WHAT IS ARC WELDING?

Arc Welding is the processes of joining metal together thru fusion which is done by the
electric Arc, by electrical current (Arc 1994). The most widely used type of Arc welding is
Shielded Metal Arc Welding or stick welding (Repp1994). The arc reaches temperatures
of around 6,000 degrees Celsius which is concentrated at the tip of the electrode
(Weldwell 2003).
The electrodes have a metal core surround by flux, which melts with the work piece
creating a fusion weld. The flux coating forms a gas and slag that shields the molting
metal pool.
This flux material is cleaned off once the weld has cooled with a wire brush. The weld
should be as strong or stronger then the metal that it is fusing together. Shielded Metal
Arc Welding is one of the most commonly used types of welding (Repp 1994). This is
because it is one of the easiest, and the equipment is inexpensive. The ease of portability
makes them very good for mobile welding.

Arc Welding Equipment

he equipment used in arc welding are as follows:
Welding machine as a converter to adjust the welding voltage
and current.
Electrode holder is insulated and used to hold the electrode.
Electrode is a metal rod with a layer of coating which is used to
allow the flow of electric current to form the electric arc.
Earthing which connects the base metal and the welding
machine power supply to prevent electric shock.
Electrode cable is an electrical connection between the electrode
holder and power supply.The cable is insulated with rubber.
Cleaning tools are used to chip and clean the traces of metal
spatters and slag produced on the surface of the welded metal.

Figure :Arc welding joint principle

Electric arc welding carried out by the flow of electricity from the electrodes on
the base metal and convert electrical energy into heat energy . Heat energy is
used to melt the electrode metal, additional metal or metal connectors are
finally done; producing a welded connection. Basically, the more electricity is
needed to reach a certain temperature to melt the metal in the short term.
Electricity supply from TNB is not suitable for welding works and does not have
an impact. Sometimes we use the power transformer to convert electricity
supply to the electric current are suitable for use in welding practice. Here are
two common types of electrical current used in welding work.
Alternating current ((a.c
a.c.).
.). A type of current that changed direction several
times in the flow of current. Alternating current is used to alter the strength and
direction 120 times within an hour or an alternating movement within 1 / 60
second. This current frequency of 60 hertz said. In other words, alternating
current with a frequency of 60 hertz would alter the strength and direction 60
times per second.
Direct current ((d.c
d.c).
). A type of current that has a fixed direction of the flow.
Remain in the current direction can only be changed by changing the cable
connection is used.

Principles of Arc Welding

An electrical arc occurs
when electrical current flows
from an electrode tip to the
surface of the metal to be
welded. This occurs when
the current carrying
electrodes in contact with
the metal to be welded, and
there is voltage between
them. The incident resulted
in a high heat in a clan
touch base metals and
consequently part of the
electrode tip melt. The
melting of the electrode tip
led to the formation of fine
metal balls which moved
into the puddles on the base
metal occurs through the
arc. This is called transfer of
metals.
Sometimes a liquid metal
that occurs is covered by a
protective gases resulting
from the melting of the
chemical coating of
electrodes and produced
from the burning of the
electrode coating.

Equipment and Accessories

Basic requirements for carrying out a welding supply electrons trick is to
appropriate voltage and current. The required voltage is between 20-100
volts while the current according ampere is between 100-1000. Therefore
clear that the power supply from TNB is not appropriate and safe to use for
welding work as too high. There are two types of arc welding machines.
Namely:
a) providing a direct current machine.
b) machine that provides alternating current.
Direct Current Welding Machine
There are two ways to obtain the
direct current used in welding
machines of this type is the set of
generators and welding equipment
router.
advantages
(A) Can be used to impose both core
and non core electrode.
(B) Welding produces a smoother and
is useful for welding thin sheet metal.
(C) More than safety.
Disadvantages
(A) the price is higher.
(B) Periodic maintenance should be
carried out on the type of generating
plant because there are moving parts.
c) Interference-interference from
'Arc blow'.

Alternating current Welding Machine

Alternating current supply for the welding
work is possible from a transformer Here the
main electricity supply to the power of 230250 volts down to a value of less than 100
volts by the converters. This transformer has
a flow control regulator that allows the
operator to choose the appropriate value of
current equal to the size of electrodes used.
In terms of efficiency and convenience,
alternating current equipment is superior.
Advantages only
(A) The price is cheaper.
(B) A little maintenance is required or may
not be needed immediately. This
is because there are no moving parts in the
transformer.
(C) Not applicable 'arc blow'.
(D) Can be used at any place.

Arc Welding Machine

Arc welding machine is a transformer where to change from a high voltage to low
voltage but high current yield for the issue of the use of arc welding. Equipped with
the electrode cable and earth cable to the desk.
Basic components in an arc welding machine
Is consists of:
transformers
Earth cable went
cable went electrodes
The electrode
Power supply
There are five types of welding machines. Namely:
- Type 'rectifier (DC)
- Type of transformer (AC)
AC / DC
- Type-driven engine. (petrol or diesel)
drives. (power)

- a combination of
- Type of electric motor

Type 'rectifier' (DC)

Arc welding machine type 'rectifier' (successor) is used because it has two options of current flow,
the reverse polarity direct current and direct current straight polarity. Positive source is connected
to the electrodes so it was the reverse polarity. Sources connected to the negative electrode
polarity, then it is straight. All types of welding work for most metals are well suited to this type of
machine. For the construction works and maintenance of machines of this type is the right choice.
Weaknesses:
- Generate 'spray arc' (arc blow)
- arc is not so stable against the type of power
- There is no option for the arc characteristics.
Types of alternating current.
Welding machines alternating current (AC) was used because it produces a more stable arc and no
valid 'arc spray' (arc blow) with the penetration of a simple and quiet.
Weaknesses:
- welding of certain metals and a limited use.
- Not all of the electrodes can be used.
- Able to operate at high ampere
Types of joint / combined AC / DC.
This type of machine can use both types of flows. It is necessary when welding certain metals with
certain currents. Has the widespread use. Can be used on many types of steel and welding position.
Weaknesses:
- the relatively high costs
- Valid 'arc spray' on some connections.

Drive Type petrol engine / diesel (DC or alternating current).

This machine can be used in areas with no electricity. Can supply either
alternating current or direct current.
Weaknesses:
- large capital and high maintenance
- Noise
- High Capital
- High maintenance costs
- Shot of the arc (arc blow)
- Requires fuel.
Types pacuan motor
This type of arc welding machines to produce a direct current. Producing direct
current two choices. That polarity direct and reverse polarity.
Weaknesses:
- There 'arc blow'.
- its maintenance is high. It uses carbon beberus
and should be changed at regular intervals

Polarity Arc Welding Machine

There are two types of polarity arc welding machine. Namely:
- Polarity Direct Current Back (cables installed on the source electrode positive)
- Direct Current Straight Polarity (lektrod cables attached to a negative source)
Characteristics of Polarity:
Features of the polarity of the DC polarity is reversed:
- The liquidity elekrod faster.
- Transparency in the shallow
- faster welding speeds are required.
Features of the polarity of direct current straight polarity is:
- The liquidity of the slow electrode
- Transparency of the
- The speed of the medium.

Effects of arc distance, angle, arc and speed of the results of the welding arc.
Arc distance
Arc distance is the distance between the tip of the metal core with the surface electrodes.
Where the arc is issued will be maintained at this distance. Arc distance is too high will cause
the molding is beautiful and also a lack of transparency. Arc distance is between 5.0mm to
6.0mm.
Arc Angle
Tilt angle formed between the electrodes to the surface in the direction of the electrode
bendakerja. The angle of the arc is not right will cause a ripple molding so elongated or oval
and make a way not beautiful moldings.
Arc Speed
Speed is the speed of movement of the arc electrode to move towards the end of the finish
welding. This speed is usually dependent on the liquidity of the electrodes.
Weld too fast to make too fine moldings and high and low transparency.
When we started the beginning of arc welding in place should make it free of paint and
materials that can impede the flow of electrical current. Rules adopted park is as if tapping
something slowly and can be issued when the arc is an arc distance should be kept at a
distance of 5.0mm to 6.0mm.
While scraping method, the electrodes in carek-carek on solid starting point as you scratch
matches. When the rising arc of the distance to be maintained as described above.

Spray arc
situation where
the rising arc
between the
electrode tip and
workpiece should
stray from the
path. Usually the
sound emitted
from the spray is
quite strong and
the size of the
normal arc also
may seem a little
large. This
happened
probably due to
its state
Earth clip position
is inaccurate.

Selection of a
welding machine
to be used
subject to the
following.
- Position Welding
- Type of metal to
be welded
- Type of
connection design
- The thickness of
the metal

Electrodes.
The electrode is functioning as a
metal additive in the arc welding
which is coated with a mixture of
a flux which comprises
of some particular type and have
different functions when
welding work done.
Electrode Production
Protective welding electrodes (SMAW)
is a fusion of the electrode coated
consumable (consumable), which
consists of various types depending
on the type of metal core and the
coating content of the electrodes. The
process of coating of flux in two ways,
namely how the extrusion (extrusion)
and how to dunk (dipping).

The electrode is a core wire that is surrounded by a type of flux. The core
metal and the flux vary depending upon what type of application it is being
used for. The flux around the core metal is used for many different
reasons. One reason is to protect the molten metal from the atmospheric
contaminates and gases that surround it. The second reason is that it helps
to control the current to flow thou the electrode to the work piece. The third
is that it helps remove oxygen from the welded metal with deoxidize. These
material are used for varying applications from raising the tensile strength of
the weld to de-oxidation. The core metal is also made of many different
metals depend upon the applications it is going to be used for. The
electrdes have a numbering system on them that look something like this
"E6011". The "E" in the code stands for the Electrode. The "60" in the code
stands for the tensile strength which is a minimum of 60,000psi. The "1" in
the code stands for the position the electrode is to be used in, the one in this
case stands for all welding positions. The last number in the code "1" stands
for the welding current either AC or DC.

Type of Coating Electrodes

Electrode coating mixture consisting of several
materials depending on the features of IRRIIRRI-use
electrodes. Among the materials are mixed in the
electrode coating is serbok iron oxideoxide-titania,
titania, sodium
silicate, potassium, asbestos, ferroferro-manganese.
Coating of the electrodes is divided into three:
ThinThin-coating (not coated)
MediumMedium-coating
-Coating thickness
Function Coating Electrodes
Function is a coating on the electrodes:
- Producing gas masks.
- Generate slag cap molding
- Stabilizing the arc
- Contains a mixture to use special features.
Coating of the electrodes can be categorized into
types:
- Rutile
- Cellulose
- Iron filings

Electrodes are classified into seven

groups, namely:
-

Soft Steel
Steel 'low alloy'
Stainless steel
Hardening surface
Nickel and nickel pancalogam
Aluminum and aluminum pancalogam
Copper and copper pancalogam

SLAG function.
Slag is a membrane that is the result of
melting molding surface coating of the
electrodes. The functions are:
- Protect the moldings from the outside
air during the cooling occurs.
- float the dirt to the surface of the
molten crater.
- Control of molding so that uniform.
- Slows down the rate of cooling to
improve the properties of metals
- Providing mechanical protection to the
transfer of metal from the electrode into
the base metal.