ARC WELDING

Arc welding (AW) is a fusion-welding process in which coalescence of the metals is achieved by
the heat of an electric arc between an electrode and the work
To initiate the arc in an AW process, the electrode is brought into contact with the work and
then quickly separated from it by a short distance
In most arc welding processes, filler metal is added during the operation to increase the volume
and strength of the weld joint
uses shielding gases

arc time (also called arc-on time)

o
Electrodes
o Two types :
Consumable electrodes
provide the source of the filler metal
Available in two principal forms: rods (also called sticks) and wire
E.g:
o carbon arc
o shielded metal arc or manual arc or stick welding
o submerged arc welding
arc shielding is provided by a cover of granular flux
The blanket of granular flux completely submerges the
welding operation, preventing sparks, spatter, and
radiation that are so hazardous in other AW processes.
Thus, the welding operator in SAW need not wear the
somewhat cumbersome faces shield required in the
other operations (safety glasses and protective gloves,
of course, are required)

o gas metal arc welding or MIG welding (metal inert gas welding)
shielding is accomplished by flooding the arc with a
gas(inert gases such as argon and helium)
Inert gases are used for welding aluminum alloys and
stainless steels
CO2 is commonly used for welding low and medium
carbon steels.
inert gases are expensive for steels
CO 2 was used as a substitute. Hence the term CO 2
welding was applied.
Mode of metal transfer is droplet
o electro -slag welding
Non consumable electrodes
made of tungsten
Any filler metal used in the operation must be supplied by means of a
separate wire that is fed into the weld pool.
Non- consumable electrode is gradually depleted during the welding
process (vaporization is the principal mechanism)

E.g
o gas tungsten arc welding or TIG
uses a non-consumable tungsten electrode
use inert gas for arc shielding
can also be used for joining various combinations of
dissimilar metals.
Common applications are for aluminum and stainless
steel
Cast irons, wrought irons, and of course tungsten are
difficult to weld by GTAW

o atomic hydrogen
o plasma arc
Arc Shielding
o At the high temperatures in arc welding, the metals being joined are Chemically reactive
to oxygen, nitrogen, and hydrogen in the air
o The mechanical properties of the weld joint can be seriously degraded by these
reactions
o Therefore arc shielding is provided
 o Arc shielding is accomplished by covering the electrode tip, arc, and molten weld pool
with a blanket of gas or flux, or both, which inhibit exposure of the weld metal to air.
o Common shielding gases include argon and helium, both of which are inert
o flux is a substance used to prevent the formation of oxides and other unwanted
contaminants, or to dissolve them and facilitate removal
During welding, the flux melts and becomes a liquid slag, covering the operation
and protecting the molten weld metal.
The slag hardens upon cooling and must be removed later by chipping or
brushing
additional functions:
provide a protective atmosphere for welding,
stabilize the arc,
Reduce spattering.
Add allowing elements
Power Source in Arc Welding
o Both direct current (DC) and alternating current (AC) are used in arc welding
o AC machines are less expensive to purchase and operate, but are generally restricted to
welding of ferrous metals
o DC equipment can be used on all metals with good results and is generally noted for
better arc control.
o when dc current is used w/p is made +ve terminal and electrode is made -ve terminal
and welding set up is said to be straight polarity
if w/p is made negative and electrode positive the setup is said to be have
reverse polarity
straight polarity result in more heat generation at w/p which result in greater
penetration
due to lower heat generation at electrode ,melting rate of electrode
reduces causing low deposition rate
o when ac current is used it combines both straight and reverse polarities
power balance in arc welding

o
o E=voltage, V
o I=current, A
o Aw = thickness*distance b/w the plates mm2

AW PROCESSESCONSUMABLE ELECTRODES
o Shielded Metal Arc Welding or manual arc or stick welding (constant current
characteristics)
o Gas Metal Arc Welding or metal inert gas (MIG)
 o Flux-Cored Arc Welding
o Electro gas Welding
o Submerged Arc Welding
AW PROCESSESNONCONSUMABLE ELECTRODES
o Gas Tungsten Arc Welding or TIG (Tungsten Inert Gas )
o Plasma Arc Welding
Heat Transfer in Arc Welding.

o
o H is the heat input J
o I is the Weld length, mm
o V is the voltage applied V
o I is the current (amperes)
o is the welding speed. mm/s
o e is the efficiency of the process
75% for shielded metal-arc welding
90% for gas metal-arc welding and submerged-arc Welding.
o welding speed:

u is the specific energy required for melting,

o
o
V-I characteristic of welding power source
o two kind of operating characteristic:
static
dynamic

o
o V=arc voltage V
o I=arc current amp
 o Power =VI
o Arc current 1/arc length (inversely proportional)
dP/dI=0 gives the max power for give current I where
if question say arc length varies from 1-2 mm and current varies from 200-250 A
o then 250 will correspond to 1
o ad 200 will corresponds to 2
o remember I is inversely proportional to arc length