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Arc Welding Methods and
Processes
Arc Welding Methods and
Processes
Harry Sadler
Manager Military and
Shipbuilding Sales
Harry Sadler
Manager Military and
Shipbuilding Sales
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What is a Fusion Weld? What is a Fusion Weld?
A metallurgical bond resulting from the
localized coalescence of base metal.
This generally requires the addition of
energy and may or may not use a
supplemental filler metal that intermixes
with the base metal.
A metallurgical bond resulting from the
localized coalescence of base metal.
This generally requires the addition of
energy and may or may not use a
supplemental filler metal that intermixes
with the base metal.
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Cross Section of a Groove Weld Cross Section of a Groove Weld
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Whats the source of energy? Whats the source of energy?
In arc welding, its the heat generated by
an electric arc.
In arc welding, its the heat generated by
an electric arc.
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Reactor Reactor
Selects Output Selects Output
Welding Current Welding Current
Bridge Rectifier Bridge Rectifier
Changes AC to DC Changes AC to DC
Inductance Coil Inductance Coil
Smoothes / Filters Smoothes / Filters
DC Output DC Output
Transformer Transformer
Single Phase Input Single Phase Input
High Volts High Volts High Amps High Amps
Low Amps Low Amps Low Volts Low Volts
Transformer Rectifier Transformer Rectifier
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AC AC - - 50/60 Hz 50/60 Hz
High Voltage High Voltage
Low Amperage Low Amperage
DC DC - - Rippled Rippled
High Voltage High Voltage
Low Amperage Low Amperage
DC DC - - Smooth Smooth
High Voltage High Voltage
Low Amperage Low Amperage
AC AC - - 20,000 Hz 20,000 Hz
High Voltage High Voltage
Low Amperage Low Amperage
AC AC - - 20,000 Hz 20,000 Hz
Low Voltage Low Voltage
High Amperage High Amperage
DC DC - - Rippled Rippled
Low Voltage Low Voltage
High Amperage High Amperage
DC DC - - Smooth Smooth
Low Voltage Low Voltage
High Amperage High Amperage
Inverter Inverter
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F (Hz) Wt (Kg) F (Hz) Wt (Kg) Eff (%) Eff (%)
60 60 19.5 19.5 90 90
1,740 1,740 3.05 3.05 96 96
10,000 10,000 2.7 2.7 97 97
50,000 50,000 1.9 1.9 98.1 98.1
100,000 100,000 1.7 1.7 98.2 98.2
200,000 200,000 1.5 1.5 98.3 98.3
Al ex Anderson, EFW Al ex Anderson, EFW
November 10, 1911 November 10, 1911
Paper Presented to AIEE Paper Presented to AIEE
Iron at 200,000 Cycles Iron at 200,000 Cycles
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Benefits Benefits
More Efficient = Lower Cost Operation
Lighter Weight = More Portable
Smaller Size = More Compact
Advanced Desig = Superior Output
More Efficient = Lower Cost Operation
Lighter Weight = More Portable
Smaller Size = More Compact
Advanced Desig = Superior Output
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DCEP (Reverse) Polarity DCEP (Reverse) Polarity
Direct Current
Heat Concentrated at
Workpiece
Forceful, Digging Arc
Medium to Deep
Penetration
Direct Current
Heat Concentrated at
Workpiece
Forceful, Digging Arc
Medium to Deep
Penetration
+
_
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DCEN (Straight) Polarity DCEN (Straight) Polarity
DC -
Heat Concentrated at
Electrode
Lower Penetration
Increased Deposition
Rates
DC -
Heat Concentrated at
Electrode
Lower Penetration
Increased Deposition
Rates
+
_
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AC Polarity AC Polarity
Alternating Current
Medium Penetration
Medium Travel
Speeds
Alternating Current
Medium Penetration
Medium Travel
Speeds
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AC AC - - 225 225 AC/DC AC/DC - - 225/125 225/125
AC AC - - 225C 225C
Transformer Welding Power Sources Transformer Welding Power Sources
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IDEALARC 250 IDEALARC 250
R3R R3R - - 400 400
R3R R3R - - 500 500
Transformer Rectifier Welding Power
Sources
Transformer Rectifier Welding Power
Sources
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Inverter Welding Power Sources Inverter Welding Power Sources
V350 V350- -PRO PRO
V275 V275- -S S
PW PW- -355M 355M
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RANGER 10,000 RANGER 10,000
RANGER GXT RANGER GXT
Engine Driven Power Sources Engine Driven Power Sources
RANGER 3 RANGER 3- -Phase Phase
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VANTAGE 500 VANTAGE 500
Engine Driven Power Sources Engine Driven Power Sources
AIR VANTAGE 500 AIR VANTAGE 500
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Constant Current Constant Current
Welding Circuit
Consists of Power
Source, Electrode and
Work Cables/Leads
The Power Source
Keeps the Current as
Constant as Possible
even when the Operator
Varies the Arc Length
Voltage is Proportional
to Arc Length
Welding Circuit
Consists of Power
Source, Electrode and
Work Cables/Leads
The Power Source
Keeps the Current as
Constant as Possible
even when the Operator
Varies the Arc Length
Voltage is Proportional
to Arc Length
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Constant Voltage Constant Voltage
Welding Circuit
Consists of Power
Source, Wire Feeder,
and Work and Electrode
Cables/Leads
Voltage is Proportional
to Arc Length
Current Changes
Dramatically to Maintain
Constant Arc Length
Welding Circuit
Consists of Power
Source, Wire Feeder,
and Work and Electrode
Cables/Leads
Voltage is Proportional
to Arc Length
Current Changes
Dramatically to Maintain
Constant Arc Length
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Arc
Welding Processes
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REQUIREMENTS FOR FUSION:
1. Atomic Cleanliness
2. Atomic Closeness
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SHIELDING OF MOLTEN PUDDLE
Shield from nitrogen, oxygen
Shield with slags
Displace atmosphere with gases
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Arc Welding Processes
Shielded Metal Arc (SMAW)
Flux Cored Arc (FCAW)
Gas Metal Arc (GMAW)
Submerged Arc (SAW)
Gas Tungsten Arc (GTAW)
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SMAW
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Shielded Metal Arc (SMAW)
Base metal
Arc stream
Gaseous shield
Electrode
Extruded covering
Molten pool
Slag
Weld
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Advantages Advantages
Low Start Up
Costs
Portability
Outdoor
All Position
Welding
Variety of
Materials
Mechanical
Properties
Low Start Up
Costs
Portability
Outdoor
All Position
Welding
Variety of
Materials
Mechanical
Properties
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Limitations Limitations
Low Efficiency
(65%)
Operating Factor
Operator Skill
Restarts
Amperage Limit
Slag
Spatter
Low Efficiency
(65%)
Operating Factor
Operator Skill
Restarts
Amperage Limit
Slag
Spatter
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AWS Numbering System-SMAW
E7018
Electrode
Tensile Strength (ksi)
Position
Type of coating & current
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FCAW-G FCAW-G
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FCAW-S FCAW-S
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FCAW-g
6
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FCAW-g
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Wire Feeders Wire Feeders
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Advantages Advantages
Bead Appearance
Little to No Spatter
High Deposition
Rates
Mechanical
Properties
High Efficiencies
(90+%)
Easy Re-strike
All Position Welding
Low Hydrogen Weld
Deposits
Bead Appearance
Little to No Spatter
High Deposition
Rates
Mechanical
Properties
High Efficiencies
(90+%)
Easy Re-strike
All Position Welding
Low Hydrogen Weld
Deposits
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Limitations Limitations
Smoke and Fumes
Portability
Outdoor Weldability
Potential for Gas
Marks
High Radiated Heat
Slag
Smoke and Fumes
Portability
Outdoor Weldability
Potential for Gas
Marks
High Radiated Heat
Slag
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FCAW-s
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Advantages Advantages
Outdoor Usability
Minimize Restarts
No Shielding Gas
Costs
High Deposition
Rates
Mechanical Properties
Effective Smoke
Removal
Dirty Steels & Off
Analysis Steels
All Position Welding
Outdoor Usability
Minimize Restarts
No Shielding Gas
Costs
High Deposition
Rates
Mechanical Properties
Effective Smoke
Removal
Dirty Steels & Off
Analysis Steels
All Position Welding
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Limitations Limitations
Smoke and Fumes
Spatter
Slag (Cleaning
Time)
Break Electrode to
Restrike
Smoke and Fumes
Spatter
Slag (Cleaning
Time)
Break Electrode to
Restrike
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E7XT E7XT- -Y Y
Electrode Electrode
70,000 psi Min. Tensile Strength 70,000 psi Min. Tensile Strength
Welding Position Welding Position
(0=Flat & Horizontal, 1= All Position) (0=Flat & Horizontal, 1= All Position)
Tubular (Flux Cored Electrode) Tubular (Flux Cored Electrode)
Usability & Performance Capabilities Usability & Performance Capabilities
AWS Classification AWS Classification
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GMAW
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Gas Metal Arc Welding (GMAW)
Solid or metal core electrode
Contact tube
Gas nozzle
Shielding gas
Base metal Base metal
Weld pool
Weld metal
Arc
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Advantages Advantages
Variety of Metals
Various Thickness
of Materials
High Efficiency
Applications
High Radiated Heat
All Position Welding
Quality Welds
Little to No Slag
Low Spatter
Variety of Metals
Various Thickness
of Materials
High Efficiency
Applications
High Radiated Heat
All Position Welding
Quality Welds
Little to No Slag
Low Spatter
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Limitations Limitations
Cost
Portability
Outdoor Welding
Clean Base Material
Potential for Cold Lap
Potential for Undercut
Operator Skill
High Radiated Heat
Cost
Portability
Outdoor Welding
Clean Base Material
Potential for Cold Lap
Potential for Undercut
Operator Skill
High Radiated Heat
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ER70S ER70S- -X X
Electrode Electrode
Rod Rod
70,000 psi Min. Tensile Strength 70,000 psi Min. Tensile Strength
Solid Solid
Chemistry, Amount of Deoxidizers (Silicon, Chemistry, Amount of Deoxidizers (Silicon,
Manganese and/or Aluminum, Zirconium and Manganese and/or Aluminum, Zirconium and
Titanium) X=2,3,4,6,7 or G Titanium) X=2,3,4,6,7 or G
AWS Classification AWS Classification
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E70C E70C- -Y Y
Electrode Electrode
70,000 psi Min. Tensile Strength 70,000 psi Min. Tensile Strength
Metal Core Electrode Metal Core Electrode
Usability & Performance Capabilities Usability & Performance Capabilities
AWS Classification AWS Classification
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SAW SAW
Submerged Arc Welding Submerged Arc Welding
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Submerged Arc Welding (SAW)
Contact Tube
Slag Flux
Flux Feed Tube
Flux Hopper
Weld
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Automatic
SAW
Automatic
SAW
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Mechanized SAW Mechanized SAW
Mechanized
SAW
Mechanized
SAW
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Mechanized SAW: Mechanized SAW:
Mechanized
SAW
Mechanized
SAW
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Handheld SAW Handheld SAW
Semiautomatic
SAW
Semiautomatic
SAW
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Advantages Advantages
High Deposition
Rates
Typically Deep
Penetration
High Operating Factor
Low Hydrogen Welds
Fast Welding Speeds
High Operator Appeal
High Quality Welds
High Deposition
Rates
Typically Deep
Penetration
High Operating Factor
Low Hydrogen Welds
Fast Welding Speeds
High Operator Appeal
High Quality Welds
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Limitations continued Limitations continued
Portability
Downhand Welding
Only
Tight Fit-Up Required
Abrasive Nature of
Flux on Machinery
Housekeeping and
Storage of Flux
Slag
Portability
Downhand Welding
Only
Tight Fit-Up Required
Abrasive Nature of
Flux on Machinery
Housekeeping and
Storage of Flux
Slag
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FXYZ FXYZ- -EM12K EM12K- -Ni1 Ni1
Flux Flux
Min. Tensile Strength Min. Tensile Strength
Type of Heat Treatment Type of Heat Treatment
Low Temp Impact Strength Low Temp Impact Strength
Solid Electrode Wire Solid Electrode Wire
Level of Manganese Level of Manganese
Nominal Carbon Content Nominal Carbon Content
Silicon Killed Steel Silicon Killed Steel
Type and Amount of Alloy in the Weld Deposit Type and Amount of Alloy in the Weld Deposit
AWS Classification AWS Classification
Electrodes & Fluxes Electrodes & Fluxes
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GTAW
10
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GTAW
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GTAW
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GTAW
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Process Selection/Application Process Selection/Application
Typically best left to those doing the Typically best left to those doing the
welding welding
SAW: long, big, automatic SAW: long, big, automatic
FCAW FCAW- -g: g: semiauto semiauto in shop in shop
FCAW FCAW- -s: s: semiauto semiauto in field in field
SMAW: small, miscellaneous, SMAW: small, miscellaneous,
repair, tacking repair, tacking
GMAW: GMAW: semiauto semiauto in shop in shop