WELDING

Debasis Mitra
Inspection Department
Contents
1. Welding
1.1 Definition
1.2 Type of welding processes.
2. Welding processes used in HPL.
2.1 Shielded Metal Arc Welding ( SMAW )
2.2 Gas Tungsten Arc Welding ( GTAW )
3. Welding process variables : - Welding Technique.
4. Fillers & Electrodes.
5. Welding Defects


1. Welding
Welding is a localized fusion of metals
produced by heating to suitable
temperatures. Pressure and/or filler may
or may not be used. The filler material has
a melting point approximately the same or
below that of the base metals.
1.1 Definition :-
1.2 Type of welding processes :-

Shielded Metal Arc Welding ( SMAW )
Gas Tungsten Arc Welding ( GTAW )
Gas Metal Arc Welding. ( GMAW )
Submerged Arc Welding ( SAW )
Flux Cored Arc Welding ( FCAW )
Electroslag welding
etc

2. Welding processes mainly used in HPL

Shielded Metal Arc Welding ( SMAW )
Gas Tungsten Arc Welding ( GTAW )

Welding Process Basics : SMAW and GTAW
Advantage and limitation of GTAW & SMAW
SMAW Process variable : Controlling issues
GTAW Process variable : Controlling Issues

Shielded Metal Arc Welding ( SMAW ) or Stick
welding as commonly known as is an arc
welding process where coalescence is produced
by heating the workpiece with an electric arc set
up between a flux coated electrode and the
workpiece.

2.1 Shielded Metal Arc Welding ( SMAW )
SMAW Process
SMAW Process : Advantages
Uses an electrode rod that is quickly consumed ( high
deposition rate)
Uses equipment that is simple, inexpensive, and highly
portable,
Uses an electrode that provides and regulates its own
flux,
Provides all position flexibility,
Is less sensitive to wind or drafts,
SMAW Process : Limitations
Yields a weld with a variable quality and appearance
based on operator skill,
Not applicable for very thin section ( < 1.6 mm )
Weld appearance not as good as GTAW
Root Penetration is not as excellent as GTAW
Gas Tungsten Arc Welding process is an arc welding
process wherein coalescence is produced by heating the
job with an electric arc struck between a tungsten
electrode and the job.
2.2 Gas Tungsten Arc Welding
GTAW Process
GTAW Process : Advantages
Produces very high-quality, superior welds,
Is excellent for thin section
Welds can be made with or without filler metal,
Provides precise control of welding variables (i.e. heat),
Heat Flux and deposition rate can be independently controlled
Excellent Root Penetration
Welding yields low distortion,
Leaves no slag or splatter.
GTAW Process : Limitations
Slow Process . Weld deposition rate is very low .
Needs more set up than SMAW . Complex than SMAW
Needs welder skill better than needed for SMAW
More expensive . Not economical for section thickness > 10
mm
Sensitive to Windy / Drafty environment

3. Welding Process Variables
Type of Current ( Power Source )
Terminal connection
Size of Electrodes
Amperage
Shielding Gas
Shielding Gas flow
Welding Process Variables : Welding technique
Arc length
Travel Speed
Travel Angle
Welding Bead / Welding Technique
Type of Power ( Current )
AC : advantage
Cheaper Power source
No ARC blow
Better Slag cleaning action

Limitations
Arc instability
Not preferred for Overhead / Vertical position


Type of Power ( Current )
DC : advantage
Mostly used
Smoother arc
Produces uniform weld bead size
Is good for short arc technique
Preferred for Vertical and Over Head welding
Produces good wetting action

Limitations
Arc Blow
Terminal connection
For GTAW
DCSP ( DC straight polarity ) /
DCEN ( DC Electrode negative )

For SMAW
DCRP ( DC Reverse polarity ) /
DCEP ( DC Electrode Positive )



Electrode Size : Selection factors
Deposition Rate requirement
Joint design ( Bevel angle / Root opening )
Position ( Flat / Horizontal / Vertical / Overhead)
Pass

Amperage setting
Higher the amperage : Higher the deposition rate

But Excess amperage produces defects

Also too low amperage produces defects

Welding Procedure Specification (WPS)
Prepared as per ASME Sec IX
Contains Essential and Non-Essential
variables.
Fillers / Electrodes as per ASME Sec II
Part C.
4. Electrodes and fillers
Functional difference between

Electrode
E-

Filler
ER-

Electrode / Filler Specification designation
As per AWS ( American Welding Society ) .

E XXAB
E Electrode ER Filler
XX minimum tensile strength of weld metal in thousands of pounds per
sq.inch.
A indicates the welding position ( 1-> all , 2-> flat , 3-> horizontal , 4->
overhead )
B - Power supply, type of covering, type of arc, penetration characteristics,
etc.
Eg; E 6012 60000 psi 1 denotes all positions 2 High rutile sodium
silicate binder etc.
5. Welding Defects
Typical cracks in welding
Solidification crack
Thank You