Welding Processes 9

basic electrodes, where metal transfer causes short circuit, the dynamic short circuit
current has to be limited to avoid evaporation and blowing apart of the drop. The
weight of the weld metal deposited per unit time is proportional to the current
intensity. The electrodes are thoroughly dried or baked after production, bacause
moisture will cause an unstable arc, heavy spatter and porosity in the weld metal.
The coating of the electrode has got several functions :
(a) Electrode material burns off faster than the coating flux that forms a crucible
and this shields the arc from the atmosphere.
(b) Flux removes the impurities from the molten metal.
(c) A gaseous envelope developed by the decomposition of the ingredients of
the flux covers the molten weld pool, thereby protecting it from atmospheric
contact.
(d) During cooling, the slag formed on the top of the weld metal acts as a
protective cover against contamination by the atmosphere.
(e) It provides alloy addition to the weld metal.
Flux also (a) helps to start and maintain the arc, (b) helps to deoxidise and
refine the weld metal, (c) helps to control the weld bead profile and reduce the
weld spatter, (d) helps to control viscosity of the slag so that vertical and overhead
welding is made possible. Arc voltage and current intensity, thermal energy and
mode of metal transfer are controlled by the coating.
The electric power source can be AC transformer or DC generator. Carbon
steels from 3 mm to 60 mm can be welded easily with work piece as one polarity.
Power sources of constant current type having drooping characteristics are used
for MMAW process. Power sources of the constant voltage type are not suitable.
The heat developed by the arc is given by
W (joules) = V (volt) × A (amps) × t (sec)
If the arc is travelling at a speed of S mm/minute, the heat input rate (HIR) of
the arc will be
HIR = V × A × 60/S Joules/mm length of the joint.
Though AC or DC power source can be successfully used, DC power source is
suitable for all types of electrodes. With AC source some non-ferrous type and a
low hydrogen ferritic type electrodes may not give a stable arc. Both starting and
maintaining a short arc will be easier with DC power. Vertical and overhead welding
on thick sections will be easier with DC. In DC straight polarity (i.e. electrode
negative) can be used for MMAW of all steels; but not for non-ferrous metals.
With straight polarity, more of the arc heat is concentrated on the electrode and
consequently melting and deposition rates are higher, welding is more rapid and
the workd piece is less susceptible to distortion. Reverse polarity (electrode positive)
is used with basic low hydrogen electrodes and for most non-ferrous metals. For
sheet metal welding, D.C. straight polarity minimises burn-through problems
because of its shallow penetration. D.C. however, can cause problems of arc blow,
specially so when welding ends of joints, corners etc. A.C. does not present such
problems.