ARC WELDING

PRESENTED BY

PRACTICAL APPLICATIONS OF
WELDING

Aircraft construction
Automobile construction
Bridges
Buildings
Pressure vessels
Storage tanks
Rail road equipments
Pipes and pipelines
Ships
Trucks and trailers
Machine tools

APPLICATIONS OF WELDING
Earth moving
machinery And
Cranes
Repair and
maintenance work
Hard-facing and
rebuilding
Fabrication of jigs
and fixtures.
House hold
furniture

METAL JOINING
METHODS
Temporary joints
- Riveting, Seaming
or Hooking,
Brazing, Bolting &
soldering

Permanent Joint

-WELDING

METHOD OF WELDING
Fusion welding welding

arc welding, gas

Non-fusion welding brazing.

silver soldering,

Pressure welding - Forge welding or

resistance welding

CLASSIFICATION OF WELDING
PROCESSES

Electric welding

Electric arc welding

Electric resistance welding
Laser welding
Electron beam welding

Electric arc welding

- Metallic arc welding
- Carbon arc welding
- Atomic hydrogen arc welding
- Inert gas arc welding
- Co2 welding
- Submerged arc welding
- Electro-slag welding
- Plasma arc welding

Electric resistance
welding
-

Spot welding
Seam welding
Butt welding
Flash butt welding
Projection welding

Gas welding processes

-

Oxy-acetylene gas welding

Oxy-hydrogen gas welding
Oxy-coal welding
Oxy-liquefied petroleum welding

The other welding processes

-

Thermit welding
Forge welding
Friction welding
Ultrasonic welding
Explosive welding
Cold pressure welding
Plastic welding.

PRINCIPLE OF ARC WELDING

When the high current passes through

an air gap from one conductor to
another, it produces very intense and
concentrated heat in the form of a
spark, which can melt and fuse the
metal very quickly to produce a
homogeneous weld.

ARC WELDING PROCESSES

OR
SHIEDED METAL ARC WELDING
In Arc welding process the source of heat
is electricity
The flux coating melts produces a
gaseous shield and slag to prevent
atmospheric contamination of molten
weld metal. (Hence this arc is called
shielded arc).

Manual Metal Arc WeldingMMAW

The welding current is provided
by an AC or DC.
The welding speed and feed of
the electrode is controlled
manually by the welder himself.
(Called Manual Metal Arc
Welding-MMAW)
The arc welding temperature
between 3600C-4000C

CURRENT
Electrons in motion is called
current.
The rate of flow of electrons is
`measured in amperes (unit).
The measuring instrument is
called ampere meter or
ammeter.

ELECTRIC PRESSURE
It is the pressure which makes
the electric current to flow it is
called voltage or electro motive
force. Its measuring unit is
VOLT. The measuring is called
volt mete.

Open circuit voltage

The voltage in between

two terminals before strike
the arc is called open
circuit voltage.

Close circuit voltage

The voltage in between two

terminals during welding is
called close circuit voltage.

AC

AC means alternating current. It

changes or reverses its direction of
flow 50 times per second, if it is 50
cycles.Eg.50 cycles means it changes
its direction 50 times per second.

Its rate of change is called

frequency i.e. hertz (HZ). In India the
frequency of AC is 50 cycles per
second.

DC
Electric current which
always flows in particular
direction is known as direct
current i.e. negative to
positive (electric direction),
positive to negative
(conventional direction).

WELDING MACHINES
Alternating current (AC) welding
machine
Direct current (DC) welding machine
AC machines -- Transformers
DC Machines -- Motor generator set
Engine generator set
Rectifier set.

AC WELDING
TRANSFORMER
This is a type of welding machine
which converts AC main supply in to
AC welding supply.
AC main supply has high voltage
low ampere.
AC welding supply has high ampere
low voltage.

AC TRANSFORMER
It is step down transformer, which
reduce the main supply voltage (220
or 440 volts) to welding supply open
circuit voltage (OCV), between 40 to
100 volts.
A Transformer
may be operated from the mains on
single phase, two phases or three
phases and may be air cooled or
oil cooled.

ADVANTAGES

Less initial cost

Less maintenance cost
Freedom from arc blow
Noiseless operations
Higher work efficiency

DIS ADVANTAGES
Not suitable for non-ferrous metals
Fine current setting not possible
It is not suitable for bare and light
coated electrodes
It has more possibility for electrical
shock because of higher open circuit
voltage
It can only be used where electrical
mains supply is available.

DC MACHINES

1. Welding generators
(Motor generator set)
(Engine generator set)
2. Welding rectifiers

Welding generators
A motor connected to main supply.
(Generate DC welding supply with the
help of welding supply.)
A petrol or diesel engine. (Generate
welding supply where electricity
main supply is not available with help
of engine driven sets.)

Welding rectifier
A welding rectifier set is used to
convert A/C welding supply in to DC
welding supply. (It consists of a step
down transformer and a welding
current rectifier cell cooling fan.)
It can be designed to provide either
AC/DC welding supply by changing a
switch.

ADVANTAGES OF DC
WELDING MACHINE
1. Polarity system
2. It can be used successfully to weld
both ferrous and non- ferrous metals,
thin sheets, cast iron metals.
3. Bare wires and light coated electrode
can be easily used.

ADVANTAGES
4. Positional welding is easy due to
polarity advantage.
5. It can be run with the help of diesel
or petrol engine where electrical mains
supply is not available.

6. It has less possibility for electrical shock

because of less Open circuit voltage

DIS-ADVANTAGES
Higher initial cost
A higher operating cost
A higher maintance cost
Trouble of arc blow during welding
Noisy operation
Occupies more space.

ARC WELDING
ACCESSORIES
1. Electrode holder
2. Earth clamp
3. Welding cables
4. Helmet and hand shield
5. Chipping hammer
6. Chipping goggles
7. Wire brush
8. Tongs
9. Lather gloves
10. Lather apron
11. Safety shoe.

Electrode holder
It is a clamping device used to grip
and manipulate the electrode
during arc welding. Its made of
copper/copper alloy for better
electrical conductivity. Holders are
made in various sizes.
i.e.200Ampsto 500 Amps.

Helmet and Hand shield

These are used to protect the eyes and face of
a welder from the arc radiation and sparks
during arc welding.

Colored (filter) glasses are made in

various shades:
Shade no.
Range of welding Amps
8-9
up to 100
10-11
100 to 300
12-14
above 300

Earth clamp

It is used to connect the earth cable

firmly to the job or welding. It is also
made of copper/copper alloys

Welding cables
These are used to carry the
welding current from the
welding machine. Cables are
made of supper flexible
rubber insulation, having fire
copper wires and woven
fabric reinforcing layers.

Chipping hammer
It

is a welding tool used to

remove the slag from the
weld bead. (Medium carbon
steel)

Wire brush

It is used for to protect

the eyes while chipping
the slag or grinding the
job.

Tongs

Tongs are used for holding hot

work pieces and for holding the
pieces in position .

Lather gloves

These are used to protect the

hands of a welder from electric
shock, arc flash, heat, sparks and
spatters

Lather apron

It is used to protect the chest,

the front and rear body and the
arms a welder during welding.

Safety shoes
It is used to protect the feet of
the welder from metal spatter.

COMMONLY WELED
BASE METAL
Metals can be classified
as
Ferrous metal
Non-ferrous
metal

Ferrous metal

Which metal contains iron

substance is called ferrous metal.
Wrought iron
Carbon steel
Stainless steel
Cast iron
Cast steel
Alloy steel.

Non-ferrous metal
Non-ferrous materials are
those that are not iron-based.
Aluminum and its alloys
Magnesium and its alloys
Nickel and its alloys,
etc.

Ferrous alloy
One more ferrous metal added
is called ferrous alloy

Non ferrous alloy

One more non-ferrous metal
added is called non ferrous
alloy.

MELTING POINTS OF METALS

232C
Tin
Lead 343C
Zinc 419C
Silver 960C
Copper1082C
Nickel 1449C
Cast iron 1232C

MELTING POINTS OF METALS

621 - 648C
Aluminium
Bronze 882 - 915C
Brass 926 - 982C
Monal metal 1343C
High carbon steel 1371C
Medium carbon steel 1426C

MELTING POINTS OF METALS

Mild steel
Stain less steel
Low carbon steel
Wrought iron
Tungsten

1500 - 1530C
1426C
1510C
1593C
3410C

SAFETY
RECOMMENDATIONS IN
WELDING

Welding and cutting of metals involve

the application of intense heat to the
objects being welded or cut.

The intense welding heat

and the sources employed to
produce it can be potentially
hazardous. There fore, to protect
persons from injury and to protect
building and equipment against fire,
etc,.

welding and cutting

safety

Safety recommendations for

installation and operation of arc
welding & cutting equipment.
Explosion, fire and other hazards
and protection against them.
Protection of welders.
Ventilation and health protection.

GENERAL PRECATIONS
Fire extinguishers or sand should be
available at hand.
Do not pick up hot jobs or objects.
Use goggles with non-flammable
lenses and frames.
Never do any chipping or grinding
without suitable goggles.
Do not use matches for lightning
torches. This may result in hard burns.

GENERAL PRECATIONS.
If welding or cuttings is to be stopped
permanently, release all pressures from
the regulators.
Arc welding machines should be properly
ground.
Welder should wear dry and fire-proof
protective clothes (apron, gloves, etc.) to
prevent the arc rays from reaching his
body.
To prevent welders from radiation, spatter
and hot slag, a helmet or hand shield must
be worn.

ARC LENGTH
The distance between
the Tip of Electrode and
the surface of the job it
is called a ARC Length.

MEDIUM ARC
The correct arc length or
Medium or Normal arc
length is approximately
equal to the diameter of
the core wire of the
electrode.

SHORT ARC
If the distance between
the tip of electrode and
the base metal is less
than the dia. of the core
wire, it is called a short
arc.

LONG ARC
If the distance between
the tip of the electrode
and the base metal is
more than the diameter
of the core wire it is
called a long arc.

POLARITY SYSTEM
Polarity indicates the direction of current
flow in the welding circuit.
In DC welding machine heat distribution
between the electrode and the base metal
and welding of non-ferrous metal 2/3 of
the heat is liberated from the positive end
and 1/3 from the negative end.
To have this advantage of unequal heat
distribution in the electrode and the base
metal, the polarity is an important factor
for successful welding.

Kinds of polarity
1. Straight polarity: In straight
polarity the electrode is connected to the
negative (-) and the work to the positive
(+) terminal of the power source.
2. Reverse polarity: In reverse
polarity the electrode is connected to the
positive (+) and the work to the negative
(-) terminal of the power source.

Straight polarity is used

for

Welding with bare, light coated and

medium coated electrodes.

welding the thicker sections to obtain

more fusion and penetration.

Reverse polarity is used

for:

welding of non-ferrous metal

welding of cast iron
welding with heavy and super-heavy
coated electrodes.
Positional welding, sheet metal
welding can possible.
(Choice of the polarity depends on
the instruction of the electrode
manufacturers.)

How will you deter mind

the wrong polarity?

Lack of fusion of base metal

Rabbit burning of electrodes
More spatter
Poor penetration
Bead appearance will not be good
Elements will be loss
Difficulty in manipulation of arc
Abnormal sound of the arc.

CHARACTERISTIC OF
ARC

Gravity force
Gas expansion
Surface tension
Electro magnetic force

GRAVITY FORCE
Molten globules formed at the arcing end of
the electrode travel towards the job in the
molten pool.
Gravitational force helps the transfer of metal
in flat or down-hand position and thus the
deposition rate of weld metal is increased.

WELDING
TECHNOLOGY

ARC WELDING

MIG WELDING

WELDING
TECHNOLOGY
GAS CUTTING

Presented
by

GAS EXPANSION

SURFACE TENSION
It is the characteristic (force) of
the base metal to attract and
retain the molten metal in it.
This effect is more useful in the
case of positional welding. The
short arc promotes more
surface tension effect.

ELECTRO MAGNETIC
FORCE

The current passing through the electrode

forms magnetic lines of force in the form
of concentric circles. This force exerts a
pinch effect on the molten metal globule
formed at the arcing end of the electrode.
The globule is detached from the
electrode and reaches the molten pool
under the influence of the magnetic force.
This effect is more useful in positional
welding.

ARC BLOW

When the arc deviates from

the regular path due to the
Magnetic disturbances it is
called Arc blow.

ARC BLOW IN DC WELDING

Whenever a current flows in the
electrode a magnetic field is formed
around the electrode. Likewise a
similar magnetic field is also formed
around the base metal.
Due to interaction of these two
magnetic fields, the arc is blown to
one side forward or backward of the
joint.

EFFECTS OF ARC
BLOW
More spatter with less
deposition of weld metal.
Poor fusion/penetration.
Weak weds.
Difficulty in depositing weld
metal at the required place in
the joint.

METHODS USED TO
CONTROL THE ARC BLOW
Welding away from the earth connection
Changing the position of the earth
connection of the work.
Changing the position of the work on the
welding table
Wrapping the welding cable fewer times
around the work,
Holding the correct electrode angle with
a short arc.
Use run on and run off plates.

ARC WELDING

Effect of variations
in welding procedure

Correct weld
With the correct arc length, rate of
travel, current setting, angle of
electrode, and technique, the
deposited metal will be uniform
width and height, and will produce
fine ripple face appearance, free
from surface defects i.e. slag
inclusion, porosity, lack of
penetration, undercut, overlap, etc.

Current too low

Uneven of bead
Poor penetration
Slag inclusions in weld
Irregular ripples

Current too high

Wide and flat beads in uneven
shape
Excessive penetration
More spatter
Ripples very poor in appearance
Porosity in crater and bead
Undercut

Arc too short

Unequal width height of bead
Irregular ripple
Burn through and more
chances of Electrode freezing

Arc too long

Unequal height of bead
Wide, coarse ripples
Crater with Blowholes and more
spatter
Insufficient root and base metal
penetration

Travel too slow

More width and height of bead

Control of deposited metal poor
Slag inclusion may appear
Overlap

Travel too past

Narrow width bead
Porosity in crater
Inadequate fusion of bead with
parent
metal
Elongated ripples.

Welding Position

1. Down hand / Flat position

2. Horizontal position
3. Vertical position
4. Overhead position
5. Inclined position

Welding joints
Butt

joint
Tee joint
Lap joint
Corner joint

ELECTRODES
Definition
An electrode is a metallic wire of
standard size and length
generally coated with flux ( may
be bare or without flux coating
also).

Classification of
Electrodes
MMAW Electrodes are classified
based on the following factors.
1. Method of coating
2. Coating factor
3. Type of flux coating
4. Purpose of flux coating
5. Core wire material.

Method of coating
Dipping

Method

Extrusion

Method

Dipping Method
The core wire is dipped in a
container Carrying flux paste.
The coating thus obtained on the
core wire is not uniform resulting
in non- uniform melting; hence
this method is not popular.

Extrusion Method
A straightened wire is fed into an
extrusion press where the coating is
applied under pressure. The coating
thus obtained on the core wire is
uniform and concentric, resulting in
uniform melting of the electrode.
This Method is used by all the
electrode manufacturers.

Coating Factor
The ratio of the coating diameter to the
core wire diameter is called the coating
factor.
Coating factor =
coating dia.of electrode/core wire dia.of
electrode

1.25 to 1.3
mm
1.4 to 1.5 mm
1.6 to 2.2 mm

Light coated electrode

Medium coated
electrode
Heavy coated
electrode

Types of Flux coating

Cellulosic
Rutile
Iron

oxide
Basic coated

Cellulose coating
These electrodes have a thin
coating with contains mostly
cellulose.
These give deep penetration
because the flux coating
produces more gases.
Very little slag is formed on
the weld. These electrode can be
used for all position welding.

Rutile
coated
electrode
These electrode have medium thick

coating.
These coating contains
mostly silicates and a little % of
cellulose.
These electrode are used for welding in
- wider gap filling
- improperly prepared joints
- structural works, ship building,
- storage tanks, gas containers,
- medium and high pressure pipe lines

Iron oxide coated electrodes

These electrodes have heavy
coating. The coating contains mainly
iron oxide and silicates.
Welding in vertical and overhead
position is difficult with these
electrodes.

Basic coated electrodes

Low hydrogen type electrodes
called Basic coated electrodes.
These electrodes have super
heavy coating of flux.
It is only used in DC machine
reverse polarity.

It is mainly used for the welding

of pressure vessels for the
following reasons.
The

arc gives less heat

Fusion of bigger to medium
drops
Molten pool solidifies quickly
Very good quality weld
Thick and H.S.steels can be
welded successfully.