KCWONG 1

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW/MIG)
Flux-cored Arc Welding (FCAW)
Gas Tungsten Arc Welding (GTAW/TIG)

KCWONG 2
Working Principle
Equipment
Filler metals
Advantages
Limitation

KCWONG 3

KCWONG 4
 Can also
l beb called
ll d
Manual Metal Arc Welding
g
(MMAW) or (MMA)

KCWONG 5

Arc is established between

electrode and base metal
Heat is generated by the arc to
melt with electrode and base metal
Molten metal is protected by both
solidified slag and fumes
KCWONG 6
P
Power source, AC or DC
El t d holder
Electrode h ld
Can be AC
Protective helmet or DC

Other accessories

KCWONG 7

KCWONG 8
 AC or DC Power Source Electrode Holder
And Controls
Electrode

Arc

Workpiece Lead Work

Electrode Lead
KCWONG 9

Operation Electrode Arc Min. Suggested

Size (mm) Current Protective Shade No.
(A) Sh d
Shade
Shielded Less than 2.5 Less than 60 7 -
M t l Arc
Metal A
2.5 - 4 60 - 160 8 10
Welding
4 6.4
64 160 250 10 12

More than 6.4 250 - 550 11 14

KCWONG 10
Grinder

Electrode
Holder

Wire
Brush
Chipping
Hammer Welding
W ldi
KCWONG
Tong 11

National Standards (BS EN ISO)

BS EN 499 (Covered electrodes for

manual metal arc welding of non-alloyed
and fire grain steels)

EN ISO 2560:2005 ((Classification

f off
Welding Consumables for Covered
Electrodes for Manual Metal Arc (111)
Welding of Non-Alloy and Fine Grain
Steels)
Welding and Cutting Processes CASTCO 12
Supersede BS EN 499
Applies a dual approach to
classification of electrode using
g
methods A and B

Welding and Cutting Processes CASTCO 13

Welding and Cutting Processes CASTCO 14

 Welding and Cutting Processes CASTCO 15

National
N i lSStandards
d d (AWS)
AWS A5A5.11 (Specification for carbon
steel electrodes for shielded metal
arc welding)
ldi )
AWS A5.5
A5 5 (Specification for low
low-
alloy steel electrodes for shielded
metal arc welding)

Welding and Cutting Processes CASTCO 16

 E XXXX
E Electrode
XX - Tensile strength x 1000 (psi)
X - Welding position
1 - all position
2 - flat or horizontal fillet position
4 - down
d hill position
iti
KCWONG 17

X - coating characteristics
p
Chemical composition g,
of the coating,
current type, and operating
electrode
characteristic of the electrode.
Number can be from 0 to 8
For example, 5, 6, 8 are low hydrogen
electrode that required keeping in
sealed container or preheat prior
welding
ldi to
t eliminate
li i t moisture
i t l
level
l

KCWONG 18
Si l and
Simple d easy sett up
P t bl
Portable
Low cost equipment

KCWONG 19

Productivity relatively slow

Slag removal

KCWONG 20
Electrode (low hydrogen type) must be
appropriately
pp p y storage
g

KCWONG 21

Porosity
Arc blow
Spatter
Slag inclusion
Incomplete fusion

KCWONG 22
 Welding Electrode
Magnetic
M ti field
fi ld produced
d d
Around electrode
F
Forward
d Bl
Blow

Back Blow

Welding Direction

KCWONG 23

KCWONG 24
 Can also
l be called
ll d
Metal Inert Gas Welding
g
(MIG)

KCWONG 25

KCWONG 26
Heat is generated by arc (between filler
wire and work-piece) to melt and fuse
work-piece
rk pi c together
t th r
Mo t n metal
Molten m ta iss prot
protected
ct byy either
th r inert
n rt
or active gas (MAG)
S lid fill
Solid i iis continuously
filler wire ti l f d tto
fed
welding
g gun
g through g wire feedingg unit
Commonly employed as a semi-automatic
process
KCWONG 27

Power source (DC prefer)

Electrode wire feed unit
Control console
Shielding
hi ldi gas supply
l system
Welding gun
Water cooling system if necessary

KCWONG 28
 KCWONG 29

Wire Feeding Unit

KCWONG 30
Cable Assembly

KCWONG 31

Welding Gun

KCWONG 32
Some typical standards for specification
of steel wire are
BS EN 12534 (Welding consumables wire
electrodes, wires, rods and deposits for gas
shielded metal arc welding of high strength
steels Classification)
AWS A5.18 (Specification for carbon steel
filler m
f metals f
for Gas Shielded Arc Welding)
g)

A01T09-pp1-dt_ndt_II.ppt 33

ER XXS-X
XXS X
ER - Electrode Rod
XX - Tensile strength x 1000 (psi)
S - Solid
S lid Wi
Wire
X - Chemical Composition (2-7,
(2 7 G)

KCWONG 34
 Spray Transfer

Globular Transfer

Short Circuiting Transfer

Pulse Transfer

KCWONG 35

Hi h
Higher-current
tddensity
it and
d iis
considered
id d to
t be
b th
the h
hottest
tt t one
V
Very fine
fi d droplets
l t
B tf
Best for h
heavier
i section
ti material
t i l
G d for
Good f ffull
ll penetration
t ti weld
ld jjoint
i t

KCWONG 36
L
Less stable,
bl increase
i spatter
L ss heat
Less h t than
th spray
sp t sf mode
transfer m d
Droplets of filler wire is significantly
larger than spray transfer mode
Only
y on down hand position
p

KCWONG 37

The least amount of heating

Excellent for welding of sheet metal and
having excessive gap
Incomplete fusion (insufficient heat)
Allows for all position welding

KCWONG 38
Protect molten pool against atmosphere
Argon, Helium and their mixtures
CO2 or argon mixture are commonly used
for welding of carbon steel

KCWONG 39

C
Capable
bl of
f welding
ldi most alloys
ll
N slag
No sl to
t be
b removed
m d
Higher productivity
Lower labour cost

KCWONG 40
Less smoke generated,
generated improve workshop
environment
easily
y observe the action of molten puddle
p
to improve arc control
no flux contamination, lowest hydrogen
problems

KCWONG 41

Not suitable for field work

Complexity and high cost of equipment
Unstable w
wire
re feed due to worn lliner
ner and
contact tube
Easy to contaminate with working
environment

KCWONG 42
Porosity due to
Lack of shielding

contamination

Incomplete fusion

KCWONG 43

KCWONG 44
Very similar to GMAW
Tubular electrode (granular flux contains)
M l
Molten metall is
i covered
dbby a layer
l of
f flux
fl
as was the case for SMAW

KCWONG 45

KCWONG 46
May not need shielding gas depend on
the
h type of
f filler
f ll wire
S
Some fill
filler wire
i capable
bl of
f providing
idi
sufficient protection to the molten
pu f g
puddle and so called self-shielding

KCWONG 47

E XXT-X (AWS A5
A5.20)
20)
E - Electrode
X - Tensile strength x 10000 (psi)
X -Welding
g position
p
0 (flat or horizontal fillet position)
1 (all position)
T - Tubular Wire KCWONG 48
X - Chemical Composition and operating
characteristics , such as
Type
yp of current
Polarity

KCWONG 49

Similar
l to GMAW
G
Hi h current capacity
High i power source as
compared to GMAW
Lack of shielding gas supply system if
self-shielding is used

KCWONG 50
Suitable for field welding
Good performance on contaminated
surface
Higher deposition rate,
rate increase
p
productivity
y

KCWONG 51

Advantages
g

Well penetration
Less skill required for operator
compared with SMAW

KCWONG 52
Require slag removal
Fumes and gases hazards
Complexity in equipment set up as
d iincrease iinitial
GMAW and iti l costt

KCWONG 53

Slag inclusion

Porosity

Incomplete fusion

KCWONG 54
 KCWONG 55

Can also
l be called
ll d
Tungsten
g Inert Gas
Welding (TIG)

KCWONG 56
Non consumable electrode
Non-consumable
El t d iis made
Electrode d of
f pure or
alloyed
ll d tungsten
Arc is created between tungsten
electrode and work piece

KCWONG 57

Filler metal must be added manually or

b mechanical
by h i lf feed
d if necessary
Arc and molten metal is shielded by
using of inert gas
g is required
no slag q to remove

KCWONG 58
 W ldi
Welding direction
di ti
Gas Nozzle
Filler
Rod Tungsten Weld meta
Electrode Protective
Gas
Arc

KCWONG 59

P
Power source
s (AC and/or
d/ DC)
Control console
Shielding gas supply system
Welding
Weld ng torch
Water cooling
g system
y if necessary
y
Electrode wire feed unit if necessary

KCWONG 60
High frequency generator aids to
initiate welding
g arc especially
p y for
welding reactive material, such as
aluminum and magnesium
Remote control (foot pedal or some
devices mounted on the torch)

KCWONG 61

KCWONG 62
AWS Code Type Tip Colour
EWP P
Pure Tungsten
T t G
Green

EWCe-2
EWCe 2 1 8-2
1.8 2.2
2 % Ceria Orange

EWLa-1 1 % Lanthanum Oxide Black

EWTh-1 0.8 1.2 % Thoria Yellow

EWTh-2 1.7 2.2 % Thoria Red

EWZr 0.15 -0.4 % Zirconia Brown

KCWONG 63

Excellence for welding thin section

material
t i l
Usually used for welding root pass
Capable of welding most materials
Perform high quality and excellence visual
appearance
pp
KCWONG 64
No slag to be removed
Process is a clean and controllable
no filler metal is added if the joint
design is permitted

KCWONG 65

Tolerance for contamination is quite low,

High level required by the operator
Not suitable for windy situation
Low productivity as the process is too
slow

KCWONG 66
Porosity

p
Incomplete fusion

Tungsten inclusion

KCWONG 67

KCWONG 68