Electric Arc and Arc Welding

Instructor: Prof. G. L. Datta

Lecture # 3

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What is an Electric Arc?

An electric arc is a discharge of electric current across a gap in a circuit . It is sustained by an ionized column of gas (plasma) through which the current flows To initiate the arc in AW, electrode is brought into contact with work and then quickly separated from it by a short distance.
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The electric arc

Electric discharge between 2 electrodes through a gas

Peak temperatures 18,000 K

10 to 2000 amps at 10 to 500 V arc voltage

Cathode drop zone

Column of ionised gas at high temperature Forces stiffen the arc column

Anode drop zone

Transfer of molten metal from electrode to workpiece

Can have a cleaning action, breaking up oxides on workpiece

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Electrical constituents of an arc

Cathode Cathode drop zone Arc column Anode drop zone Anode V = Vc + Va + Vcl
Vc PS Vcl Va + V

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Arc Welding (AW)

A fusion welding process in which coalescence of the metals is achieved by the heat from an electric arc between an electrode and the work. Electric energy from the arc produces temperatures ~ 5500 C, hot enough to melt any metal. Most AW processes add filler metal to increase volume and strength of weld joint.
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Arc Welding
A pool of molten metal is formed near electrode tip, and as electrode is moved along joint, molten weld pool solidifies in its wake.

Basic configuration of an arc welding process.

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Two Basic Types of AW Electrodes

Consumable consumed during welding
process Source of filler metal in arc welding

Nonconsumable not consumed during welding process Filler metal may be added separately.

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Consumable Electrodes
Forms of consumable electrodes 1. Welding rods (sticks): 25 to 45 cm in length and 10 mm or less in diameter and must be changed frequently. 2. Weld wire: can be continuously fed from spools with long lengths of wire, avoiding frequent interruptions. In both rod and wire forms, electrode is consumed by arc and added to weld joint as filler metal.
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Non-consumable Electrodes
Made of tungsten which resists melting Gradually depleted during welding (vaporization is principal mechanism) Any filler metal needed must be supplied separately into weld pool.

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Arc Shielding
At high temperatures in AW, metals are chemically reactive to oxygen, nitrogen, and hydrogen in air Mechanical properties of joint can be seriously degraded by these reactions To protect operation, arc must be shielded from surrounding air in AW processes Arc shielding is accomplished by: Shielding gases, e.g., argon, helium, CO2 Flux
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Arc Length
Longer arc lengths = increased puddle heat, flatter welds, deeper penetration Shorter arc lengths = less puddle heat, flatter welds, less penetration Use arc length to control puddle size, penetration, and burn through.
Normal arc length is 1.5 mm 3.1 mm Use a slightly longer arc length during a start or restart.
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Arc energy
EI Q 0.06 v
Low arc energy Small weld pool size Incomplete fusion High cooling rate Unwanted phase transformations Hydrogen cracking
Q = arc energy in kJ/mm E = arc voltage, volts I = current, amps v = travel speed in mm/min

High arc energy Large weld pool size Low cooling rate Increased solidification cracking risk Low ductility and strength Precipitation of unwanted phases (corrosion and ductility)

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Classifications of Arc Welding

SMAW / MMAW

TIG / GTAW
Arc Welding

MIG / GMAW

SAW
FCAW
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MAG

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Shielded Metal Arc Welding (SMAW) also known as Manual Metal Arc Welding (MMAW)
Instructor: Prof. G. L. Datta

Lecture # 4

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Covered electrodes
Core wire
Solid or tubular 2 mm to 8 mm diameter, 250 to 450 mm long

Coating
Extruded as paste, dried to strengthen Dipped into slurry and dried (rare)

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Shielded metal arc welding process

The oldest and the most versatile process Uses a covered consumable electrode consisting of a core wire around which a concentric clay like mixture of silicate binders and powdered materials such as fluoride, carbonates, oxides of metal alloys and cellulose is extruded. This covering acts as a source of arc stabilizer, gases to displace air, alloying elements, and slag to protect and insulate the deposited metal. About 75 to 80 of the total welding work is done with shielded electrodes.

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Shielded Metal Arc Welding

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Basic Characteristics of SMAW

Manual welding Control of arc length important for quality Application-specific electrode to be used 10 to 15 length of weld per electrode interrupted welding for long runs Any type of power source ac, dc, rectified dc can be used Weld metal chemical composition adjustable Weld covered with slag
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SMAW Plant

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Power source Power cable Electrode holder Welding hood Chipping hammer Wire brush Hand gloves Apron
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Current Requirements in SMAW Process

Gauge # 10 8 6 Dia of core wire, mm 3.1 4 5 Current, amps 80 - 100 100 - 130 130 - 160

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Advantages of SMAW
a) Simplest of all arc welding processes b) Equipment portable c) Finds innumerable applications due to availability of wide variety of electrodes d) A wide range of metals and alloys can be welded e) Welding in all positions f) Cost may be less than other welding processes.

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Limitations of SMAW
(a) Low productivity - Low power, low duty cycle (frequent electrode changes), electrode of finite length, and low speed of welding. (b) Possibility of slag inclusion. (c) Hydrogen from flux coatings making the weld prone to hydrogen embrittlement cracking. (d) Quality dependent on manual skill. (e) Low depth of penetration. (f) Welding fume.
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Gas Metal Arc Welding (GMAW) / Metal-arc Inert Gas Welding (MIG)

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Gas Metal Arc Welding (GMAW)

Uses a consumable bare metal wire as electrode and shielding accomplished by flooding arc with a gas. Wire is fed continuously and automatically from a spool through the welding gun Shielding gases include inert gases such as argon and helium for aluminum welding, and active gases such as CO2 for steel welding Bare electrode wire plus shielding gases eliminate slag on weld bead - no need for manual grinding and cleaning of slag.
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GMAW Terminology

(CONTACT TIP)

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Gas Metal Arc Welding Gun GMAW

Solid or Metal Cored Electrode

(CONTACT TIP)

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Gas Metal Arc Welding Equipment

DCEP (DCRP) (Reverse Polarity)

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Copper Coated MS MIG Wire

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Lincoln Electric GMAW Equip.

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GMAW Advantages over SMAW

Better arc time because of continuous wire electrode Sticks must be periodically changed in SMAW Better use of electrode filler metal than SMAW End of stick cannot be used in SMAW Higher deposition rates Eliminates problem of slag removal Can be readily automated

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Flux Cored Arc Welding

Lecture # 5

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Flux-Cored Arc Welding

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Main Features of FCAW

Two Variations:
Gas Shielded Self Shielded

Gas Shielded
Like GMAW, but cored electrode contains flux Requires shielding gas

Self Shielded
Like GMAW, but cored electrode contains flux Flux produces its own shielding gas

Self Shielded FCAW Process

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Self Shielded FCAW

Vaporizing flux produces Carbon Dioxide Molten slag coats droplets. Limited ability to shield puddle from N2 in air, nitride formers added to flux. Nitrides in the weld metal increase hardness and decrease toughness. Less sensitive to drafts than gas shielded.
Used where SMAW used, eg. outdoors.

Can use long stickout, low current.

Useful for sheet metal or bridging gaps

Gas Shielded FCAW Process

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Gas Shielded FCAW

Shielding gas N2, O2, H2O away
75%Ar-25%CO2 for spray transfer. 100% CO2 for short arc transfer.

Deoxidants in flux to tie up O2 from CO2. Higher deposition rate. Slag removal is an extra step. Metal cored electrodes contain no flux, just metal powders. Therefore it is a GMAW process, not a FCAW process.

Flux Cored Electrodes

Uniform distribution of flux is critical Hermetic sealing is critical to prevent moisture pickup that can lead to hydrogen cracking Flux in core Affects arc characteristics Provides for chemical interaction with weld to 1) add alloying elements 2) tie up N2 and O2 Forms a slag (glassy covering) to protect the weld from the air
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Flux Cored Arc Welding

Advantages Higher production rate than SMAW & GMAW Some electrodes can be used in any position Limitations Oxide and flux inclusions in weld metal Nitride inclusions in self shielded FCAW weld metal Smoke and ultra violet radiation Slag must be removed between passes
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Assignment # 2
1. Perform an internet search for GMAW & FCAW wire electrodes: Metal, Wire diameter, Spool size and names of Manufacturers. 2. Perform an internet search for Shielding gases: Sources of gases.

Review Questions
Distinguish between a spark and an arc. Can you express arc-voltage as a function of arc-length? Why SMAW process uses a lower current than MIG process? Why cant you use high current in TIG process? Why do you get high deposition rate from FCAW process?
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Review Questions
What polarity is used with Gas Metal Arc? Which shielding gas does give the greatest penetration? The most spatter? Compare the productivity of all the processes which use flux. Compare the productivity of all the processes which dont use any flux. Why is MIG preferred over SMAW?
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Review Questions
The following parameters are used in an SMAW process: I = 120 amps, E = 26 volts, v = 100 mm/min. determine (a) arc power and (b) heat input into the work piece. What is meant by low arc energy and high arc energy? Give a comparison. Compare the characteristics of (a) SMAW and FCAW, and (b) SMAW and MIG processes.
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Thank You

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