Weld using manual metal arc welding process

(MEM05015C)
LEARNING RESOURCE MANUAL

Metal Fabrication & Welding

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Product Code:2960

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MEM05015C/1 First Edition

TRAINING AND EDUCATION SUPPORT INDUSTRY SKILLS UNIT MEADOWBANK

Publishing details: Published by Manufacturing, Engineering, Construction and Transport Curriculum Centre - TAFE NSW in February 2008 Corner Showground and Green Roads, Castle Hill, NSW 2154 Copyright details: Manufacturing, Engineering, Construction and Transport Curriculum Centre, TAFE NSW, 2008 Copyright of this material is reserved to the Manufacturing, Engineering, Construction and Transport Curriculum Centre, TAFE NSW. Reproduction or transmittal in whole or part, other than for the purposes and subject to the provision of the Copyright Act, is prohibited without the written authority of Manufacturing, Engineering, Construction and Transport Curriculum Centre, TAFE NSW.

Copyright acknowledgments: MEC&T Curriculum Centre would like to acknowledge the assistance and permission of the following companies for the use of copyright material.

978 0 7348 2713 5 Weld using manual metal arc welding process MEM05015C

FEEDBACK We value your opinion and welcome suggestions on how we could improve this resource manual. Keep in mind that the manual is intended to help students learn and is not a text book. Send your comments and suggestions to: Training and Education Support, Industry Skills Unit, Meadowbank Level 3, Building J, See Street MEADOWBANK NSW 2114 Ph: (02) 9942 3200 Fax: (02) 9942 3257

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Cigweld Pty Ltd WIA Welding Industries of Australia Lincoln Electric Australia

Contents
Introduction Scope of Unit and Performance Criteria .............................................................1 Student Assessment Guide ................................................................................2 Unit Purpose .................................................................................2 Prerequisites .................................................................................2 Assessment ......................................................................................................4 Unit Mapping ......................................................................................................4 Recognition of Prior Learning (RPL)...................................................................5 Theory Objectives ........................................................................................................... 8 Basic electrical terms & def nitions ...................................................................10 The manual metal arc welding (MMAW) process .............................................11 Welding machines ............................................................................................12 MMAW accessories ..........................................................................................14 Types of current ................................................................................................15 Open circuit voltage - arc voltage .....................................................................17 Duty cycle .........................................................................................................18 Electrodes.........................................................................................................18 Current Range ..................................................................................................21 Advantages of manual metal arc welding .........................................................22 Limitations of manual metal arc welding...........................................................23 Distortion ..........................................................................................................24 Safety ...............................................................................................................24 Manual metal arc welded f llet & butt joints ......................................................27 Review questions .............................................................................................29 Practical exercises and projects Vertical f llet weld ..............................................................................................36 Overhead f llet weld ..........................................................................................38 Vertical f llet weld plate to section .....................................................................40 Overhead f llet weld section to plate .................................................................42 Suggested Weld assessment 1 - All positional f llet & butt welds section to plate ....................................................................................44 Horizontal butt weld ..........................................................................................46 Horizontal butt weld section to section .............................................................48 Vertical butt weld ..............................................................................................50 Vertical butt weld section to section..................................................................52 Overhead butt weld ..........................................................................................54 Suggested Weld assessment 2 - All position butt & f llet weld section to section .................................................................................56

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MEM05015C Weld using manual metal arc welding process First Edition - February 2008 MEC&T Curriculum Centre, TAFE NSW

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MEM05015C Weld using manual metal arc welding process First Edition - February 2008 MEC&T Curriculum Centre, TAFE NSW 7

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Theory

MMAW operating principles

Objectives:
At the end of this unit you will be able to: describe the following electrical terms used the MMAW welding processes: voltage settings current amperage conductor resistance electric arc theory open circuit voltage arc voltage duty cycle types of current

outline the operating procedure of MMAW: electric arc f ux coated electrode metal transfer & weld pool

list typical industrial applications of MMAW:

identify metals commonly welded by the MMAW process:

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compare AC and DC power sources: transformer/rectif ers generators inverters E4112 E4113 E4112 E4113

low carbon steel low alloy steel stainless steel nickel and nickel alloys

identify the components of AC and DC welding plants: power source terminals secondary and primary cables MMAW accessories

state the method of classifying general purpose (GP) electrodes:

discuss the function and industrial application of rutile electrodes & current ranges for commonly used electrodes:

MEM05015C Weld using manual metal arc welding process First Edition - February 2008 MEC&T Curriculum Centre, TAFE NSW

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structural steel construction repair & maintenance welding applications pipeline welding

discuss the storage and care requirements for rutile electrodes: location humidity packaging List the advantages & limitations of the MMAW process: plant cost portability welding consumables & recovery rates positional welding location of welding operations welding deposition rates welding quality operator appeal & required skill levels

Describe the principles of distortion in relation to MMAW: heat uneven expansion & contraction job dimensions Control methods - before during after

revise the hazards directly related to the use of manual metal arc welding equipment:

identify

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secondary cables clothing workshop behaviour machine location

electrical fumes heat arc radiation

list the electrical safety requirements:

typical f llet & butt weld joints: horizontal/vertical outside corner lap square butt weld joints vee butt weld joints bevel butt joints prepared edge butt weld joints

MEM05015C Weld using manual metal arc welding process First Edition - February 2008 MEC&T Curriculum Centre, TAFE NSW

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Basic electrical terms & def nitions

Several welding processes are classif ed as ARC WELDING when the heat energy required for welding is generated by an electric arc and in most cases an arc is struck between covered electrodes and workpieces. It is important that welding operators have a basic understanding of arc theory and electrical terminology associated with this process.

Electricity Voltage

Electricity is a form of energy associated with movement of electrons.

Voltage is the unit of electrical pressure. This electrical pressure (or force) is responsible for the current f ow in a welding circuit.

Current

Current (amperage) is the measure of the electron f ow through an electrical energy conductor. An ampere can be described as a unit quantity of electricity passing through a given point per second. This is similar to the rate water f ows through a pipeline.

Resistance

Electrical resistance is a measure of how strongly a material opposes the f ow of electric current. The unit of resistance is ohums ()

Theory of an electric arc

An arc is generated by electrons f owing across a gap between an electrode and a metal workpiece, the electrical energy being changed into heat & light. The arc is started by momentarily touching or scratching the electrode on the metal workpiece then withdrawing it about 3 or 4 millimetres to form a gap. The f ow of electrons, that is the welding current, continues to f ow across the small gap f rst formed as a spark, or arc. The small gap has become electrically charged or ionized and current is able to continue to f ow across the gap in the form of an arc.
power source ammeter A V voltmeter workpiece welding cable electrode holder electrode

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Basic power circuit for MMAW

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MEM05015C Weld using manual metal arc welding process First Edition - February 2008 MEC&T Curriculum Centre, TAFE NSW

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arc

In welding, an electrical conductor is a metal through which electricity will easily f ow. Copper is the most used conductor, followed by aluminium.

Conductor

The manual metal arc welding process

In electric arc welding, an arc is established between a consumable f ux coated electrode and the workpiece. The heat of the arc melts the parent metal, and at the same time the tip of the electrode, causing droplets of slag covered weld metal to transfer across the arc to the workpiece. The droplets of weld metal and the molten weld pool are protected from the harmful effects of oxygen and nitrogen in the atmosphere by an envelope of protective gases such as carbon dioxide when the electrode f ux coating melts. During the heat of the arc, chemical compounds in the f ux coating react to form a slag which rises to the surface of the weld pool forming a protective covering. As well as protecting the cooling weld metal from atmospheric contamination, the slag covering also slows the cooling rate of the deposited weld metal. On completion of the weld, the slag covering is removed by light chipping.
Direction of travel
electrode flux coating solidified slag

deposited weld metal

Since the electrode f ux coating usually melts at a higher temperature than the core wire, the f ux coating will extend beyond the core wire assisting in concentrating the arc stream and stabilising the arc. This is why the f ux coating extends beyond the core wire of a used electrode, whereas the core wire of an un-used electrode is usually exposed to allow easy initial striking of the arc.

Applications

Manual metal arc welding (MMAW) is widely used in fabrication industries, mainly on-site structural steel, in the construction of buildings, bridges and pipelines. MMAW is also used for repair & maintenance of earthmoving and other plant & equipment.

Metals commonly joined using MMAW include:

low carbon steels low alloy steels stainless steels nickel & alloys of nickel

Cast iron & copper alloys can also be successfully welded using the MMAW process

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Typical MMAW Operation

MEM05015C Weld using manual metal arc welding process First Edition - February 2008 MEC&T Curriculum Centre, TAFE NSW

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parent metal 11

molten weld pool

molten slag covered metal droplets

Welding machines
Alternating current (AC) welding machines
Alternating current welding machines (usually air cooled) are transformers which step down line voltage (220/240 or 415/440 volts) to provide a safe welding voltage. The welding current supplied by the secondary circuit of the transformer is set by the operator to suit the type and size of electrode. Transformer welding machines are less complex and slightly less expensive than other types.

Transformer/rectif ers

An eff cient and reliable transformer/rectif er is a machine designed to transform AC input current to DC output current suitable for welding. Transformer/ rectif ers have no moving parts and, similar to the transformer, are quiet to operate, convenient and cost less than motor generator units. If an AC current is needed from this type of machine, all the operator has to do is to select the AC output switch. Transformer/rectif ers are often designed to provide either AC or DC outputs. DC is normally preferred for high quality work because of its greater arc stability, but AC may be required at higher currents to avoid arc blow.

The direct current output may be supplied by a transformer/rectif er or a generator power source. DC Welding gives operators choice of polarity

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Direct current (DC) welding machines

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Inverters

The inverter is a modern technology multi-functional power source that provides high eff ciency output requirements for different electrodes in a smaller size welding machine with energy conservation advantages. These power sources are multi-process, capable of manual metal arc, gas metal arc, gas tungsten arc welding (DC) and carbon arc gouging. Some inverter machines can deliver both AC and DC welding output.

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MEM05015C Weld using manual metal arc welding process First Edition - February 2008 MEC&T Curriculum Centre, TAFE NSW

AC/DC transformer/ rectier

Motor generator

An AC/DC Inverter