mm thick. Welds have been completed on 25 mm thick plate
but require a great deal of time and, consequently, are expensive.
Most applications are less than 12 mm thick, and require less than 500
amperes of current.
Welding Electrode
machine
Surface
particles lifted Electron flow
Work piece
Medium penetration
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SHIELDED GAS ARC WELDING
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Table 7.1. Selection of nozzle size and electrode size for gas tungsten-arc
welding
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15o 30o
45o
Grind here
DCSP DCRP AC
3/8” max
Electrode diameter
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A B B Y Y.c A B B Y Y.c
Y
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After the base metal has been properly cleaned and clamped or tacked
together, welding can be started. On aluminium, the arc is usually started by
bringing the electrode near the base metal at a distance of about one
electrode diameter so that a high-frequency spark jumps across the gap and
starts the flow of welding current. Steel, copper alloys, nickel alloys, and
stainless steel may be touched with the electrode without contamination to
start the arc. Once started, the arc is held stationary until a liquid pool
appears. Filler rod can be added to the weld pool as required (Fig. 7.8).
Highest current values and minimum gas flow should be used to produce
clean, sound welds of desired penetration (Table 7-3).
F T ra n sf o F T ra n sf o
PD rm PD rm
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SHIELDED GAS ARC WELDING
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A B B Y Y.c A B B Y Y.c
The shielded gas is pure argon and pre-heating is required for drying
only to produce welds of the highest quality. All surfaces and welding wire
should be degreased and the area near the joint and the welding wire should
be stainless steel wire brushed or scrape to remove oxide and each run
brushed before the next is laid.
The angles of torch and filler rod are shown in Fig. 7.8. After
switching on the gas, water, welding current and HF unit, the arc is struck
by bringing the tungsten electrode near the work (without touching down).
The HF sparks jump the gap and the welding current flows. Arc length
should be about 3 mm. Practice starting by laying the holder on its side and
bringing it to the vertical position, but using the ceramic shield as a fulcrum
can lead to damage to the holder and ceramic shield. The arc is held in one
F T ra n sf o F T ra n sf o
PD rm PD rm
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A B B Y Y.c A B B Y Y.c
15o
Direction of
30o travel
The flow rate should be checked and the line inspected for leaks. A
brown film on the weld metal indicates presence of oxygen in the argon while
a chalky white appearance of the weld metal accompanied by difficulty in
controlling the weld indicates excessive current and overheating. The weld
continues with the edge of the portion sinking through, clearly visible, and
the amount of the sinking which determines the size of the penetration bead
is controlled by the welding rate.
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SHIELDED GAS ARC WELDING
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equipment is essentially similar except for gas supply. With the tungsten
inert gas shielded arc welding process, inclusions of tungsten become
troublesome with currents above 300 A. The MIG process does not suffer
from these advantages and larger welding current giving greater deposition
rates can be achieved. The process is suitable for welding aluminium,
magnesium alloys, plain and low-alloy steels, stainless and heat-resistant
steel, copper and bronze, the variation being filler wire type of gas shielding
the arc.
The consumable electrode of bare wire is carried on the spool and is fed
to a maually operated or fully automatic gun through an outer flexible cable
by motor-driven rollers of adjustable speed, and rate of burn-off of the
electrode wire must be balance by rate of wire feed. Wire feed rate
determines the current used.
In addition, a shielding gas or gas mixture is fed to the gun together
with welding current supply, cooling water flow and return (if the gun is
water cooled) and a control cable from gun switch to control contractors.
A d.c. power supply is required with the wire electrode connected to the
positive pole ( Fig. 7.9).
Arc welding Gas flow
power supply meter
Electrode
feed Contactor lead,welding
rools current,electrode, and
inert gasto welding
gun
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During this process an electric arc is used to heat the weld zone. The
electrode is fed into the weld pool at a controlled rate and the arc is shielded
by a protective gas such as argon, helium, or carbon dioxide (Fig. 7.9). Gas
metal-arc welding can be either the short-circuiting process or the spray-arc
process (Fig. 7.10).
Inert/noble gas
Shielded gas
Arc
Melting pool
Work piece
Work piece
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A B B Y Y.c A B B Y Y.c
per unit of time.) Most applications of the spray-arc process are in thick
metal fabrications, e.g., in heavy road-building machinery, ship construction,
and beams for bridges.
Work piece
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SHIELDED GAS ARC WELDING
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A B B Y Y.c A B B Y Y.c
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SHIELDED GAS ARC WELDING
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The primary purpose of the inert gas is to shield the weld crater
from contamination. Shielding gas may also affect (1) the transfer of
metal across the arc, (2) fusion and penetration, (3) the shape of weld
deposit, (4) the speed of completing the weld, (5) the ability of filler
metal to flow over the surface without undercutting, and (6) the cost of
the finished weld.
No single inert gas is satisfactory for all welding conditions.
Some specific jobs are more efficiently welded with a mixture of gases.
For example, low alloy steels are welded with a mixture of argon,
helium, and carbon dioxide (Table 7.4).
Electrodes used for filler metal with the MIG process are much
smaller in diameter than those used with the metal-arc process. Sizes
may range from 0.4 mm to 5.5 mm in diameter. Small diameter
electrodes require high feed rates, from 100 to 1,400 inches per minute.
The composition of the electrode usually matches that of the base
metal, but for welding high-strength alloys, the composition of the
electrode may vary widely from that of the base metal.
For example, an aluminium-zinc-magnesium alloy (7039) is
welded with an aluminium-magnesium alloy (5356).
F T ra n sf o F T ra n sf o
PD rm PD rm
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7.4.1. Current.
7.4.2. Voltage.
Curve representing
Curve representing porosity
undercutting
Voltage Voltage
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Table 7-5 Typical arc voltage for MIG using drop transfer and 1/16 inch
diameter electrode.
*Not recommended.
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No undercut. Undercutting.
Travel speed Travel speed
26 in/min 32 in/min
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SHIELDED GAS ARC WELDING
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i. The gun switch operates the gas and water solenoids and
when released the wire drive is switched on together with
the welding current.
ii. The gun switch operates the gas and water solenoids and
strikes the wire end on the plate operates the wire drives
and welding current (known as ‘scratch start’).
iii. The gun switch operates the gas and water solenoids and
wire feed with welding current known as ‘scratch start’.
The gun is held at an angle of 80o or slight less to the line of the weld to
obtain a good view of the weld pool, and welding proceeds from right to left
with nozzle held 6 – 12 mm from the work.
The further the nozzle is held from the work less the efficiency of the
gas shield, leading to porosity. If the nozzle is held too close to the work
spatter may build up, necessitating frequent cleaning of the nozzle, while
acting between nozzle and work can be caused by a bent wire guide tube
allowing the wire to touch the nozzle, or by spatter build-up short-circuiting
wire and nozzle. If the wire burns back to the guide tube it may be caused by
a late start of the wire feed, fouling of the wire in the feed conduit or the feed
rolls being too tight. Intermittent wire feed is generally due to insufficient
feed rolls pressure or looseness wire due to wear in the rolls. Excessively
sharp bends in the flexible guide tubes can also lead to this trouble.
Root run is performed with no weave and filler runs with as little
weave as possible consistent with good fusion since excessive weaving tends
to promote porosity. The amount of wire projecting beyond the contact tube
is important because the greater the projection, the greater the I2R effect and
the greater the voltage drop which may reduce the welding current and affect
F T ra n sf o F T ra n sf o
PD rm PD rm
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SHIELDED GAS ARC WELDING
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A B B Y Y.c A B B Y Y.c
Electrode
Work piece
Cathode
Holder
Field
Anode
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SHIELDED GAS ARC WELDING
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A B B Y Y.c A B B Y Y.c
Electrode
Work piece
Anode
Holder
Field
Cathode
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ACTIVITY 7
7.5. How far should the electrode extend beyond the nozzle of the TIG
torch?
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FEEDBACK ON ACTIVITY 7
7.2. The gas does not combine with the base metal or filler.
7.4. The electrode diameter should match the current value. If the current is
too high for the diameter of the electrode the life of the electrode will
be short. When the current is too low for a given electrode diameter,
the arc will not be stable. The end of the electrode should remain
bright, as if it was polished.
7.5. The electrode should extend beyond the nozzle a distance equal to the
electrode diameter.
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SHIELDED GAS ARC WELDING
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SELF-ASSESSMENT 7
1. From the standpoint of operation, how are TIG and MIG processes
different? How are they similar?
4. How much of the heat used for arc welding is liberated at the electrode
when using straight polarity?
6. What would happen if the tungsten electrode were bent off centre?
7. Name two defects that could occur with gas shielded-arc welding
processes and explain how each could be avoided.
F T ra n sf o F T ra n sf o
PD rm PD rm
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FEEDBACK OF SELF-ASSESSMENT 7
1. TIG uses a tungsten electrode that does not melt into the weld;
because the electrode is shielded and cooled by inert gas flow. A
separate filler rod is used as needed
Electrode
(tungsten)
Inert/noble
gas
Filler rode
Shielded gas
arc
Direction of travel
80 – 90o
20 – 30o
Melting pool
Work piece
TIG in progress. The tungsten does not melt into the puddle for
filler. This is a nonconsumable electrode.
F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y
Y
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ABB
ABB
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SHIELDED GAS ARC WELDING
C
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A B B Y Y.c A B B Y Y.c
Inert/noble gas
Shielded gas
Arc
Melting pool
Work piece
MIG in progress
2. Positive (+)
3. Across the arc into the base metal and to the positive terminal.
4. One-third (1/3)
7. (a) Eyes and skin – arc is more intense. Wear leather and specially
treated cloth.
(b) Breathing – provide adequate ventilation.