033 Arc Welding 2010

ARC WELDING
Dr. N. RAMACHANDRAN, NITC
LIQUID STATE PROCESS

PARTIAL MELTING
BY STRIKING AN ARC
AFTER THE INVENTION OF ELECTRICITY
HOW ARC STRUCK?
ARC COLUMN THEORY
ARC WELDING
ELECTRIC ARC
WITHOUT ADDITIONAL
AUTOGENEOUS
EXTERNAL SOURCE
NONCONSUMABLE- CONSUMABLE
CARBON ARC WELDING (CAW) - OLDEST

METALLIC ARC WELDING (MAW)
COATING MATERIALS
ARC TO BE CREATED BY ELECTRICITY
WHEN? WITH THE INVENTION OF AC DYNAMO IN 1877
BEGINNING IN 1881- TO CONNECT PLATES OF STORAGE BATTERY

1886- BUTT WELDING TECHNIQUE WAS DEVELOPED
BUTTED, CLAMPED HIGH CURRENT PASSED

AT THE JOINT, RESISTANCE OF METAL TO ELECTRIC CURRENT
PRODUCES HIGH HEAT- PIECES FUSED
ARC WELDING- MELTING AND FUSING OF METAL BY ELECTRODES
1ST BY N.V. BERNADO USING CARBON ELECTRODES
CONSISTANTLY IMPROVED
1895 N.G. SLAVIANOFF USED METALLIC ELECTRODES
1905 BARE ELECTRODES COATEDSHIELDING--- (SAW)
PORTABLE AND AUTOMATIC WELDING MACHINES
ARC WELDING PROCESSES

USE OF CONSUMABLE ELECTRODES
SHIELDED METAL ARC WELDING
(SMAW)
SIMPLEST AND MOST VERSATILE
ABOUT 50% OF INDUSTRIAL WELDING
BY THIS PROCESS
CURRENT- 50 TO 300 A, < 10 KW
AC/DC USED
FOR THICKNESSES UPTO 19 20 MM
SHIELDED METAL ARC WELDING

(SMAW)
Shielded metal arc welding (SMAW),

Also known as Manual Metal Arc (MMA) welding
Informally as stick welding
is a manual arc welding process that uses a
consumable electrode coated in flux to lay the weld.
An electric current, in the form of either

alternating current or direct current from a
welding power supply, is used to form an electric arc
between the electrode and the metals to be joined.
ARC COLUMN THEORY
ELECTRICAL / IONIC THEORY
IONS FROM ANODE TO CATHODE,

AS METAL IONS ARE +VE CHARGED
TOUCH AND THEN ESTABLISH A GAP
TO BALANCE THE ATOMIC STRUCTURE
ANODE +
IONS COLLIDE WITH GAS MOLECULES

PRODUCES A THERMAL IONISATION LAYER
DC
CATHODE -
IONISED GAS COLUMN AS HIGH

RESISTANCE CONDUCTOR
ON STRIKING CATHODE, HEAT GENERATED
TERMED AS IONIC THEORY
NOT COMPLETE IN EXPLAINING ARC
COLUMN THEORY
THUS, ELECTRON THEORY
ELECTRON THEORY
ARC COLUMN THEORY
IONS FROM ANODE TO CATHODE

AS METAL IONS ARE +VE
CHARGED
-VELY CHARGED ELECTRONS
DISSOCIATED FROM CATHODE
MOVE OPPOSITE WITH HIGH
VELOCITY
ANODE +
CATHODE -
DC
(MASS- 9.1x 10-28 gm)

CAUSES HEAT IN ARC COLUMN
RELEASES HEAT ENERGY IN
STRIKING THE ANODE
CALLED
ELECTRON IMPINGEMENT
AND
IONIC BOMBARDMENT
11
ANODE+
HIGH HEAT
ELECTRON IMPINGEMENT
LOW HEAT
MEDIUM HEAT
IONIC BOMBARDMENT
CATHODE -
12
MAGNETIC FLUX THEORY

THE COLUMN NOT FLAIRING
DUE TO THE FLUX LINES AROUND
THE ARC COLUMN.
(Right hand Thumb Rule)
THIS COMPLETES THE ARC COLUMN THEORY
13
POLARITY
AC
1.
2.
3.
4.
5.
6.
Currents higher than

those of DCRP can be
employed (400 A to 500
Afor 6 mm electrode)
Arc cleaning of the base
metal
Normal penetration
Equal heat distribution
at electrode and job
Electrode tip is colder as
compared to that in
DCRP
Average arc voltage in
argon atmosphere is
16V
14
DCRP
1.
2.
3.
4.
5.
6.
Currents generally less

than 125 amps (upto 6
mm dia electrodes) to
avoid overheating
2/3rd heat at electrode
and 1/3rd at the job
Least penetration
Average arc voltage on
argon atmosphere is
19V
Chances of electrode
overheating, melting and
losses
Better arc cleaning
action
15
DCSP
1.
2.
3.
4.
5.
6.
Welding currents upto

1000 amps can be
employed for 6 mm
electrodes
33.33% heat is generated
at the electrode and
66.66% at the job.
Deep penetration
Average arc voltage in an
argon atmsphere is 12 V
Electrode runs colder as
compared to AC or DCRP
No arc cleaning of base
metal
16
17
METALLURGY OF WELDING
During joining, localized heating occurs.
This leads to metallurgical and physical changes in materials welded.
Hence, study of:

. 1. Nature of welded joint
2.
3.
4.
5.
6.
Quality and property of welded joint

Weldability of metals
Methods of testing welds
Welding design
Process selection- important
(3) Heat Affected Zone (HAZ)

(2) Fusion Zone
1) Base Metal
Structures: (1) SMALL (2) MEDIUM (3) LARGE

Properties of (2) and (3) important
19
Cooling of Beadsimilar to a casting in mould, which is metallic here.

Cooling is slow Hence the structure is coarse and
Strength toughness and ductility low .
But use of proper electrodes improves these .
The purpose of coating the electrode is to

achieve the improved properties. If without,
nitrides and oxides of base metal form and
these result in weak and brittle nature.
With coating, properties comparable with base metal
achieved.
20
Gas shield
Arc column makes CRATER on
striking the surface- Temperature
above 1500 C
Flux + impurities- less dense. Floats as SLAG

Slag prevents heat loss- makes an evenly distribution
of heat radiation.
Preheating to receive the molten metal at an elevated temperature and
modify the structure. Not for M.S.
Locked in stresses due to heating and cooling- to be relieved by
PEENING, or other heat treatment processes.
21
MAGNETIC ARC BLOW -- FOR AC SUPPLY.
Current through conductor- magnetic Flux lines perpendicular to

current flow- apply Right hand Thumb Rule.
Three areas of magnetic field
1. Arc; 2. Electrode; 3. Work piece, when ground.
Forward pull of Arc column results, called as Magnetic Arc Blow.
22
EQUIPMENT
23
24
PURPOSE OF COATING
Gives out inert or protective gas- shields
Stabilizes the arc- by chemicals
Low rate consumption of electrode- directs arc and
molten metal
Removes impurities and oxides as slag
Coatings act as insulators- so narrow grooves welded
Provide means to introduce alloying elements
Bare electrodes - carbon- more conductive- slow

consumption in welding
Dr. N. RAMACHAN
25
ELECTRODE COATING INGREDIENTS

Slag forming ingredients- silicates of sodium, potassium, Mg,
Al, iron oxide, China clay, mica etc.
Gas shielding- cellulose, wood, starch, calcium carbonate
De-oxidising elements- ferro manganese, ferro silicon- to
refine molten metal
Arc stabilizing calcium carbonate, potassium silicate,
titanates, Mg silicate etc.
Alloying elements- ferro alloys, Mn, Mo., to impart special
properties
Iron powder- to improve arc behaviour, bead appearance
Other elements - to improve penetration, limit spatter,
improve metal deposition rates,
Dr. N. RAMACHAN
26
As the weld is laid, the flux coating of

the electrode disintegrates, giving off
vapors that serve as a shielding gas
and providing a layer of slag, both of
which protect the weld area from
atmospheric contamination.
Because of the versatility of the
process and the simplicity of its
equipment and operation, shielded
metal arc welding is one of the world's
most popular welding processes.
27
It dominates other welding processes in the

maintenance and repair industry, used
extensively in the construction of steel
structures and in industrial fabrication.
The process is used primarily to weld iron
and steels (including stainless steel) but
aluminum, nickel and copper alloys can also
be welded with this method.
Flux-Cored Arc Welding (FCAW) , a
modification to SMAW is growing in
popularity
28
(A).BARE ELECTRODE MOLTEN METAL TRANSFER

(B). LIGHT COATED ELECTRODE ARCACTION
Various welding electrodes

and NITC
an electrode holder
Dr. N. RAMACHANDRAN,
30
SAFETY PRECAUTIONS
Uses
an open electric arc, so

risk of burns to be prevented
by protective clothing in the
form of heavy leather gloves
and long sleeve jackets.
The brightness of the weld area
can lead arc eye, in which
ultraviolet light causes the
inflammation of the cornea and
can burn the retinas of the eyes.
Welding helmets with dark face
plates to be worn to prevent this
exposure
31
New helmet models have been

produced that feature a face plate
that self-darkens upon exposure
to high amounts of UV light
To protect bystanders, especially
in industrial environments,
transparent welding curtains
often surround the welding area.
These are made of a polyvinyl
chloride plastic film, shield
nearby workers from exposure to
the UV light from the electric arc,
but should not be used to replace
the filter glass used in helmets.
32
ARC EYE
Arc eye, also known as arc flash or welder's flash or

corneal flash burns, is a painful condition sometimes
experienced by welders who have failed to use adequate
eye protection.
It can also occur due to light from sunbeds, light
reflected from snow (known as snow blindness), water
or sand. The intense ultraviolet light emitted by the arc
causes a superficial and painful keratitis.
Symptoms tend to occur a number of hours
33
Signs
Intense lacrimation
Blepharospasm
Photophobia
Fluorescein dye staining will reveal corneal ulcers
under blue light
Management
Instill topical anaesthesia
Inspect the cornea for any foreign body
Patch the worse of the two eyes and prescribe analgesia
Topical antibiotics in the form of eye drops or eye
ointment or both should be prescribed for prophylaxis
against infection
34
Shielded Metal Arc

Welding
What Is Welding ?
Process of joining metals / alloys
The process performed by Heat with or
without Pressure
Filler metal may or may not be used
The joint will be homogeneous
Classification Of Welding
1 Pressure Welding With Heat &
Pressure
2 Fusion Welding With Heat &

mostly with Filler
Pressure Welding Process

Metal parts heated to forging temperature
Heating by Oven, Oxy fuel flame or
Electric Resistance
Pressure applied on heated parts by
Hammer, Hydraulic Press or Mechanical
lever
The Parts remain permanent
homogeneous joint
Types Of Pressure
Welding
Forge Welding
Resistance Butt / Flash Butt / Stud
Welding
Resistance Spot Welding
Resistance Seam welding
Fusion Welding Process

Metal parts locally heated to melt along the
joint.
Heating by oxy fuel flame or electric Arc.
Invariably filler metal added to molten pool.
On cooling, molten puddle solidifies to
permanent homogeneous joint.
Types Of Fusion Welding

Shielded Metal Arc Welding- SMAW
Gas Tungsten Arc Welding - GTAW
Gas Metal Arc Welding - MIG / MAG
Submerged Arc Welding SAW
Gas welding Oxy Fuel Gas
Electron Beam Welding - EBW
Thermit Welding
SMAW Process
Core Wire
An electric Arc struck between

electrode and base metal joint
Base metal melts under arc Flux Coating
Electrode tip melts in drops
and transfers to molten pool
of BM
Electrode with Arc moves
along the joint keeping
Arc
constant arc length
On cooling pool solidifies
Pool
Base Metal
Equipment, Accessories &

tools
Power Source
Welding Cables, Holder & Earthing
Clamp
Head Screen, Hand gloves,
Chipping Hammer & Wire Brush
Types Of Power Source

Inverter- DC
Thyrester DC
Motor Generator / Diesel Generator Set -DC
Rectifier DC
Transformer - AC
Characteristic Of Power
Source
Manual welding
Machine welding
Drooping Cons. A
Linear Cons. V
V1
Vertical
Curve
V2
Horizontal
Curve
V1
V2
A1 A2
A
A1
A2
Electrode
Consumable
Metallic Wire Coated with Flux
Conducts Current and generates Arc
Wire melts & deposited as filler in joint
Flux Coating On Electrode

Sodium Chloride
Potassium Chloride
Titanium Dioxide
Sodium Silicate
Ferrosilicon
Iron Powder
Alloying Elements
Binding Material
Function Of Flux In
welding
Stabilizes Arc
Prevents contamination of weld metal
Cleans the weld from unwanted
impurities
Increases fluidity of molten metal
Generates inert gas shielding while metal
transfers
Function Of Flux In
welding
Forms slag after melting & covers weld
Allows deposited metal to cool slowly
Introduces alloying elements in the weld
Increases deposition efficiency
Minimizes the spatter generation
Helps in even & uniform bead finish
CS & LAS Electrode Sizes

& Recommended Currents
Core Wire in
mm
Current
Time
required
for burning
in seconds
14
40 60 A
50-55
---
350
12
60 85 A
60-65
---
3.15
450
10
100 130
A
80 -85
120 - 140
450
130 180
A
85-90
110 - 120
450
150 210
A
90-95
80 - 90
6.3
450
240 250
A
95-100
60 -70
Dia
Length
300
2.5
No
Gage
Average
electrodes
consumed in
8 Hrs shift
ASME Classification Of
Electrodes
SFA 5.1
E 7018
E = Electrode
70 = UTS in 1000 psi ( 60/70/80/90/100/ 110)
1 = Position (1= all, 2= 1G, 1F & 2F, 3= 1G
& 1F)
8 = Type of coating (0,1,2,3,5,6,8)
Baking Of Basic Coated

Electrodes
Bake the loose electrodes in a baking Oven
Baking Temperature 250 C to 300 C
Baking Time 2Hrs to 3 Hrs
Reduce the temperature to 100 C to 150 C
Hold the electrodes at this temperature till use
Unused / left over electrodes to be re-baked
ELECTRODE IDENTIFICATION
Arc welding electrodes are identified using
the A.W.S, (American Welding Society)
numbering system and are made in sizes
from 1/16 to 5/16 .
An example would be a welding rod
identified as an 1/8" E6011 electrode.
The electrode is 1/8" in diameter
The "E" stands for arc welding electrode.
Next will be either a 4 or 5 digit number stamped

on the electrode. The first two numbers of a 4
digit number and the first 3 digits of a 5 digit
number indicate the minimum tensile strength (in
thousands of pounds per square inch) of the weld
that the rod will produce, stress relieved.
Examples would be as follows:
E60xx would have a tensile strength of 60,000 psi
E110XX would be 110,000 psi
The next to last digit indicates the position the
electrode can be used in.
EXX1X is for use in all positions
EXX2X is for use in flat and horizontal positions
EXX3X is for flat welding
54
The last two digits together, indicate the

type of coating on the electrode and the
welding current the electrode can be used
with. Such as DC straight, (DC -) DC
reverse (DC+) or A.C.
Type of coatings of the various electrodes
are explained elsewhere.
Examples of the type current each will work
with are as below.
55
ELECTRODES AND CURRENTS USED

EXX10 DC+ (DC reverse or DCRP) electrode positive.
EXX11 AC or DC- (DC straight or DCSP) electrode
negative.
EXX12 AC or DC EXX13 AC, DC- or DC+
EXX14 AC, DC- or DC+
EXX15 DC+
EXX16 AC or DC+
EXX20 AC ,DC- or DC+
EXX28 AC or DC+
56
CURRENT TYPES
SMAW is performed using either AC or
DCcurrent. Since DC current flows in one
direction, DC current can be DC straight,
(electrode negative) or DC reversed (electrode
positive). With DC reversed,(DC+ OR DCRP)
the weld penetration will be deep. DC straight
(DC- OR DCSP) the weld will have a faster melt
off and deposit rate. The weld will have medium
penetration.
Ac current changes it's polarity 120 times a
second by it's self and can not be changed as
can DC current.
57
ELECTRODE SIZE AND AMPS USED
The table shown will serve as

a basic guide of the amp
range that can be used for
different size electrodes.
These ratings can be different
between various electrode
manufactures for the same
size rod.
The type coating on the
electrode could effect the
amperage range.
Check manufacturers
recommended amperage
settings.
Electrode Table
ELECTRODE
DIAMETER
AMP
RANGE
PLATE
1/16"
20 - 40
UP TO 3/16"
3/32"
40 - 125
UP TO 1/4"
1/8
75 - 185
OVER 1/8"
5/32"
105 - 250
OVER 1/4"
3/16"
140 - 305
OVER 3/8"
1/4"
210 - 430
OVER 3/8"
5/16"
275 - 450
Note! The thicker the material
to be welded, the higher the
current needed and the larger
the electrode needed
OVER 1/2"
58
SOME ELECTRODE TYPES

E6010 :
Used for all position welding using DCRP. It produces a deep
penetrating weld and works well on dirty,rusted, or painted metals
E6011:
Same characteristics as of the E6010, but can be used with AC and
DC currents.
E6013:
Used with AC and DC currents. It produces a medium penetrating
weld with a superior weld bead appearance.
E7018:
Known as a low hydrogen electrode and can be used with AC or DC.
The coating on the electrode has a low moisture content that reduces
the introduction of hydrogen into the weld. The electrode can
produce welds of x-ray quality with medium penetration.
(This electrode must be kept dry. If wet, it must be dried in a rod oven
before use.)
59
Why Baking?
To remove the moisture (H2O) from

coating to avoid possible cracking of
weld
How Does Moist Electrode

Generate Crack Within Weld?
Moist electrodes introduce atomic hydrogen at
high temperature in weld
On cooling, atomic hydrogen try to form
molecules
The reaction results in stresses and fine cracks
Cracks occur within hardened metal - HAZ
Known as Hydrogen Embrittlement , Under
Bead Crack, HIC, Delayed Crack
Important Terminologies used

in Critical Welding Operation
Preheating
Post Heating or Dehydrogenation
Intermediate Stress leaving
Inter pass Temperature
Post Weld Heat Treatment
What Is Preheating?
Heating the base metal along the weld joint to a
predetermined minimum temperature
immediately before starting the weld.
Heating by Oxy fuel flame or electric resistant
coil
Heating from opposite side of welding wherever
possible
Temperature to be verified by thermo chalks prior
to starting the weld
Why Preheating?
Preheating eliminates possible cracking of
weld and HAZ
Applicable to
Hardenable low alloy steels of all thickness

Carbon steels of thickness above 25 mm.
Restrained welds of all thickness
Preheating temperature vary from 75C to

200C depending on hardenability of
material, thickness & joint restraint
How does Preheating

Eliminate Crack?
Preheating promotes slow cooling of
weld and HAZ
Slow cooling softens or prevents
hardening of weld and HAZ
Soft material not prone to crack even in
restrained condition
What Is Post Heating?

Raising the pre heating temperature of the weld
joint to a predetermined temperature range (250
C to 350 C) for a minimum period of time (3 Hrs)
before the weld cools down to room temperature.
Post heating performed when welding is
completed or terminated any time in between.
Heating by Oxy fuel flame or electric resistant coil
Heating from opposite side of welding wherever
possible
Temperature verified by thermo chalks during the
period
Why Post Heating?

Post heating eliminates possible
delayed cracking of weld and HAZ
Applicable to
Thicker hardenable low alloy steels
Restrained hardenable welds of all
thickness
Post heating temperature and duration
depends on hardenability of material,
thickness & joint restrain
How does Post Heating

Eliminate Crack?
SMAW introduces hydrogen in weld metal
Entrapped hydrogen in weld metal induces
delayed cracks unless removed before
cooling to room temperature
Retaining the weld at a higher temperature
for a longer duration allows the hydrogen to
come out of weld
What Is Intermediate Stress

Relieving?
Heat treating a subassembly in a furnace
to a predetermined cycle immediately on
completion of critical restrained weld
joint / joints without allowing the welds to
go down the pre heat temperature. Rate
of heating, Soaking temperature, Soaking
time and rate of cooling depends on
material quality and thickness
Applicable to
Highly restrained air hardenable material
Why Intermediate Stress

Relieving?
Restrained welds in air hardenable steel highly
prone to crack on cooling to room temperature.
Cracks due to entrapped hydrogen and built in
stress
Intermediate stress relieving relieves built in
stresses and entrapped hydrogen making the
joint free from crack prone
What Is Inter- Pass

Temperature?
The temperature of a previously layed
weld bead immediately before
depositing the next bead over it
Temperature to be verified by thermo
chalk prior to starting next bead
Applicable to
Stainless Steel
Carbon Steel & LAS with minimum impact
Why Inter Pass Temperature?

Control on inter pass temperature avoids over
heating, there by
Refines the weld metal with fine grains

Improves the notch toughness properties
Minimize the loss of alloying elements in welds
Reduces the distortion
What Is Post Weld Heat

Treatment?
Heat treating an assembly on completion
of all applicable welding, in an enclosed

furnace with controlled heating/cooling
rate and soaking at a specific
temperature for a specific time.
Rate of heating, Soaking temperature,
Soaking time and rate of cooling depends
on material quality and thickness
Applicable to
All type of CS & LAS
Why Post Weld Heat

Treatment?
Welded joints retain internal stresses within
the structure
HAZ of welds remains invariably hardened
Post Weld Heat Treatment relieves internal
stresses and softens HAZ. This reduces the
cracking tendency of the equipment in service
Welding Terminologies used

in Qualifications
Heat In Put
Heat Effected Zone HAZ
Dilution
Overlap In Weld Overlay
Tempering Bead
What Is Heat In Put In

Welding?
The extent of heat energy generated in
Joules per unit length while making each
weld bead.
Heat In Put is the Function of Welding
Current, Arc Voltage, And the Welding Speed
It is measured in Joules Heat In Put In Joules / mm
= (A x V x 60) Travel Speed in mm / min
Why Control On Heat in Put?

Heat In put controls the grain size of weld
metal.
Lower the Heat in put finer the grain size.

Finer the Grain size Better the impact properties
Heat In Put Also controls Dilution, HAZ &

Geometry of Bead size
What Is Heat Affected Zone

(HAZ)
A small volume of BM adjacent to weld
fusion line, which is totally changed in
its structure due to intense heat of
each weld bead is known HAZ
Diluted BM
Weld Zone
HAZ
Fusion Line
Weld Zone
Diluted BM
What Is Significant Of HAZ

It is a part and parcel of weld joint
It is inevitable
It has properties different from BM &
Weld Metal
Diluted BM
Weld Zone
HAZ
Fusion Line
Weld Zone
Diluted BM
What Is Dilution In Weld

In all Fusion welding, a small portion of BM
very close to the welding heat gets melted and
added to weld zone / fusion zone. Dilution is
the ratio of molten base metal volume (Area)
to the volume ( Area) of total fusion zone
% Dilution = (Area of Diluted BM Total Fused Area) 100
HAZ
Fusion Line
Weld / Fusion Zone
Diluted BM
What Is Significant Of
Dilution
Weld metal chemistry changes
depending on
the extent of dilution
Chemical elements influence Physical
properties of the joint.
Weld chemistry influences corrosion
resistance of weld overlays
Diluted BM
Weld Zone
HAZ
Fusion Line
Weld Zone
Diluted BM
What Is Overlap In Weld

Overlay?
The extent of covering or over lapping of
previous weld bead by the adjacent bead.
Less Dilution
40 to 50 % Over
Lap
More
Thickness
Less
Thickness
10 to 15 % Over
Lap
More Dilution
What Is Significant Of
Overlap
In
Weld
Overlap of 40
to 50%
resultsOverlay?
in Less Dilution &
more weld overlay Thickness per layer

Less dilution results weld metal chemistry more
towards filler metal chemistry
Less Dilution
More
Thickness
40 to 50 % Over Lap
Less
Thickness
10 to 15 % Over Lap
More Dilution
What Is Temper Bead

Technique?
In a multi pass groove & Fillet Welds, each bead
& its HAZ are getting tempered (heat treated) by
the welding heat of the next bead.
Thus all beads & their HAZ, except those in last
layer, are tempered.
Temper beads are the specially & carefully
welded temporary beads on the top of final weld
reinforcement with out allowing to generate any
HAZ within the BM. Temper beads are to be
ground flush with the required reinforcement.
Temper Bead
Temper Bead T1 & T2 Not To Generate
HAZ In BM
Temper Beads To Be Ground Flush
Rqd.
Reinforcement
T1
T2
5
4
3
2
1
T1 & T2 To be ground
Flush
4
3
HAZ
Good Engineering
Practices In SMAW
Do Welding with properly baked electrodes
Basic coated CS electrodes to be baked to
250C to 300C for two hours
Baked electrodes to be directly used on job
or to be retained in a hold over oven at
100C to 150C until use
Unused balance electrodes shall be
returned to baking oven
Good Engineering
Practices In SMAW
Do not weld with damp Electrodes
Do not try to heat electrodes by touching
the job (Short circuiting)
Do not use electrodes with damaged coating
Do not use electrodes with cracked coating
Do not bend the electrodes after holding it
in the holder
Good Engineering
Practices In SMAW
Do not weld on groove / surface with
mill scale or rusting
Prior to welding, clean the weld
groove with power wire wheel
Do not weld with unidentified
electrodes
Do not leave balance electrodes
unattended on shop
Good Engineering
Practices In SMAW
All connections with earthing and
welding cables shall be tight fitted
Earthing clamp shall always be
tightly connected to the job
Burn the full length of electrode till
37 mm stub length
Good Engineering
Practices In SMAW
Earthing cable shall directly connect
to the job with an earthing clamp.
Tacks for set up shall be minimum 5
times the electrode diameter
Weaving shall be limited to three
times the electrode diameter.
Only trained & qualified welders
shall be employed for welding
Good Engineering
Practices In SMAW
Do not direct fan or blower to welding arc
Remove paint if any from the area near
welding
While welding in open, area shall be
covered to protect from rain water &
breeze
Weld edge preparation shall be free from
serrations
Good Engineering
Practices In SMAW
Use poison plates between the job
material & structural supports.
Do not damage parent metal while
removing temporary supports.
Locations where from temporary
supports are removed shall be
touched up by welding / grinding
and PT checked.
Good Engineering
Practices In SMAW
Remove visible defects from welds
before placing the subsequent beads
Do not weld over a visible crack
Electrodes kept out side more than 2
Hrs shall be returned to baking oven
Maximum 15 electrodes at a time
shall be taken from oven for welding
Good Engineering
Practices In SMAW
When preheat is required, heat from
opposite side of welding.
Use temperature indicating crayons
for checking temperature
Do not Weld more than specified
weld size- Fillet / Reinforcement.
Safety Precautions in
Shielded Metal Arc Welding
Safety Precautions In
SMAW
Welders shall use safety devises
Hand gloves, Head screen with right
glass & Safety shoes
Welders shall use full sleeve boiler suit
Use welding glass-DIN 11/12 up to 250
Amps and 13 above 250 Amps
Do not look at the arc with naked eyes
SMAW
Do not throw Stubs on ground. They shall
be placed in stub collector.
Do not keep electrode in the holder when
work is not in progress
Do not touch the electrode held on holder
and the the job when the power source is
on
Keep welding cables duly wound near
power source when no welding is done
SMAW
Do not breath welding fumes
When working in confined area,
ensure adequate ventilation / exhaust
Gas cutting torch / preheating burner
shall not be taken inside confined
area unless the flame is lit
When not in use, switch off the the
power source from electric supply
SMAW
Acetone / inflammable liquids
(Chemical for dye penetrant test) shall
not be brought near welding
Gas cutting unit / fuel gas cylinders
shall be away from welding area
Wet safety Shoes or wet hand gloves
shall not be worn while welding

033 Arc Welding 2010

Transféré par

Informations du document

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

033 Arc Welding 2010

Transféré par

Droits d'auteur :

Formats disponibles

ARC WELDING

Dr. N. RAMACHANDRAN, NITC

LIQUID STATE PROCESS

CARBON ARC WELDING (CAW) - OLDEST

BEGINNING IN 1881- TO CONNECT PLATES OF STORAGE BATTERY

BUTTED, CLAMPED HIGH CURRENT PASSED

Dr. N. RAMACHANDRAN, NITC

ARC WELDING- MELTING AND FUSING OF METAL BY ELECTRODES

1ST BY N.V. BERNADO USING CARBON ELECTRODES

ARC WELDING PROCESSES

SHIELDED METAL ARC WELDING

Shielded metal arc welding (SMAW),

An electric current, in the form of either

ARC COLUMN THEORY

ELECTRICAL / IONIC THEORY

IONS FROM ANODE TO CATHODE,

IONS COLLIDE WITH GAS MOLECULES

IONISED GAS COLUMN AS HIGH

ARC COLUMN THEORY

IONS FROM ANODE TO CATHODE

(MASS- 9.1x 10-28 gm)

Dr. N. RAMACHANDRAN, NITC

Dr. N. RAMACHANDRAN, NITC

MAGNETIC FLUX THEORY

Dr. N. RAMACHANDRAN, NITC

Currents higher than

Dr. N. RAMACHANDRAN, NITC

Currents generally less

Dr. N. RAMACHANDRAN, NITC

Welding currents upto

Dr. N. RAMACHANDRAN, NITC

Dr. N. RAMACHANDRAN, NITC

Hence, study of:

Quality and property of welded joint

(3) Heat Affected Zone (HAZ)

Structures: (1) SMALL (2) MEDIUM (3) LARGE

Cooling of Beadsimilar to a casting in mould, which is metallic here.

The purpose of coating the electrode is to

Flux + impurities- less dense. Floats as SLAG

MAGNETIC ARC BLOW -- FOR AC SUPPLY.

Current through conductor- magnetic Flux lines perpendicular to

Forward pull of Arc column results, called as Magnetic Arc Blow.

Dr. N. RAMACHANDRAN, NITC

Dr. N. RAMACHANDRAN, NITC

Dr. N. RAMACHANDRAN, NITC

Bare electrodes - carbon- more conductive- slow

ELECTRODE COATING INGREDIENTS

As the weld is laid, the flux coating of

It dominates other welding processes in the

(A).BARE ELECTRODE MOLTEN METAL TRANSFER

Various welding electrodes

an open electric arc, so

New helmet models have been

Arc eye, also known as arc flash or welder's flash or

Symptoms tend to occur a number of hours

Shielded Metal Arc

2 Fusion Welding With Heat &

Pressure Welding Process

Fusion Welding Process

Types Of Fusion Welding

An electric Arc struck between

Equipment, Accessories &

Types Of Power Source

Flux Coating On Electrode