WELDER MANUAL

1) What is welding?
Process of joining two materials Permanently by Heat and or Pressure.

2) Welder’s Safety – PPE :

1)Glasses 2)Shoes 3)Gloves 4)Shield 5)Respiratory Mask 6)Aprons

3) Welding Positions :

4) Types of Welding processes :

1)SAW 2)GMAW 3)GTAW 4)SMAW 5)FCAW
5) CONSUMABLES
i) GMAW (Process Code= 135)
ELECTRODE:
ER70S-6 ER 309-L
E- Electrode E- Electrode
R- Filler Rod
70 70,000psi (Tensile Strength) R- Rod
S- Solid Wire 309 Stainless Steel with Carbon Steel
6 Solid Wire Chemistry L- Low carbon
SHIELDING GAS:
1) ACM = Arogon + CO2 Mixture (Around 80% Argon and 20% CO2) 2) Pure CO2
ii)SAW (Process Code= 121)
F7A4 – EM12K
F Flux E Electrode
7 70,000 psi Tensile strength M Medium Mn
A As welded 12 0.12 % C
4 Impact Strength -40o C K Silicon Killed Wire (De Oxidized)
Flux baking temp=300 deg Flux holding temp=100 deg minimum
6) BASE MATERIAL: Other Materials
S355JO S355JR
S STRUCTURAL STEEL S275JR
355 Yield Strength 355 N/mm2 S355J2
J 27 Joules (Impact Strength) S355 NL
0 Impact Strength at 0o C S235 JR

7) Heat Input(Q) Calculation

Q=(K x Voltage x Current ) For GMAW K=0.8 , For SAW K=1
Travel Speed

8) Modes of metal transfer in GMAW Process

1)Globular 2)Short circuit 3)Pulsed 4)Spray We use Globular and spray

9)Pre-Heating – To remove Moisture in work piece (Temperature- As per WPS) We use 100 degrees minimum

10)Inter-Pass Temperature = Maximum temperature between one pass to another pass (Temperature- As per
WPS) We use 350 degrees maximum

11)Polarity – Direct Current Electrode Positive (DCEP) for SAW and GMAW (Also called reverse polarity)

12)Stick Out – Distance between Electrode and Workpiece

GMAW = 10-15 mm SAW = 20-25 mm

13)Welding Symbols
Example:

14) How to decide the welding parameters for a welding

Ans : Using WPS (Welding Procedure Specification)

15) Where do you find a WPS?

Ans : In chart diplayed in every booms. (WPS synopsis)

16) Which position you are qualified to weld?

Ans : Your position is given in the Approved Welder List displayed in each bay.

17) After completion of weld, at shift end what will you do?
Ans: Write the history card. Return the unused flux and coil to store.

18) If flux temperature is less than 100 degrees what will you do?
Ans: Inform supervisor. Then retuen the flux to store and take new baked flux and start welding.