AMANDA WALDRON

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Arc Welding Processes

Five types of arc welding used in building construction will be discussed: 1. Gas metal arc welding (GMAW) 2. Gas tungsten arc welding (GTAW) 3. Flux Cored Arc Welding (FCAW); (FCAW-G) or (FCAW-S) 4. Submerged arc welding (SAW) 5. Shielded metal arc welding (SMAW)

The following is an illustration of typical welds used in steel construction

(taken from: Edward Allen, Joseph Iano. Fundamentals of Building Construction: Materials and Methods)

Figure 6: Typical welds in steel construction

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Gas Metal Arc Welding (GMAW)

Figure 1.1: Gas Arc metal welding

Gas Metal Arc Welding is an arc welding process that uses the heat of an electric arc established between a consumable metal electrode and the work to be welded (figure 1.1). 1 An inert shielding gas such as argon, helium, or CO 2 enshrouds the arc, but the GMAW electrode is consumable wire. Referred to as MIG welding where either solid wire or metal cored wire is being used for MIG welding process. this process requires a wire feed system to push the wire through the cable. The electrode is a bare metal wire that is transferred across the arc and into the molten weld puddle. The wire, the weld puddle, and the area in the arc zone are protected from the atmosphere by a gaseous shield since the wire does not have flux.. Inert gases, reactive gases, and gas mixtures are used for shielding. The metal transfer mode is dependent on shielding gas choice and welding current level (figure 1.2).

Figure 1.2: Modes of metal transfer

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Since metal is being transferred from the electrode and deposited in the weld, the nature of this transfer can greatly affect the arc characteristics and resultant weld. Specialized GMAW current modes are used to achieve specific forms of metal transfer. Spray transfer GMAW with an argon-shielded, high-current, DCRP arc produces a fine spray of metal droplets at rates of hundreds per second. In spray transfer there is little apparent sputtering of the arc because of the smooth transfer of metal. This results in a rather stable emission of optical radiation. In the pulsed arc (GMAW-P), the spray of droplets is produced primarily during high-

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current pulses, although a steady arc sustaining current exists between pulses. In the buried arc process, CO 2-rich gas mixtures are used to inhibit spray transfer and crater in the steel with lest optical radiation emitted. The short-circuiting arc (GMAW-S) process for welding thin sections also produces a train of high-current pulses resulting from a controlled short at least every 20 ms.
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The edges or surfaces of parts to be joined by welding shall be prepared by shear or plasma arc cutting. Where hand cutting is involved the edge will be ground to a smooth surface. All surfaces to be welded shall be wire brushed prior to welding. In multi-pass welds the weld bead is wire brushed between passes to ensure fusion with the adjacent base metal and penetration into the root of the previously deposited weld metals. Slag or flux remaining after a pass, is removed before applying the next covering pass. After the final pass all slag and weld spatter is removed.

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1,2

Michigan Occupational Safety & Health Administration Consultation Education & Training Division. Onsite consultation abatement method advice for: arc welding process. 2005 3 CWB Group. Welding procedure guide. 2008

Gas Tungsten Arc Welding (GTAW)

Figure 2: Gas tungsten arc welding

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Referred to as TIG welding; rod or solid wire is being used for TIG welding process. Process performed using the heat of an arc established between a nonconsumable tungsten electrode and the work piece (figure 2). The electrode, the arc, and the area surrounding the molten weld puddle are protected from the atmosphere by an inert gas shield. The electrode is not consumed in the weld puddle as in shielded metal arc welding. If a filler metal is necessary, it is added to the process by leading the molten puddle (figure 2). Gas tungsten arc welding produces exceptionally clean welds no slag is produced, the finished weld requires virtually no cleaning. Argon and Helium, the primary shielding gases employed, are inert gases, so do not chemically combine with other elements. They are used to exclude the reactive gases, such as oxygen and nitrogen, from forming compounds detrimental to the weld metal. provided through a concentric gas nozzle surrounding the electrode.
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Because of the requirements for compressed gas, a specialized welding gun, and more sophisticated current regulation equipment, this process is found most often in heavy industry. Helium, because of its higher ionization temperature, produces a hotter arc and is preferred for specialized applications where a deeper penetrating arc is desired. Regardless of the shielding gas used, GTAW is generally regarded as the process which produces the highest quality conventional weld. This type of welding is most commonly used for aluminium, magnesium, stainless steel and copper alloys. This process is slower than FCAW or SMAW but is best for lightweight or thin materials. All surfaces to be welded is wire brushed prior to welding. In multipass welds the weld bead is wire brushed between passes. Back gouging of welds must produce a groove having a profile and a depth adequate to ensure fusion with

AMANDA WALDRON

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the adjacent base metal and penetration into the root of the previously deposited weld metals.

4 5

Common electric arc welding processes CWB Group. Welding procedure guide. 2008

Flux Cored Arc Welding (FCAW)

Figure 3: Flux- cored arc welding

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Flux-cored-arc welding is a variation of metal-inert-gas welding where the electrode wire is replaced by a gas-shielded flux cored wire or self-shielded flux cored wire (an electrode wire with flux inside the wire). 7 The edges or surfaces of parts to be joined by welding is prepared by oxy-acetylene machine cutting. Where hand cutting is involved the edge is ground to a smooth surface. All surfaces and edges shall be free from all defects which would adversely affect the quality of the weld. All loose or thick scale, rust, moisture, grease or other foreign material that would prevent proper welding or produce objectionable fumes, are removed. The flux cored electrode is a continuous electrode that is fed into the arc where it is melted and transferred into the molten puddle. The process requires wire feed spools and cable. The rod is pushed through the center of the cable and through the welding gun. The flux cored process depends on a gas shield to protect the weld zone from detrimental atmospheric contamination. Figure 3 illustrates two primary ways this is accomplished. The gas shielding (often CO2), is either applied externally, in which case the electrode is referred to as a gas shielded flux cored electrode, or it is generated from the decomposition of gas forming ingredients contained in the electrode's core. The latter electrode is known as a self-shielding flux cored electrode. Cored electrodes are most commonly 1.6mm (1/16 inch) in diameter, although electrode diameters of 2.4 mm (3/32 inch) are also used. In

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addition to the gas shield, the flux cored electrode produces a slag covering for further protection of the weld metal as it cools. The slag is manually removed with a wire brush or chipping hammer.

Michigan Occupational Safety & Health Administration Consultation Education & Training Division. Onsite consultation abatement method advice for: arc welding process. 2005 7 CWB Group. Welding procedure guide. 2008

Submerged Arc Welding

Figure 4: Submerged arc welding

Submerged Arc Welding (SAW) is different from the previously explained arc welding processes in that the arc is not visible (figure 4). The arc is submerged beneath loose granular flux. A continuous electrode is fed by automatic drive rolls through an electrode holder where current is picked up at the contact tube. The electrode moves into the loose flux and the arc is initiated. The flux is deposited from a separate container that moves at the same pace as the electrode assuring complete coverage. The flux helps form the molten puddle, slows the cool air ingress, and acts as a protective shield. The flux, which is in close contact with the arc, is fused into a slag cover and that which is not fused is collected for reuse. The flux can contain alloying elements that, when molten, will pass into the weld metal affecting the metallurgy. Some fluxes are specifically prepared for their alloy altering capabilities while others, known as neutral fluxes, are chosen when a minimal alloy change is desired. Although these latter fluxes are called "neutral", they still have the ability to slightly alter the weld chemistry.

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Although there are hand-held welding guns for the submerged arc process, the majority of SAW is done with fully automatic equipment. The basic components include a wire feeder, a power source, a flux delivery system, and in some instances, an automatic flux recovery system. The gun is held parallel with the joint and 45 degrees of less from the vertical. The flux cone is lightly touched on the work piece while the arc area is adequately covered with flux.

Technical processes: submerged arc welding

Shielded Metal Arc Welding

Figure 5: Welding action of a cellulosic stick electrode

In arc welding, the source of heat is an electric arc. The temperatures reached in an electric arc may be as high as 5500C. An electric arc is a sustained spark created intentionally by a gap between welding electrode and the work piece. Because of larger heat output and less oxidation, the quality of weld produced by electric arc is much better than gas-weld. A flux coated electrode is being used for SMAW welding process also known as MMW or manual metal arc. 10Shielded arc welding is the most common of the five arc-welding processes. It is commonly referred to as stick welding or electric arc welding. Heat from an electric arc is maintained at the coated metal electrode ( 11 typically 2-6mm i.e. 3/32- in) and the

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work piece. Fusion of the base-metal ( 12principally nickel and ferrous base metals), the metal electrode and the coating is achieved as the heat exceeds the melting point of the electrode. The decomposition of the flux coating ( 10 with materials such as fluorides, oxides, carbonates, metal alloys, and binders to stabilize the arc) produces gases that shield the molten metal from the oxides and nitrides in the atmosphere as it is transferred across the arc (figure 5). Molten slag develops as a result of the chemical reactions which serve to shield the weld metal from the atmosphere during solidification. Surfaces to be welded is dry, clean and free from loose scale, oil or grease. The decking fitted tightly to the supporting member before welding begins. A chalk line will be used to locate welds over the supporting member. The welds will be circular, and have a minimum nugget diameter of 13 mm (1/2"). At least 87.5% of the circumference will be fully fused to the supporting member.
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Held at right angles to the decking, the electrode is lifted slowly, so that a gap of 23 mm between the tip of the electrode and the work piece is maintained. The arc is struck and a short arc maintained. Due to heat generated in the arc, the tip of the metal electrode starts melting and the gap increases. The electrode is slowly moved toward the work at the same rate at which the tip of the electrode is melting maintaining. If the gap increases too much the machine voltage will not be able to maintain the arc. A great amount of heat (and intense light) is generated by the arc. It not only melts the electrode tip, but also melts the work piece at the location of the arc maintaining a pool of molten metal as shown in Fig. 5. Simultaneously, the coating at the tip of the electrode vaporises and creates a gaseous shield around the molten metal. The electrode coating also contains flux (which reacts with impurities to form slag) and other ingredients which help stabilise the arc. All slag remaining shall be removed from the finished welds. For galvanized decking a coat of zinc rich primer shall be applied to the finished weld.

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9,10

11-13

Gupta, H. et al. Manufacturing processes. New Age International: New Dheli, 2009 Common electric arc welding processes

Arc Welding Defects

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Improper welding procedure and lack of skill on the part of welder may result in many welding defects. Four welding defects are described below: Porosity: Molten metal has a tendency to absorb gases. The entrapped gases cause porosity or blow holes in the weld bead. Remedy lies in cleaning the work piece surface of all oil, grease and paint etc. before welding and ensuring that electrode coating is free from dampness. If necessary, electrodes can be dried in an oven before use. Slag inclusion: Slag or other non-metallic inclusions that are entrapped in the weld bead. The most common reason for slag inclusion is that between two electrode runs, the slag, has not been completely removed by chipping and wirebrushing. Mitigation includes thoroughly wire brushing between passes. Undercut: Undercutting is often caused due to high amperage used. It denotes the melting away of the base metal at the line where the final layer of weld bead merges into the surface of the base metal. The undercut portion must be rectified by depositing weld metal on it. Cracking: Cracks can take place either in the weld bead itself (called hot cracks) or in the heat affected zone (cold cracks). Hot cracks may take place due to narrow deep welds and are caused due to shrinkage of weld metal, particularly if impurities like sulphur are present in the weld metal. Excessive joint restraint can also cause such cracks. Cold cracks occur due to inadequate ductility or presence of hydrogen

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in hardenable steels. Preheating and post heating of base material will help in avoiding cold cracks.

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Gupta, H. et al. Manufacturing processes. New Age International: New Dheli, 2009

References
CWB Group. Welding procedure guide. 2008 Common electric arc welding processes Gupta, H. et al. Manufacturing processes. New Age International: New Dheli, 2009 Michigan Occupational Safety & Health Administration Consultation Education & Training Division. Onsite consultation abatement method advice for: arc welding process. 2005 Technical processes: submerged arc welding