Teknologi Las

(Welding Technology)

INTRODUCTION to
WELDING PROCESSES
 MANDATORY REFERENCES
Harsono Wiryosumarto dan Toshie Syahrizal, 2008, Teknologi Las
Okumura, 2000. Teknologi (Modul), Jurusan Teknik
Pengelasan Logam, Pradnya Perkapalan, Politeknik Bengkalis.
Paramita, Jakarta, Cetakan
Kedelapan.
NONMANDATORY REFERENCES
 Althouse, Andrew R, et. al., Modern Welding, The Goodheart-
Willcox Company, Inc., Illinois, 1988.

 AWS, ANSI/AWS A3.0-94, Standard Welding Terms and Definitions,

American Welding Society, Miami, 1994.

 ASME, 1998 ASME Boiler & Pressure Vessel Code, Section IX -

Welding and Brazing Qualification, The American Society of
Mechanical Engineers, New York, 2000

 Jenney, Cynthia L., and Annette O'Brien, Welding Handbook,

Volume 1 - Welding Science and Technology, American Welding
Society, Miami, 9th Edition, 2001.

 O'Brien, R.L., Welding Handbook, Volume 2 - Welding Processes,

American Welding Society, Miami, 8th Edition, 1991.
Early metal-joining methods included such processes as forming a
sand mold on top of a piece of metal and casting the desired
shape directly on the base metal, Figure 1-1
Another metal-joining method used in early years was to place two
pieces of metal close together and pour molten metal between
them. When the edges of the base metal melted, the flow of metal
was then dammed and allowed to harden. Figure 1-2.
Welding Process
JOINING METHOD CHART
Introduction: WELDING PROCESSES

The number of different welding processes has grown in

recent years. These processes differ greatly in the manner in
which heat, pressure, or both heat and pressure are applied,
and in the type of equipment used.

 Figure in the next slide, lists various welding methods.

 Certain methods listed in the figure require hammering,
pressing, or rolling to effect the coalescence in the weld
joint.
 Other methods bring the metal to a fluid state, and the
edges flow together.
Introduction: WELDING PROCESSES

Welding is a process in which two or more parts are joined permanently

at their touching surfaces by a suitable application of heat and/or
pressure. Often a filler material is added to facilitate coalescence.

Welding process is special equipment used with method, for

producing welds. Welding process may be classified using various
methods, such as processes that use pressure and those which do not,
but they may also be classified into two major groups as fusion or solid
phase:
1. Fusion welding processes (the weld requires melting/mixing and re-
solidification.
2. Solid phase/state welding processes (the weld is made in the plastic
condition)
Introduction: WELDING PROCESSES

Welding processes:
1. Fusion welding: In this process, base metal is melted by means of
heat. Often, in fusion welding operations, a filler metal is added to the
molten pool to facilitate the process and provide bulk and strength to
the joint.
Commonly used fusion welding processes are: arc welding,
resistance welding, oxyfuel welding, electron beam welding and laser
beam welding.

2. Solid-state welding: In this process, joining of parts takes place by

application of pressure alone or a combination of heat and pressure.
No filler metal is used.
Commonly used solid-state welding processes are: diffusion welding,
friction welding, ultrasonic welding.
Introduction: WELDING PROCESSES
Fusion Welding Processes:
Introduction: WELDING PROCESSES
Four main requirements of any Fusion Welding Processes:

Protection:
of the molten filler metal in transit and base metal from oxidation and to
protect the weld zone from ingress of gases such as hydrogen & oxygen.

Cleaning:
Of the weld metal to remove oxides and impurities and refine the grains

Adequate properties:
Adding alloying elements to the weld to produce the desired mechanical
properties

Heating:
Of high enough intensity to cause melting of base metals and filler metals.
Introduction: WELDING PROCESSES
Welding Parameters:
Shielded metal arc welding (SMAW) is the most common method of
joining metal. High-quality welds can be made rapidly and with excellent
uniformity. A variety of metal types and metal thicknesses can be
joined with one machine, Figure 1-8.
Gas tungsten arc welding (GTAW) is easily performed on almost
any metal. Its clean, high-quality welds often require little or no
postweld finishing, Figure 1-9.
Gas metal arc welding (GMAW) is extremely fast
and economical. This process is easily used for
welding on thin-gauge metal as well as on heavy
plate. The high welding rate and reduced postweld
cleanup are making gas metal arc welding an
outstanding welding process, Figure 1-10.

Flux cored arc welding (FCAW) uses the same

type of equipment that is used for the gas metal arc
welding process. A major advantage of this process
is that with the addition of flux to the center of the
filler wire the weld's properties can be changed.
Although welds must be cleaned after completion,
the improved quality, flexibility, and welding speed
offset this requirement.
Oxyacetylene is one part of the larger group of processes known as
oxyfuel gas (OF). This group of processes can be used for welding
(OFW), cutting (OFC), and brazing (TB). This group is one of the most
versatile of the welding processes. The equipment required is
comparatively inexpensive, and the cost of operation is low, Figure 1-7.
 Selection of the Joining Process

The selection of the joining process for a particular

job depends upon many factors.

No one specific rule controls the welding

process to be selected for a certain job.

A few of the factors that must be considered when

choosing a joining process include:
Availability of equipment - The types, capacity,
and condition of equipment that can be used to
make the welds.

Repetitiveness of the operation - How many of

the welds will be required to complete the job, and
are they all the same?

Quality requirements - Is this weld going to be

used on a piece of furniture, to repair a piece of
equipment, or to join a pipeline?

Location of work - Will the weld be in a shop or on

a remote job site?
Materials to be joined - Are the parts made out of a
standard metal or some exotic alloy?

Appearance of the finished product - Will this be

a weldment that is only needed to test an idea, or
will it be a permanent structure?

Size of the parts to be joined - Are the parts small,

large, or different sizes, and can they be moved or
must they be welded in place?

Time available for work - Is this a rush job needing

a fast repair, or is there time to allow for pre and
postweld cleanup?
Skill or experience of workers - Do the welders
have the ability to do the job?

Cost of materials - Will the weldment be worth

the expense of special equipment materials or
finishing time?

Code or specification requirements - Often the

selection of the process is dictated by the
governing agency, codes, or standards.
The welder must not only decide on the welding
process but must also select the method of
applying it.

The following methods are used to perform

welding, cutting, or brazing operations.

Manual - The welder is required to manipulate the

entire process.

Semiautomatic - The filler metal is added

automatically, and all other manipulation is done
manually by the welder.
Machine - Operations are done mechanically
under the observation and correction of a welding
operator.

Automatic - Operations are performed

repeatedly by a machine that has been
programmed to do an entire operation without
interaction of the operator.

Automated - Operations are performed

repeatedly by a robot or other machine that is
programmed flexibly to do a variety of processes.
Resumes Last Week: Introduction
WELDING PROCESSES

Empat hal utama dalam Fusion Welding Process:

WELDING PROCESSES
Welding Parameters:

 Arc voltage (voltase):

Terkait dengan panjang busur las. Settig voltage akan mempengaruhi
profil las.

 Welding current (arus):

Berdampak pada kedalaman fusi/penetrasi pada base metal dan weld
runs.

 Polarity (polaritas):
Menentukan apakah Arc Energy (heat) terkonsentrasi pada elektroda
atau pada logam induk (base metal/parent material)
 Varians of welding processes

The most popular processes are

Arc welding (las busur listrik):
 Shielded metal arc welding (SMAW), which often
called stick welding / Manual Metal Arc Welding
 Gas tungsten arc welding (GTAW)/ TIG Welding
 Gas metal arc welding (GMAW)/ MIG/MAG Welding
 Flux cored arc welding (FCAW), and
 Submerge arc welding (SAW).
Oxyfuel gas welding:
Oxyacetylene welding (OAW)
SHIELDED METAL ARC WELDING (SMAW)/
STICK WELDING/
MANUAL METAL ARC (MMA) WELDING
SHIELDED METAL ARC WELDING

 Adalah proses pengelasan dengan busur

listrik, dimana panas didapat dari busur nyala
yang memancar antara electrode dengan flux
dan base metal/parent metal
PROCESS
WELDING CURRENT
The welding current is an
electric current.
An electric current is the
flow of electrons.
Electrons flow through a
conductor from negative (-)
to positive (+).

Resistance to the flow of electrons (electricity) produces heat.

The greater the resistance, the greater the heat.
Air has a high resistance to current flow. As the electrons jump the air gap
between the end of the electrode and the work, a great deal of heat is
produced.
Electrons flowing across an air gap produce an arc.
 MEASUREMENT

Voltage, or volts (V), is the

measurement of electrical
pressure.
Voltage controls the maximum gap
the electrons can jump to form the
arc.

Amperage, or amps (A), is the measurement of the total number of

electrons flowing.
Amperage controls the size of the arc.
Wattage is a measurement of the amount of power in the arc.
The amount of power, watts, being put into a weld per cm controls the width and
depth of the weld bead.
TEMPERATURE
The temperature of a welding arc
exceeds 6000OC.
The exact temperature depends on the
resistance to the current flow. The
resistance is affected by the arc length
and the chemical composition of the
gases formed as the electrode covering
burns and vaporizes.
As the arc lengthens, the resistance
increases, thus causing a rise in the arc
temperature.

The shorter the arc, the lower the arc temperature produced.
Most shielded metal arc welding electrodes have chemicals added to their
coverings to stabilize the arc. These arc stabilizers reduce the arc resistance,
making it easier to hold an arc. By lowering the resistance, the arc stabilizers also
lower the arc temperature. Other chemicals within the gaseous cloud around the
arc may raise or lower the resistance.
HEAT

The amount of heat produced is

determined by the size of the
electrode and the amperage setting.
Not all of the heat produced by an
arc reaches the weld. Some of the
heat is radiated away.
Heat also is lost through conduction
in the work.

In total, about 50% of all heat produced by an arc is missing from the weld.
The 50% of the remaining heat the arc produced is not distributed evenly
between both ends of the arc.
This distribution depends on the composition and polarity of the electrode's
coating.
CURRENTS

The three different types of current used for welding:

1. Alternating current (AC)
2. Direct-current electrode negative (DCEN)
Direct-current straight polarity (DCSP)
3. Direct-current electrode positive (DCEP)
Direct-current reverse polarity (DCRP)

Each welding current has a different effect on the weld.

Direct-current electrode negative (DCEN)
Direct-current straight polarity (DCSP)

In direct-current electrode negative, the electrode is negative, and the

work is positive.
DCEN welding current produces a high electrode melting rate.
Direct-current electrode positive (DCEP)
Direct-current reverse polarity (DCRP)

In direct-current electrode positive, the electrode is positive, and the

work is negative.
DCEP current produces the best welding arc characteristics.
Alternating current (AC)

In alternating current, the electrons change direction every 1/120 of a second

so that the electrode and work alternate from anode to cathode.
The rapid reversal of the current flow causes the welding heat to be evenly
distributed on both the work and the electrode; that is, half on the work
and half on the electrode.
The even heating gives the weld bead a balance between penetration and
buildup.
TYPES OF WELDING POWER

The shielded arc process requires a constant current arc voltage

characteristic.
This output power supply provides a reasonably high open circuit voltage
before the arc is struck.
The high open circuit voltage quickly stabilizes the arc.
The arc voltage rapidly drops to the lower closed circuit level after the arc is
struck.
With a constant voltage output, small changes in arc length would cause the
power (watts) to make large swings.
The welder would lose control of the weld.
OPEN CIRCUIT VOLTAGE
Open circuit voltage is the voltage at the electrode before striking an arc
(with no current being drawn).
This voltage is usually between 50 V and 80 V.
The higher the open circuit voltage, the easier it is to strike an arc.
The higher voltage also increases the chance of electrical shock.

CLOSED/OPERATING CIRCUIT VOLTAGE

Operating voltage, or closed circuit voltage, is the voltage at the arc during
welding.
This voltage will vary with arc length, type of electrode being used, type of
current, and polarity.
The voltage will be between 17 V and 40 V.
 SHIELDED METAL ARC WELDING

• Shielded metal arc welding uses the heat of an electric arc between
a covered metal electrode and the work.
• Shielding comes from the decomposition of the electrode flux
coating.
• Filler metal is supplied by the electrode core wire and covering.
• This process is manually applied. The basic equipment is a power
source, electrode cable, work cable, an electrode holder, a work
clamp, and the electrode.
• Electrodes for SMAW operate variously on AC (alternating current),
DCEP (reverse polarity), or DCEN (straight polarity).
 SHIELDED METAL ARC WELDING

• SMAW is the most widely used welding process because of its low cost,
flexibility, portability, and versatility.
• The SMAW process is very flexible in terms of the metal thicknesses that
can be welded and the variety of positions it can be used in.
• Metal as thin as 2 mm thick to several feet thick can be welded using the
same machine with different setting.
• The flexibility of the process also allows metal in this thickness range to be
welded in any position.
• SMAW is a very portable process because it is easy to move the equipment
and engine-driven generator type welders are available.
• The process is versatile, and it's used to weld almost any metal or alloy,
including cast iron, aluminum, stainless steel, and nickel.
SHIELDED METAL ARC WELDING

 Electric Arc ( busur nyala listrik )

Adalah electron yang continue mengalir
melalui media yang pendek antara dua
electrode ( - ke + ) yang diketahui dengan
terjadinya energi panas dan radiasi udara
atau gas antara electrode akan diionisir
oleh electron yang terpencar oleh
electrode
SHIELDED METAL ARC WELDING

 Untuk menimbulkan busur nyala listrik,

kedua kutub electrode dihubungkan
singkat dengan cara disentuhkan lebih
dulu ( arc starting ) dan pada bagian yang
bersentuhan ini akan terjadi pemanasan
( temperatur naik ), hal ini yang mendorong
terjadinya busur.
SHIELDED METAL ARC WELDING

Fungsi Flux (Solutan)

* Menstabilkan busur nyala listrik
* Membentuk gas pelindung arc &
weld pool dari udara
* Membentuk slag ( - kontaminasi
udara dan - kecepatan pendinginan)
* Untuk memperbaiki sifat² mekanis,
tahan korosi Dll
* Menambah elemen² kimia lain
SHIELDED METAL ARC WELDING

Electrode Electrode
Tanpa Flux dengan Flux

Arc Tidak
Stabil ArcStabil

Electrode Electrode
Tanpa Flux dengan Flux

Gas
Terak las pelindung
COVERED ELECTRODES

• A shielded metal arc weld is strengthened by adding alloying elements to

the electrode covering.
• Unfortunately, some ingredients and the binder in the covering can attract
and hold moisture (a source of hydrogen), which can cause cracking in
certain metals.
• A group of electrodes specifically formulated to result in weld deposits
having very low levels of hydrogen are referred to as low hydrogen.
• Electrodes that are classified as low hydrogen have identification numbers
ending with 5, 6, or 8.
The electrode coating provides the following:

1. Arc stabilization from ionizing elements (which dictate the usability of

the electrode on AC, DCEP, or DCEN).
2. Gas shielding for the weld puddle when some of the coating breaks
down.
3. Slagging agents contained in the coating that remove impurities from
the work surface and weld puddle.
4. Deoxidizers, contained in the coating that reduce the tendency for
porosity in the weld.
5. An insulating blanket formed by the slag that protects the cooling weld
metal from the atmosphere.
6. Alloying elements contained in the coating that strengthen the weld
metal.
7. Increased weld metal deposition, when iron powder is incorporated
in the coating.
ADVANTAGES:
1. Low initial investment cost
2. Simple and operationally reliable
3. Low cost filler materials
4. Wide range of filler materials
5. Same equipment for all materials
6. Spans a large thickness range
7. All welding positions
DISADVANTAGES:

1. Slow (changing electrodes)

2. A layer of solidified slag must be removed
3. Low-hydrogen electrodes require special
storage
4. Low deposition efficiency