ARC WELDING MACHINES

PRESENTED
BY

M.GNANASEKARAN

ARC WELDING MACHINE

In

arc welding process, the source of heat is

electricity. (High ampere-low voltage)

The required electrical energy for welding is obtained

from an arc welding machine, a power source.

ARC WELDING SYSTEM

Necessity
The equipment is used to:
To provide AC or DC welding supply for arc welding
Provide higher voltage (OCV) for striking the arc and lower

voltage (AV) for maintaining the arc.

Change the high voltage of the main supply (AC) to low
voltage and heavy current supply (AC or DC) suitable for
arc welding.
Establish a relationship between arc voltage and welding
current during arc welding
Weld with all gauges of electrode
Weld thin and thick plates, both ferrous and non-ferrous
metals.

TYPES OF WELDING MACHINE

Basically Power sources
are,
Alternating current
welding machine,
Direct current welding
machine.
These may be further
classified as AC machines
and DC machines.

TYPES OF WELDING MACHINE

AC machines
Transformers
DC Machines
Motor generator set
Engine generator set
Rectifier set
Inverter type machine

AC WELDING TRANSFORMER
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.

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.
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.

AC WELDING TRANSFORMER
A Transformer may be

operated from the mains on

single phase, two phases or
three phases and may be
air cooled or oil cooled.
Single phase transformers

supply lower currents, and

are therefore used for
welding thinner sections
with small diameter of
electrode.

AC WELDING TRANSFORMER
Generally we are using,
Simple works
General works
Hard works

220 amps (I Phase)

300 amps (II Phase)
600 amps (III Phase)

AC WELDING MACHINE
ADVANTAGES
Less initial cost
Less maintenance

cost
Freedom from arc
blow
Noiseless operations
Higher work efficiency.

DIS-ADVANTAGES
Fine current setting not possible
Not suitable for non-ferrous metals
It is not suitable for bare and light coated electrodes
It can only be used where electrical mains supply is

available.
It has more possibility for electrical shock because of

higher open circuit voltage.

DC WELDING MACHINES
DC means

direct current. It
flows steadily
and constantly
in one direction.

DC WELDING MACHINES
DC Machines are
1. Welding generators
2. Welding rectifiers

Welding generators may be driven

by:
- 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. This machine
is called AC/DC welding
machine.

Inverter types weld machines

A solid-state inverter is a circuit

which uses solid-state devices to

convert DC into high frequency AC,
usually in the range 1 KHz to 50
KHz. Since transformer size is
inversely proportional to frequency,
transformer size reductions of up to
75% are possible by using inverter
circuits.

Inverter types weld machines

Basic Inverter circuit components and current wave forms through them

The figure above gives a schematic illustration of the inverter components

and the electrical waveform passing through each of the components.

ADVANTAGES OF DC WELDING
MACHINE
Polarity system
It can be used successfully to weld ferrous

and non- ferrous metals, thin sheets, and

cast iron metals.
Bare wires and light coated electrode can be

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

Care and Maintenance of

Arc Welding Machines
Every machine and accessory used for any useful

purpose requires some care and maintenance to

increase its usage for a long time. In the case of arc
welding machines and accessories the following points
or of importance.
Arc welding machines: do not keep the machine in

open air. In a DC welding generator do not put the

starting switch on DELTA position directly; keeps the
switch on START position first. Run it for a few seconds
and they put the switch in DELTA position. Do not
disconnect the cooling fan of a welding generator.

Care and Maintenance of

Arc Welding Machines
Maintain the cooling oil level in the transformer welding set.
Periodically drain the cooling oil from the transformer and

purify, and then refill the transformer. Fix the input cables
from the mains to the machine and the electrode and earth
cable firmly. Replace the carbon brushes of the DC welding
generator whenever necessary.
Do not clean any welding machine with water. The dust and

impurities are to be removed by compressed air only.

Operate all control knobs and handles gently.