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KCWONG 2
Working Principle
Equipment
Filler metals
Advantages
Limitation
KCWONG 3
KCWONG 4
Can also
l beb called
ll d
Manual Metal Arc Welding
g
(MMAW) or (MMA)
KCWONG 5
Other accessories
KCWONG 7
KCWONG 8
AC or DC Power Source Electrode Holder
And Controls
Electrode
Arc
KCWONG 10
Grinder
Electrode
Holder
Wire
Brush
Chipping
Hammer Welding
W ldi
KCWONG
Tong 11
National
N i lSStandards
d d (AWS)
AWS A5A5.11 (Specification for carbon
steel electrodes for shielded metal
arc welding)
ldi )
AWS A5.5
A5 5 (Specification for low
low-
alloy steel electrodes for shielded
metal arc welding)
X - coating characteristics
p
Chemical composition g,
of the coating,
current type, and operating
electrode
characteristic of the electrode.
Number can be from 0 to 8
For example, 5, 6, 8 are low hydrogen
electrode that required keeping in
sealed container or preheat prior
welding
ldi to
t eliminate
li i t moisture
i t l
level
l
KCWONG 18
Si l and
Simple d easy sett up
P t bl
Portable
Low cost equipment
KCWONG 19
Slag removal
KCWONG 20
Electrode (low hydrogen type) must be
appropriately
pp p y storage
g
KCWONG 21
Porosity
Arc blow
Spatter
Slag inclusion
Incomplete fusion
KCWONG 22
Welding Electrode
Magnetic
M ti field
fi ld produced
d d
Around electrode
F
Forward
d Bl
Blow
Back Blow
Welding Direction
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KCWONG 24
Can also
l be called
ll d
Metal Inert Gas Welding
g
(MIG)
KCWONG 25
KCWONG 26
Heat is generated by arc (between filler
wire and work-piece) to melt and fuse
work-piece
rk pi c together
t th r
Mo t n metal
Molten m ta iss prot
protected
ct byy either
th r inert
n rt
or active gas (MAG)
S lid fill
Solid i iis continuously
filler wire ti l f d tto
fed
welding
g gun
g through g wire feedingg unit
Commonly employed as a semi-automatic
process
KCWONG 27
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KCWONG 30
Cable Assembly
KCWONG 31
Welding Gun
KCWONG 32
Some typical standards for specification
of steel wire are
BS EN 12534 (Welding consumables wire
electrodes, wires, rods and deposits for gas
shielded metal arc welding of high strength
steels Classification)
AWS A5.18 (Specification for carbon steel
filler m
f metals f
for Gas Shielded Arc Welding)
g)
A01T09-pp1-dt_ndt_II.ppt 33
ER XXS-X
XXS X
ER - Electrode Rod
XX - Tensile strength x 1000 (psi)
S - Solid
S lid Wi
Wire
X - Chemical Composition (2-7,
(2 7 G)
KCWONG 34
Spray Transfer
Globular Transfer
Pulse Transfer
KCWONG 35
Hi h
Higher-current
tddensity
it and
d iis
considered
id d to
t be
b th
the h
hottest
tt t one
V
Very fine
fi d droplets
l t
B tf
Best for h
heavier
i section
ti material
t i l
G d for
Good f ffull
ll penetration
t ti weld
ld jjoint
i t
KCWONG 36
L
Less stable,
bl increase
i spatter
L ss heat
Less h t than
th spray
sp t sf mode
transfer m d
Droplets of filler wire is significantly
larger than spray transfer mode
Only
y on down hand position
p
KCWONG 37
KCWONG 38
Protect molten pool against atmosphere
Argon, Helium and their mixtures
CO2 or argon mixture are commonly used
for welding of carbon steel
KCWONG 39
C
Capable
bl of
f welding
ldi most alloys
ll
N slag
No sl to
t be
b removed
m d
Higher productivity
Lower labour cost
KCWONG 40
Less smoke generated,
generated improve workshop
environment
easily
y observe the action of molten puddle
p
to improve arc control
no flux contamination, lowest hydrogen
problems
KCWONG 41
KCWONG 42
Porosity due to
Lack of shielding
contamination
Incomplete fusion
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KCWONG 44
Very similar to GMAW
Tubular electrode (granular flux contains)
M l
Molten metall is
i covered
dbby a layer
l of
f flux
fl
as was the case for SMAW
KCWONG 45
KCWONG 46
May not need shielding gas depend on
the
h type of
f filler
f ll wire
S
Some fill
filler wire
i capable
bl of
f providing
idi
sufficient protection to the molten
pu f g
puddle and so called self-shielding
KCWONG 47
E XXT-X (AWS A5
A5.20)
20)
E - Electrode
X - Tensile strength x 10000 (psi)
X -Welding
g position
p
0 (flat or horizontal fillet position)
1 (all position)
T - Tubular Wire KCWONG 48
X - Chemical Composition and operating
characteristics , such as
Type
yp of current
Polarity
KCWONG 49
Similar
l to GMAW
G
Hi h current capacity
High i power source as
compared to GMAW
Lack of shielding gas supply system if
self-shielding is used
KCWONG 50
Suitable for field welding
Good performance on contaminated
surface
Higher deposition rate,
rate increase
p
productivity
y
KCWONG 51
Advantages
g
Well penetration
Less skill required for operator
compared with SMAW
KCWONG 52
Require slag removal
Fumes and gases hazards
Complexity in equipment set up as
d iincrease iinitial
GMAW and iti l costt
KCWONG 53
Slag inclusion
Porosity
Incomplete fusion
KCWONG 54
KCWONG 55
Can also
l be called
ll d
Tungsten
g Inert Gas
Welding (TIG)
KCWONG 56
Non consumable electrode
Non-consumable
El t d iis made
Electrode d of
f pure or
alloyed
ll d tungsten
Arc is created between tungsten
electrode and work piece
KCWONG 57
KCWONG 58
W ldi
Welding direction
di ti
Gas Nozzle
Filler
Rod Tungsten Weld meta
Electrode Protective
Gas
Arc
KCWONG 59
P
Power source
s (AC and/or
d/ DC)
Control console
Shielding gas supply system
Welding
Weld ng torch
Water cooling
g system
y if necessary
y
Electrode wire feed unit if necessary
KCWONG 60
High frequency generator aids to
initiate welding
g arc especially
p y for
welding reactive material, such as
aluminum and magnesium
Remote control (foot pedal or some
devices mounted on the torch)
KCWONG 61
KCWONG 62
AWS Code Type Tip Colour
EWP P
Pure Tungsten
T t G
Green
EWCe-2
EWCe 2 1 8-2
1.8 2.2
2 % Ceria Orange
KCWONG 65
KCWONG 66
Porosity
p
Incomplete fusion
Tungsten inclusion
KCWONG 67
KCWONG 68