ARC WELDING Arc welding uses of the heat of the electric arc for fusion of plates for welding.

Connect power supply to anode and cathode Close the circuit by touching electrode together Short circuiting: thermo ionic emission followed by electro magnetic field emission on separation Increased conductivity of gap facilitates to establishing the arc Ionization of gases is arc gap due to electron collision Thus continuous flow of electron i.e. arc

Effect of arc gap

Increase in gap increases the resistance for flow of current and so potential difference. Excessive gap can extinguish the arc due to increased loss of electrons from arc surfaces and heat by convection

Stability
Depends on mode of metal transfer Gravity Upward Downward Surface tension Electromagnetic interaction Density Size of metal

 DC allows better control over heat input using either straight (DCEN) or reverse polarity (DCEP). DCEN is used for thicker plates of higher thermal conductivity DCEP for thinner sections and shallow penetration DC is preferred for odd (vertical, overhead) position welding

Polarity

AC Arc Welding Set Up

Function of electrode coatings

To introduce alloying elements in weld to Sp. properties. Control the slag viscosity for vertical/overhead welds to avoid falling down of molten metal and better control over puddle. Coating extending beyond the stick electrode core wire concentrates Common the arc and directs the filler Electrodes are Available in diameters of 1.6, 2.0, material at desired position 3.2, 4, 5, 6, 8 and 9 mm Act as insulator to avoid short and the length is 350 Or 450 mm. circuiting in narrow gap welding Baking of electrode done Increase DR by adding iron to remove Moisture from the Coating as they powders
are mostly hygroscopic.

Manual Metal Arc Welding (MMAW) Shielded Metal Arc Welding (SMAW)
It is highly versatile and least expensive process and can be used for both simple and sophisticated jobs. Heat melts the electrode, base metal and coating on the electrode, all of this weld in the weld bead All position welding flat, horizontal vertical, overhead SMAW can done by both AC or DC power source using general current rating from 50 to 500 A with voltages from 20 to 40 V.

Limitations Slow welding speed due to low DR ranging from 1 to 8 kg/hr in the flat position (further less in vertical and overhead positions) Wastage in form of unused end of electrode, slag and gas besides chances of slag inclusions and moisture pick-up in coating.

Electrode designation
Electrode are designated using a set of 6 characters which combines alphabets and numbers First is alphabet E/R indicates method of manufacturing (E: extruded and R: reinforced) Second is number (1-9) indicates type of coating on electrode Third is number (1-9) indicates welding position on electrode Forth is number (1-9) indicates welding current on electrode Fifth is a set of three numbers indicating ultimate strength of weld Sixth is a alphabet indicating type of electrode

Types of Welding Positions

MI-102: Manufacturing Techniques

I. I. T. ROORKEE

[4.6.6] Electrode Designation

powder, powder, powder,

Current

Resistance And TIG Spot Weld

Resistance Welding
A group of fusion welding processes that use a combination of heat and pressure to accomplish coalescence Types Resistance spot welding (Principal use) Resistance seam welding Resistance projection welding Developed in early 1900 Less skill is required

Resistance Welding
No shielding gas No flux No consumable electrodes, no filler material Heat required for welding is produced by means of electric resistance between members to be joined H = I2Rt Heat in Joules I (current) in Amperes R(resistance) in Ohms T(time of current flow) in seconds H = I2RtK K energy losses through radiation and conduction

Resistance Welding

Resistance Welding

Resistance Welding

Resistance Welding

Resistance Welding

Resistance Welding

Resistance Welding

Resistance Welding

Resistance Welding

Resistance Welding

Resistance Welding

Resistance Welding
Top Electrode Water Weld Nugget

Distance

Resistance Bottom Electrode

Spot Welding Cycle

Cycle: (1) parts inserted between electrodes, (2) electrodes close (3) current on (4) current off (5) electrodes opened

(a) Spot welding cycle (b) Plot of force and current

Process Operation

[Reference: Welding Process Slides, The Welding Institute]

Nugget
Microscopic irregularities - 20% contact

(a)
Three heat growth areas at 2/60 of a second after the weld current starts (1) On the surface of top electrode where it makes contact to the part. (2) Part to part contact which is directly between the electrodes. (3) On the surface of lower electrode where it makes contact to the part.

(b)

Point 1 Point 2 Point 3

Nugget
Nugget grows to a cross sectional area of up to the electrode tip contact size

(a) (b) Thickness is just less than twice the thickness of thinner of the two pieces being welded.
Time is programmed to be just less than the time it takes for the molten nugget to reach an electrode contact area

4/60th of a second after the welding current starts.

Single Impulse Welding Cycle

Electrode Force Welding Current

Squeeze Time

Weld Time Welding Cycle

Hold Off Time Time

Welding Handbook, Volume 2, AWS, p.538]

Squeeze time - Time interval between timer initiation and the first application of current. Weld time - Time that welding current is applied to the work in making a weld. Hold time - Time during which force is maintained on work after the last impulse of current ends. Off time - Time during which the electrodes are off the work and the work is moved to the next weld location

Resistance Welding

Resistance Welding

Resistance Welding

Pulsing

Pulse 1

Pulse 2

Pulse 3

Pulse Time

Cool Time

Without Pulsing

With Pulsing

Electrode
Electrode tips are made of copper alloys and other materials Classification: Group A Copper based alloys Group B Refractory metal tips Size of the electrode tip point controls the size of the resistance spot weld Weld nugget diameter should be slightly less than the diameter of the electrode tip point.

Resistance Welding

Resistance Seam Welding (RSEW)

Uses rotating wheel electrodes to produce a series of overlapping spot welds along lap joint Can produce air-tight joints Applications: Gasoline tanks Automobile mufflers Various sheet metal containers

Resistance Seam Welding (RSEW)

Resistance Projection Welding (RPW)

A resistance welding process in which coalescence occurs at one or more small contact points on the parts Contact points determined by design of parts to be joined May consist of projections, embossments, or localized intersections of parts

Resistance Projection Welding (RPW)

(1) Start of operation, contact between parts is at projections (2) when current is applied, weld nuggets similar to spot welding are formed at the projections

Resistance Welding

Resistance Welding

Resistance Projection Welding (RPW)

(a) Welding of fastener on sheetmetal (b) cross-wire welding

Other Resistance Projection Welding Operations

(a) Welding of fastener on sheetmetal and (b) cross-wire welding

Advantages

Adaptability for Automation in High-Rate Production of Sheet Metal Assemblies

High Speed Economical Dimensional Accuracy

Limitations

Difficulty for maintenance or repair Generally have higher cost than most arc welding equipments Produces unfavorable line power demands Low tensile and fatigue strength The full strength of the sheet cannot prevail across a spot welded joint Eccentric loading condition

Resistance Welding

Submerged Arc Welding

Submerged Arc Welding ( SAW) Welding arc is shielded by a granular flux consisting of lime,silica,manganese oxide,calcium fluoride Flux: insulates weld area,allows deep thermal penetration Prevents spatter and spark over molten metal Shielded glass etc is unnecessary 3002000 Amp (max 5000Amp for multiarc) Speed 5 m/min

Submerged Arc Welding ( SAW) Thick plate welding 4 to 10 times more weld material than SMAW.
SAW Deposition rate 45 kg/h SMAW Deposition rate 5 kg/h

Generally automatic or mechanized Pressurized or gravity flux feed. DC or AC power SAW filler material
Standard wire (1.6 - 6 mm) Twisted wire (oscillating movement)

Advantages
High deposition rates No arc flash or glare Minimal smoke and fumes Flux and wire added separately - extra dimension of control Easily automated Joints can be prepared with narrow grooves Can be used to weld carbon steels, low alloy steels, stainless steels, chromium-molybdenum steels, nickel base alloys

Limitations
Flux obstructs view of joint during welding Flux is subject to contamination porosity Normally not suitable for thin material Restricted to the flat position for grooves - flat and horizontal for fillets Slag removal required Flux handling equipment

Electroslag Welding (ESW)

Electroslag Welding(ESW)
Arc is created Flux is added and melted by arc Electrode submerges in molten slag and arc is extinguished 600 A at 40-50 V 50 mm 900 mm Travel speed 12 36 mm/min Used for heavy structural steel, Pressure vessels etc.

Thank you