Topics covered

WELDING PROCESSES.
WELDING CONSUMABLES
WELDING EQUIPMENTS
WELDING PROCEDURE
WELDING DEFECTS ITS CAUSES
AND REMIDIES
SAFETY

WELDING PROCESS

Types Of Welding
Welding
Gas Welding

Arc Welding

Normal practiced process

Manual Metal Arc Welding
Gas Tungsten Arc Welding
Gas Metal Arc Welding
Flux Cored Arc Welding
Sub Merged Arc Welding

MMAW
GTAW
GMAW
FCAW
SAW

WELDING PROCESS
The present process of welding used to
manufacture various components generally are as
follows
MMAW- Manual Metal Arc Welding Process
GMAW- Gas Metal Arc Welding process
GTAW - Gas Tungsten Arc Welding
FCAW- Flux Cored Arc Welding
SAW- Submerged Arc Welding

SMAW/MMAW

GTAW

GMAW(MIG/MAG)

FCAW

SAW

Advanced process

Narrow Gap Welding

Laser Beam Welding
Electron Beam Welding
Friction Stir Welding
Plasma Welding
Plasma Transfer Arc Technique (PTA)
Robotic Welding
Orbital Welding

Selection of Welding process

Type of Base Material

The Joint Design
The place of welding
Welding Position
Type of consumables availability
The skill availability of personnel
The types of equipment availability

WELDING CONSUMABLES
&
WELDING EQUIPMENTS.

RECOMMEDATIONS

The selection of the correct welding consumables

depends on the following parameters
Base materials composition
The weld ability of the steel
Selection of the welding consumables as per
ASME section-II- C
Acceptance of AWS or any other standards
depends on the clients requirements.

WELDING CONSUMABLES
The Welding consumables like the welding electrodes and
filler wires that are required and are recommended are as
follows
E-6013 Welding Electrodes for Welding in MMAW
process for Carbon steel, Mild steel, For the general
purpose welding applications up to thickness 18 mm or
3/4th inch.
For thickness over the above mentioned must be welded
with Low Hydrogen electrodes as per AWS E 7018 or
E7018-1 Type of welding consumables.

Welding consumables for various

steels.
General Mild steel Up to 18mm
AWS 6013 class welding electrodes,
ER 70 SG Filler wires in case of GTAW &
ER 70 S-6 in case of GMAW process.
General Mild steel Above 18mm
AWS 7018class ER 70 S2 & ER 70 S-6

Selection contd.
For Radiography joints
The following grades consumables are
mandatory.
AWS E6013 & E7018 classified Electrodes
ER 70 S2 TIG welding filler wires
ER 70 S-6 MIG Welding continuous filler
wires.

Consumables- gases
ER 70 S-6 Solid wire for welding the
GMAW (MAG) welding process
ER 70-S-2 TIG filler applications incase of
carbon steel welding .
The use of 100 % CO2 gas for MAG
welding and 100 % pure Argon gas for TIG
welding applications are the main criteria.

Alloy steels
AWS class of low alloy electrodes & wires

Consumables- LAS
In the case of use of Low alloy steels where
C, Mo, Cr and other alloys are involved the
creep properties are important and hence the
matching composition of the weld metals
are mandatory

Consumables S.S.
Welding of Stainless steels like commonly
used steels such as 304, 304L, 308L, 309,
316. and other categories such as 310, 321,
347, Duplex, Super Duplex Steels, the
respective grade of Electrodes and the Filler
wires to be used with proper shielding
gases.

Stainless steel
301,304,308 Class
AWS E 308 & 308 L grades Electrodes
and ER 308 L TIG/ MIG welding wires.
316 and 316 L
-AWS E- 316 & 316 L
-ER 316 L TIG and MIG fillers

SS Contd.
For 309 Grade steels
AWS E 309 Electrodes
ER 309 L Wires
Dissimilar metals of SS and SS-MS
AWS 309L and 309 MoL
ER 309L & ER 309 MoL

SS Contd.
Stabilized steels of 321, 347
Namely Niobium/Columbium, Ti and Ta stabilized
steels the use of
AWS E- 347 electrodes and wires of
ER 347 grade is recommended.
For other grades like 310,312, 317 the respective
grades of consumables be used.

Other metals
Cast Iron
Non-Ferrous Alloy:
Aluminium, Copper, Nickel, Magnesium
etc.

Welding Position

















      



 

 

 
 

 

 

              
     


 



      
        
     


 

 


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Proper Arc Length

Long arc results in:
Large globules melting
Wavering arc
Wide spatter and irregular bead

Short arc results in:

Electrode sticks
Poor penetration
Convex bead
Slag inclusions
Irregular bead

Use short length for vertical welds

Speed of Travel
Travel speed influences:
Bead width
Penetration
General shape of the bead

Use a uniform speed

Both hands on the electrode holder
Operator comfort

Bead should be about twice the diameter of the

electrode wire

Read the Bead

WELDING EQUIPMENT

TYPES OF EQUIPMENTS

Standard Type of welding Equipments

Arc Welding Transformers
D.C. Rectifiers
Thyristor controlled Welding Rectifiers
Welding Invertors
TIG Welding Equipments
MIG/MAG Welding machines
Sub Merged Arc Welding machines

MMA Power sources

Transformer

Rectifier

Welding generator

category of MIG Welding

Pulsed MIG Welding Machines,

Inverter based MIG Welding Machines
Synergic Pulsed MIG Welding Machines
Surface Tension Transfer Machines (STT)

Cont
Under TIG Welding category we can have
DC Pulsed welding machines
AC/ DC TIG welding machines
AC Square wave pulsing machines

Advanced Welding Machines:

Electron Beam Welding machines
Narrow Gap welding machines
Laser cutting and welding
Plasma Welding

Selection of the correct equipment

Selection of the right type of equipment is
important to get the desired welding properties.
The selection decides the feasibility of the use of
the process.
The selection should be based on the availability
of the equipment,
The acceptance of the process
The convenience of the operation.

Welding Defects

TYPE OF DEFECTS

Lack of fusion
Lack of Penetration
Undercut
Crack
Porosity
Slag inclusion

Lack of Penetration

Lac of Fusion

Undercut

Porosity

Crack

ITS CAUSES AND REMIDIES

Re-drying of Consumables/ Proper Storage

Base metal Cleaning.
Flow rate of Shielding GAS
Welding Parameter.
Use of correct welding consumables.

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