TOPIC of PRESENTATION

WELDING,
ELECTRODES TYPES AND
APPLICATION PROCEDURES,
WELDING DEFECTS

PRESENTED BY
KHURRAM ILYAS
AM (MECHANICAL)

PRESENTATION CONTENTS

Welding & Uses

Types & Processes of Welding
Welding Symbols & Joints
Classification of Electrodes
Types & Applications of Electrodes
Welding Defects
Safety & Working Conditions

WELDING
Welding is joining two pieces of
metal by:
Heating to temperature high enough
to cause softening or melting
With or without application of pressure
With or without use of filler metal

Uses
Welding is used for making permanent
joints.
It is used in the manufacture of automobile
bodies, aircraft frames, railway wagons,
machine frames, structural works, tanks,

Ship Structures

Weldability of a Metal
Mechanical Soundness
Joint will be free from discontinuities,
gas porosity, shrinkage, slag, or cracks
Serviceability
Weld is able to perform under varying
conditions or service (e.g., extreme
temperatures, corrosive environments,
fatigue, high pressures, etc.)

Weld Fluxes
Typical fluxes
SiO2, TiO2, FeO, MgO, Al2O3
Produces a gaseous shield to prevent
contamination
Influence shape of weld bead during
solidification

Types of Welding
Fusion Welding

Homogeneous

Gas Welding
Electroslag
High Energy Beam
Electric Arc

Pressure Welding

Heterogeneous
Brazing

Soldering

MIG
TIG
Shielded Metal Arc Stick

Classification of welding
processes:
(i) Arc welding
Carbon arc
Metal arc
Metal inert gas
Tungsten inert gas
Plasma arc
Submerged arc
Electro-slag
(ii) Gas Welding

Oxy-acetylene

(iii) Resistance Welding

Butt
Spot
Seam
(iv) Related Process
Oxy-acetylene cutting
Hard facing
Brazing
Soldering

TYPES
Plastic Welding or Pressure Welding:
The piece of metal to be joined are heated to a plastic state
and forced together by external pressure.
Example: Resistance welding
Fusion Welding or Non-Pressure Welding:
The material at the joint is heated to a molten state and
allowed to solidify.
Filler metal may be added.
Heat is supplied by various means

Electric Arc
Oxyacetylene gas
Plasma Arc
Laser

Example: Gas welding, Arc welding

Types of Fusion Welding

Shielded Metal Arc (Stick)

Metal Inert Gas (MIG)
Tungsten Inert Gas (TIG)
Oxyacetylene Cutting/Welding

Arc welding
Equipments:

A welding generator (D.C.) or Transformer (A.C.)

Two cables- one for work and one for electrode
Electrode holder
Electrode
Protective shield
Gloves
Wire brush
Chipping hammer
Goggles

Arc Welding
Uses an electric
arc to combine
metals
Arc welding is the
most common
method of welding
metals
Electricity travels
from electrode to
base metal to

Electric Arc Welding -- Polarity

SMAW - DC Polarity
Straight Polarity

Reverse Polarity

()

(+)

(+)

()

Shallow penetration
(thin metal)

Deeper weld penetration

AC - Gives pulsing arc

- used for welding thick sections

Arc Welding Equipments

Shielded Metal Arc (Stick)

An electric arc is generated between a
coated electrode and the parent metal
The coated electrode carries the electric
current to form the arc and provides filler
metal for the weld bead
Electric current may be AC or DC. If the
current is DC, the polarity will affect the
weld size and application

Shielded Metal Arc (cont)

Process:

Intense heat at the arc melts the tip of the

electrode
Tiny drops of metal enter the arc stream and
are deposited on the parent metal
As molten metal is deposited, a slag forms over
the bead which serves as an insulation against
air contaminants during cooling
After a weld pass is allowed the cool, the
oxide layer is removed by a chipping hammer
and then cleaned with a wire brush before the
next pass.

Metal Inert Gas (MIG)

Uses a consumable electrode (filler wire made of the
base metal)
Inert gas is typically Argon

CONSUMABL
E ELECTRODE

DRIVE WHEELS

POWER
SOURC
E

Gas Metal Arc Welding Torch

SHIELDING GAS

BASE METAL

ARC COLUMN

PUDDLE

Tungsten Inert Gas (TIG)

Tungsten electrode acts as a cathode
A plasma is produced between the tungsten
cathode and the base metal which heats the base
metal to its melting point
Filler metal can be added to the weld pool
TUNGSTEN
ELECTRODE
POWER
SOURC
E

TUNGSTEN
ELECTRODE

(CATHODE)

++ ++
SHIELDING GAS

BASE METAL

ARC COLUMN

PUDDLE

--BASE METAL (ANODE)

Arc welding
Advantages
Most efficient way
to join metals
Lowest-cost joining
method
Joins all commercial
metals

Limitations
Manually applied,
therefore high labor
cost.
Need high energy
causing danger
Defects are hard to
detect at joints.

Comparison of A.C. and D.C. arc

welding
Alternating Current (from Transformer)

More efficiency
Power consumption less
Cost of equipment is less
Higher voltage hence not safe
Not suitable for welding non ferrous metals
Not preferred for welding thin sections
Any terminal can be connected to the work or
electrode

Comparison of A.C. and D.C. arc

welding
Direct Current (from Generator)

Less efficiency
Power consumption more
Cost of equipment is more
Low voltage safer operation
suitable for both ferrous non ferrous metals
preferred for welding thin sections
Positive terminal connected to the work
Negative terminal connected to the electrode

GAS WELDING
Sound weld is obtained by selecting proper size of flame,
filler material and method of moving torch
The temperature generated during the process is 3300 0c
When the metal is fused, oxygen from the atmosphere and
the torch combines with molten metal and forms oxides,
results defective weld
Fluxes are added to the welded metal to remove oxides
Common fluxes used are made of sodium, potassium.
Lithium and borax.
Flux can be applied as paste, powder, liquid, solid coating
or gas.

GAS WELDING EQUIPMENT...

1.

Gas Cylinders

Pressure
Oxygen 125 kg/cm2
Acetylene 16 kg/cm2

2.

Regulators

Working pressure of oxygen 1 kg/cm2

Working pressure of acetylene 0.15 kg/cm2
Working pressure varies depends upon the thickness of
the work pieces welded.

Pressure Gauges
4. Hoses
5. Welding torch
6. Check valve
7. Non return valve
3.

Oxyacetylene Welding
Flame formed by burning a mix of
acetylene (C2H2) and oxygen
TORCH TIP

Inner Cone: 50006300 deg F

2300 deg F
Combustion Envelope
3800 deg F

Fusion of metal is achieved by passing

the inner cone of the flame over the
metal
Oxyacetylene can also be used for
cutting metals

Oxy-Acetylene welding

Welding Positions
INCREASING DIFFICULTY

FLAT
HORIZONTAL
VERTICAL

OVERHEAD

Welding Positions
Overhead
Vertical

1 - 28

Generalized Welding Symbol

Weld Depth (usually equal to plate

thickness)

Example Welding Symbol

Geometry symbol for V-groove

One-sided welds are max 80% efficient

Two sided are 100% efficient
1/2
1/2

1/2
1/2

Joint Design

BUTT JOINT
FILLET JOINT
STRAP JOINT

LAP JOINT

CORNER JOINT

Weld Symbols (Butt Joints)

Backing

Weld Symbol (Fillet Joints)

Weld Symbol (Corner

Joints)

WELDING ELECTRODE CLASSIFICATIONS

MILD STEEL COATED ELECTRODES
E 7018
E : Indicates that this is an electrode
70 : Indicates how strong this electrode is when welded.
(Measured in thousands of pounds per square inch)
1 : Indicates in what welding positions it can be used.
8 : Indicates the coating, penetration, and current type used.
WELDING POSITIONS
1 Flat, Horizontal, Vertical (up), Overhead
2 Flat, Horizontal
4 Flat, Horizontal, Overhead, Vertical (down)
Flat Position usually groove welds, fillet welds only if welded like a V
Horizontal Fillet welds, welds on walls (travel is from side to side).
Vertical welds on walls (travel is either up or down).
Overhead weld that needs to be done upside down.
6013 = General purpose electrode, Best Finish, Low Penetration.
7018 = Structural Steel, Good Finish, High Penetration, Good positional electrode, high
strength deposit, high efficiency.

WELDING ELECTRODE CLASSIFICATIONS

Class
E60xx
E70xx
E80xx

Min. Tensile Strength Min. Yield Strength

62,000 psi 50,000 psi
70,000 psi 57,000 psi
80,000 psi 67,000 psi

6013 = Best Finish, Low Penetration, General purpose electrode.

7018 = Good Finish, High Penetration, Good positional electrode, high strength deposit, high efficiency
CHEMICAL SYMBOLS FOR THE ELEMENTS
C Carbon Most effective hardening element in steel
Mn Manganese Hardening element second to carbon
Si Silicon Deoxidizer, moderate strengthener
P Phosphorus Causes cracking if too high
S Sulfur Aids in machining - Cracking problems like P
Cr Chromium Hardness (low) - corrosion resistance (high)
Ni Nickel Hardening element - better cold toughness
Mo Molybdenum Hardenability - high temp tensile - creep strength
B Boron Very small amounts increase hardness
Cu Copper Corrosion resistance (low) - cracking (high)
Al Aluminum Deoxidizer - improves mechanical properties
Ti Titanium Removes: Oxygen, S, N, and C
N Nitrogen Improves strength - lowers toughness
Cb Columbium Hardness - Improves mechanical properties
V Vanadium Hardness - Improves mechanical properties

DESCRIPTION &
APPLICATION OF
DIFFERENT TYPES OF
ELECTRODES

Cutting Electordes (Cito cut-CG100)

AC or DC DESCRIPTION and APPLICATIONS:

For rapid arc-cutting of all kinds of steels, cast iron, armor plated and non-ferrous
metals,
Cutting is conveniently used in piercing (used to cut a hole at the centre of the
plate or away from the edge of the plate), gouging (to cut a groove into the steel
surface) and cutting operations on difficult to machine metals and alloys, air and
deep-hardening steels, hard overlay materials and metals which are difficult or
impossible to cut with a torch; e.g., cast iron, stainless steels, armor plates.
CURRENT SETTING
Thickness of Material Diameter Amperage
mm
A
Up to 25 mm 3.2 1/8 150-200
6.0-50.0 mm 4.0 5/32 180-250
50.0 mm & above 5.0 3/16 200-300

E7018

DESCRIPTION:

A specially formulated moisture resistant basic coated electrode for highest quality
weld. Can also be used for high carbon and sulfur steels, besides mild steel, without
danger of underbead cracking. Arc is quiet and stable with sufficient penetration to reach
corner of joints. High ductility makes it most suitable for welding thick and heavy
sections. Presence of iron powder in the coating gives high deposition efficiency and
high welding speed.
APPLICATIONS:

Shipbuilding, bridges, heavy construction work, cast steels, low alloy, high tensile steels,
pressure vessels, truck chassis, high carbon steels, sulfur bearing steels, welds which are
subjected to x-ray inspection, etc.
TYPICAL ANALYSIS OF ALL WELD DEPOSIT %
Carbon Manganese Silicon Sulfur Phosphorus
0.05 0.7 0.4 0.025 0.025
TYPICAL MECHANICAL PROPERTIES OF ALL-WELD DEPOSIT:
Tensile Strength, MPa 490-530
Yield Strength, MPa 420-470
RECOMMENDED CURRENT:
Diameter
mm Amperage
2.5 70-90
3.2 100-130
4.0 140-180

ELECTRODE 308

Description
Welding of 18-8 austenitic stainless steels for chemical apparatus, containers and
plants. Slag is easy to detach and arc is stable, less spatter loss and bead
appearance is beautiful.
Guideline in Usage
1. Electrodes should be redried at 250 to 300C for one hour before use.
2. Excessively wide weaving may cause welding defects. Keep weaving width tol ess
than 2.5 times electrode diameter.
3. Remove dirt such as oil and dust from the groove.
Welding Parameters
Size
2.0mm
2.6mm
3.2mm
4.0mm
5.0mm
Length
250mm 300mm 350mm 350mm 350mm
Current (Amp)
F, Fillet
30-50
60-85
85-120
115-150 150-190
V, OH
30-50
50-70
75-105
95-130

Typical Chemistry (wt%)

Carbon
0.05
Silicon
0.80
Manganese
0.77
Chromium
19.1
Nickel
9.7
Molybdenum 0.11
Sulphur 0.006
Phosphorus
0.01

Typical Mechanical Properties

Tensile Strength
590 N/mm2
Elongation
43

ELECTRODE 309

Description
G309 is a lime-Titania type electrode. Weld ability is excellent. Spatters are less and
crack resistance is good. Welding of dissimilar metals such as stainless steel 309S,
304 to carbon steel or low alloy steel.
Guideline in Usage
1 Preheat is unnecessary.
2. Keep the short arc and low amperage. Weaving width should be within 2.5 times
electrode diameter.
3. Electrodes should be redried at 250 to 300C for one hour before use.
4. Remove dirt such as oil and dust from the groove.
Welding Parameters
Diameter (mm)
Length (mm)
300
Current(Amp)
F
V,OH

2.6 3.2
350 350
60 85
50 75

4.0 5.0
350
85 120 115 150
75 105 95 120

Typical Chemical Composition of Weld Metal

C
Si
Mn P
S
Ni
Cr Mo
0.05 0.84 0.91 0.020
0.004
13.1 23.9 0.050
Typical Mechanical Properties of Weld Metal
Tensile Strength
Elongation
N/mm2

655
41

150 200

Weld Defects &

Discontinuities

Weld Defects
Undercuts/Overlaps

Grain Growth
A wide T will exist between base metal and HAZ.
Preheating and cooling methods will affect the
brittleness of the metal in this region

Blowholes
Are cavities caused by gas entrapment during the
solidification of the weld puddle. Prevented by proper
weld technique (even temperature and speed)

Weld Defects
Inclusions
Impurities or foreign substances which are forced into the weld
puddle during the welding process. Has the same effect as a
crack. Prevented by proper technique/cleanliness.

Segregation
Condition where some regions of the metal are enriched with
an alloy ingredient and others arent. Can be prevented by
proper heat treatment and cooling.

Porosity
The formation of tiny pinholes generated by atmospheric
contamination. Prevented by keeping a protective shield over
the molten weld puddle.

Residual Stresses
Rapid heating and cooling results in thermal
stresses harmful to joint strength.
Prevention

Preheating reduces expansion/contraction forces

(alloys) and removes moisture from the surface
Heat Treatment soak the metal at a high
temperature to relieve stresses
Jigs and Fixtures prevent distortion by holding
metal fixed

UNDERCUT

Crater Pipe

Excess Penetration Bead

Excess Weld Metal

Excessive Penetration Bead

HAZ Hydrogen Cracking

Incomplete Fusion

Incomplete Fusion

Incomplete Root Penetration

Laminellar Tearing

Linear Inclusions

Linear Misalignment

OVERLAP

OverLap

POROSITY

Reheat cracking

Root Concavity

Solidification Cracking

SPATTER

Stray Arcing

UnderCut

Weld Metal Hydrogen Cracking

INCOMPLETE FUSION

UNDERFILL

EXCESSIVE CONVEXITY

EXCESSIVE CONCAVITY

EXCESSIVE WELD
REINFORCEMENT

INCOMPLETE PENETRATION
&
EXCESSIVE PENETRATION

UNACCEPTABLE
WELD PROFILES

Safety and Working

Conditions
Noisy
Hearing protection
needed

Awkward positions
Spacious
surroundings or
cramped quarters
High off ground in
scaffolds with safety
harness

1 - 75

Job Hazards
Fire danger
Burns (including "sunburn" from
electric arcs)
Noxious fumes from materials
vaporized at high
temperatures
Hazards
can be minimized
Eyestrain
or eliminated by use
of proper protective
Welders flash
clothing and equipment.
Electric shock
1 - 76

Thank you!