Metal Joining and Cutting Processes

Module 3 - 1
Module 3
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Metal Joining
and
Cutting
Processes
W
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o c i e t y
Welding Process
Knowledge A Benefit to Inspectors
Module 3 - 2
Helps spot problems

Leads to better inspection
Gains respect of welders
Gains cooperation
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WIT Coverage of Welding

Processes
Module 3 - 3
Advantages
Limitations
Equipment
Filler Metals
Techniques
Problems
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Module 3 - 4
3 Basic Process Groups

Welding
Brazing
Cutting
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Module 3 - 5
Weldment
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Module 3 - 6
Common Features of
Welding Processes
Source of energy
Source of shielding
Filler metal (optional)
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Module 3 - 7
Shielded Metal
Arc Welding
(SMAW)
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Module 3 - 8
SMAW
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Module 3 - 9
EXXXX
SMAW Electrode Identification System
Electrode
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Module 3 - 10
EXXXX
Strength
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Module 3 - 11
EXXXX
Position
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Module 3 - 12
Position Description
1 - used in all positions
2 - used in flat or horizontal fillets
only
3 - not used at present time
4 - used for downhill progression
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Module 3 - 13
EXXXX
Coating/Operating Characteristics
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Electrode Coating
Classification
Module 3 - 14
F #s
F1
F2
F3
F4
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EXX20, EXX24, EXX27

EXXX2, EXXX3, EXXX4
EXX10, EXXX1
EXXX5, EXXX6, EXXX8
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Module 3 - 15
Low Hydrogen Electrodes

Types end in a 5, 6, or 8
Purchase in sealed, metal
containers
Store after opening in heated,
vented oven
Limit atmospheric exposure
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Electrode Suffixes - 1 of
2
Module 3 - 16
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Electrode Suffixes - 2 of
2
Module 3 - 17
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Module 3 - 18
Stainless Steel Electrodes

E308, E308L - Weld 304 and 304L
E316, E316L - Weld 316 and 316L
E309 - Weld Stainless to Carbon
Steel
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SMAW Equipment
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Module 3 - 19
o c i e t y
Module 3 - 20
Constant
Current
Power
Source
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Module 3 - 21
Constant Current
As arc voltage, V, drops, arc current, A, rises

Arc V related to distance from electrode to work
Electrode moved closer, Arc V falls, Arc A rises
Electrode moved away, Arc V rises, Arc A drops
Arc current directly related to heat input
Welder controls heat input to work
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Module 3 - 22
SMAW Advantages
Simple equipment
Inexpensive
Very portable
Welds most alloys
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Module 3 - 23
SMAW Limitations
Relatively slow
Slag removal
Electrode storage considerations
Arc blow- solutions noted in text
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Module 3 - 24
Magnetic
Aspects of
Current Flow
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Module 3 - 25
Arc Blow
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Module 3 - 26
SMAW Discontinuities
Porosity
Slag inclusions
Spatter
Incomplete joint penetration
Incomplete fusion
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Module 3 - 27
Gas Metal Arc Welding (GMAW)
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Module 3 - 28
GMAW Schematic
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Module 3 - 29
ERXXSX
GMAW Electrode Identification System
Electrode
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Module 3 - 30
ERXXSX
Rod
(Designation used also for GTAW filler)
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Module 3 - 31
ERXXSX
Strength
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Module 3 - 32
ERXXSX
Solid Wire
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Module 3 - 33
ERXXSX
Chemical Composition
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Module 3 - 34
GMAW
Equipment
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Module 3 - 35
GMAW Nomenclature
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Constant Potential Power

Source
Module 3 - 36
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Module 3 - 37
Constant Potential Source

Is self-regulating (maintains
constant arc length)
Reduces effect of vertical
movement of gun
Less operator sensitive
Somewhat easier to learn
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Module 3 - 38
GMAW Modes
of Transfer - 1
of 4
Spra
y
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Module 3 - 39
GMAW Modes of
Transfer - 2 of 4
Globul
ar
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GMAW Modes of Transfer

- 3 of 4
Module 3 - 40
Pulsed Arc
The welding current is variable; it is
pulsed between high and low current
cycles set by the welder
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GMAW Modes of Transfer

- 4 of 4
Short-Circuiting Transfer
Module 3 - 41
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Module 3 - 42
Factors for Transfer Modes

Shielding gas
Current level
Voltage level
Power supply
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Module 3 - 43
GMAW Advantages
Semiautomatic process
High productivity
No slag to remove
Clean process
Continuous filler metal feed
Welds most alloys
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Module 3 - 44
GMAW Limitations
Unsuitable for windy conditions
Little tolerance for contamination
Usually limited to shop welding
Equipment is more complex
Consumables - liners, contact tips
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Module 3 - 45
GMAW Discontinuities
Porosity
Incomplete fusion
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Module 3 - 46
Flux Cored
Arc Welding
(FCAW)
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Self-shielded FCAW
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Module 3 - 47
o c i e t y
FCAW Guns - Gas & Selfshielded
Module 3 - 48
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Module 3 - 49
EXXT-X
FCAW Electrode Identification System
Electrode
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Module 3 - 50
EXXT-X
Strength
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Module 3 - 51
EXXT-X
Position
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Module 3 - 52
EXXT-X
Tubular
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Module 3 - 53
EXXT-X
Chemical Composition
Operating Characteristics
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Module 3 - 54
Stainless Steel Electrodes

E308T-X E308LT-X E316T-X E316LT-X E309T-X
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Welding 304
Welding 304L
Welding 316
Welding 316L
Welding SS to CS
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Module 3 - 55
Gasshielded
FCAW
Equipment
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Module 3 - 56
Selfshielded
FCAW
Equipment
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Module 3 - 57
FCAW Advantages
High productivity
Deep penetration
Tolerates contamination
Suitable for field work
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Module 3 - 58
FCAW Limitations
Slag removal
Smoky process
Electrode cost
Equipment complexity
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Module 3 - 59
FCAW Discontinuities
Slag inclusions
Porosity
Incomplete fusion
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Module 3 - 60
Gas
Tungsten
Arc
Welding
(GTAW)
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GTAW Nomenclature
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Module 3 - 61
o c i e t y
Module 3 - 62
AWS Tungsten Electrode

Classifications
Class
EWP
EWCe-2
EWLa-1
EWTh-1
EWTh-2
EWZr
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Alloy
Pure tungsten
1.8-2.2% ceria
1% lanthanum oxide
0.8%-1.2% thoria
1.7-2.2% thoria
0.15-0.40% zirconia
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Color
Green
Orange
Black
Yellow
Red
Brown
o c i e t y
Module 3 - 63
GTAW Filler Metals

Carbon Steels
ER70S-2, ER70S-3, etc.
Stainless Steels
ER308, ER308L, ER316, etc.
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Module 3 - 64
Effect of DCEN
Current on
GTAW
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Module 3 - 65
Effect of DCEP
Current on
GTAW
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Module 3 - 66
Effect of AC
Current on
GTAW
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Module 3 - 67
Gas Tungsten
Arc Welding
Equipment
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Module 3 - 68
GTAW Advantages
Good for thin materials
High quality welds
Good appearance
Very clean
No slag
Mechanization potential
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Module 3 - 69
GTAW Limitations
Relatively slow
Low tolerance for contamination
Shielding gas expensive
Purging gas expensive
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Module 3 - 70
GTAW Discontinuities
Porosity
Incomplete fusion
Tungsten inclusions
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Causes of Tungsten
Inclusions
Module 3 - 71
Contact between:
Tungsten and base metal
Tungsten and filler metal
Excess current
Excess tungsten extension
Improper tungsten tip grinding
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Module 3 - 72
Submerge
d Arc
Welding
(SAW)
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Module 3 - 73
SAW
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FXXX-EXX
X
SAW Filler Metal Identification System
Module 3 - 74
Flux
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FXXX-EXX
X
Module 3 - 75
Tensile Strength
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FXXX-EXX
X
Module 3 - 76
Heat Treatment
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FXXX-EXX
X
Module 3 - 77
Impact Test Temperature
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FXXX-EXX
X
Module 3 - 78
Electrode
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FXXX-EXX
X
Module 3 - 79
Electrode Classification
(Low, Medium, High - Mn%)
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FXXX-EXX
X
Module 3 - 80
Electrode Classification
(8 through 16 for chemistry)
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Module 3 - 81
F7A6-EM12K
SAW Filler Metal Example
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Module 3 - 82
SAW
Equipment
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Module 3 - 83
SAW Advantages
High deposition rate
Deep penetration
Mechanized process
Hand-held process
Good for overlay of large areas
High operator appeal
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Module 3 - 84
SAW Limitations
Flat or horizontal fillets only
Extensive setup time
Needs positioning equipment
Arc not visible to operator
Slag removal
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Module 3 - 85
SAW Discontinuities
Groove alignment
Slag inclusions
Porosity
Incomplete fusion
Cracking (W/D ratio)
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Module 3 - 86
Width vs Depth Ratio

Crack
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Module 3 - 87
Plasma Arc
Welding
(PAW)
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Plasma Arc Welding
Module 3 - 88
Bare
Rod
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Transferred vs
Nontransferred Arc
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Module 3 - 89
o c i e t y
Module 3 - 90
PAW Advantages
Intense arc
Deep penetration
Clean process
Keyhole welding
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Module 3 - 91
Keyhole
Welding
Technique
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Module 3 - 92
PAW Limitations
Shielding by gas only
Low tolerance for contamination
Complex equipment setup
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Module 3 - 93
PAW Discontinuities
Tungsten inclusions
Copper inclusions
Tunneling - keyhole
Incomplete fusion
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Module 3 - 94
Electroslag Welding (ESW)
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Module 3 - 95
Electrosla
g Welding
Equipment
---Conventio
nal
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Module 3 - 96
Electroslag
Welding
Equipment
--Consumable
Guide
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Module 3 - 97
ESW Advantages
Joins heavy sections
High deposition rates
Single or multiple electrodes
Minimum joint preparation
Low distortion
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Module 3 - 98
ESW Limitations
Vertical casting process
Very extensive setup time
Uses water-cooled shoes
Flux storage
Largely confined to vertical
orientation and flat position only
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Module 3 - 99
ESW Discontinuities
Gross porosity
Slag inclusions
Large grains
Gross shrinkage
Cracks
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Module 3 - 100
Oxyacetylene
Welding (OAW)
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Module 3 - 101
Oxyacetylene Welding
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Module 3 - 102
OAW
Equipment
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Module 3 - 103
OAW Filler Metals

RG RG -
45
60
R refers to rod
G refers to gas
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Module 3 - 104
OAW Advantages
Simple equipment
Suitable for thin materials
Very portable
No electricity required
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Module 3 - 105
OAW Limitations
Very slow process
Manual only
Less concentrated heat
Low productivity
Flame adjustment sensitive
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Module 3 - 106
OAW Discontinuities
Severe oxidation, or
Severe carburization
Incomplete fusion
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Module 3 - 107
Stud Welding
(SW)
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Module 3 - 108
Stud
Welding
Components
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Module 3 - 109
Stud
Welding
Cycle
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Module 3 - 110
SW Studs and Fasteners
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Module 3 - 111
Stud Welding - Studs

Flux on tip cleans weld area
Stand off tips also used
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Module 3 - 112
SW Advantages
Simple
Fast
Repetitive
Automatic stud feeding (option)
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Module 3 - 113
SW Limitations
Needs clean surface
Equipment malfunctions
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Module 3 - 114
SW Discontinuities
Lack of flash
Incomplete fusion
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Module 3 - 115
Laser Beam
Welding
(LBW)
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Module 3 - 116
LBW - 1 of 2
Laser
Light Amplification by Stimulated Emission
of Radiation
A fusion welding process

Heat from concentrated light source
Keyhole welding
Light beam very small x-section
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Module 3 - 117
LBW - 2 of 2
Light can be transmitted by fiber
optics or mirrors
Non-contact process
Shielding gas often required
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Module 3 - 118
Cross Section of LB Weld
Weld
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Module 3 - 119
LBW Advantages - 1 of 2
Low heat input

Less grain growth and distortion
High D/W ratios of 10:1 attainable

Relatively thick single pass welds - (up to
1.25 )
Welds thin metals or small diameter wires

Closely spaced components, small welds
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Module 3 - 120
LBW Advantages - 2 of 2
Welds wide variety of materials
Beams readily focused and aligned
Not influenced by magnetic fields
Welds metals of dissimilar physical
properties
No vacuum or X-ray shielding required
Beams transmitted to many work stations
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Module 3 - 121
LBW Limitations
Joints must be accurately positioned
Surfaces must be forced together
Alloy reflectivity and thermal
conductivity
Plasma control device often required
Cost
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Module 3 - 122
LBW Discontinuities
Porosity
Embrittlement
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Electron Beam Welding

(EBW)
Module 3 - 123
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Module 3 - 124
EBW
Originally required high vacuum
Can now operate in low, or no,
vacuum
A fusion joining process
Heat applied from stream of highenergy electrons from gun
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Module 3 - 125
EB
Schematic
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Module 3 - 126
Electron
Beam
Welding
Fixture
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Module 3 - 127
EB Weld
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Module 3 - 128
EBW Advantages
Similar to LBW
Deeper penetration capability
High purity, especially for vacuum
environment
High welding speeds
Ability to change weld shape
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Module 3 - 129
EB Limitations
Similar to LBW
Vacuum chamber may be required
Vacuum chamber size can limit
assembly size
X-Rays generated
Cost
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Module 3 - 130
EBW Discontinuities
Cracking
Root voids
Porosity
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Module 3 - 131
Resistance
Welding - 1 of
3
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Resistance Welding - 2 of
3
Module 3 - 132
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Resistance Welding - 3 of
3
Module 3 - 133
Heat obtained from resistance of

workpieces as current flows
through them
Electrodes are usually copper
3 types - RSW, PW, RSEW
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Module 3 - 134
RSW Advantages
Very fast welding times - < 1 sec /
spot
Semiautomatic or automatic
Good for thin materials
No flux required
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Module 3 - 135
RSW Limitations
Inspection of welds may be difficult
Primarily a shop process
Electrodes must be clean
Metal surfaces must be clean
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Module 3 - 136
RSW Discontinuities
Non-fusion areas
Cracks
Misalignment of RSEW electrodes
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Welding Applications &

Personnel
Module 3 - 137
Manual
Semiautomatic
Mechanized
(machine)
Automatic
Welder
Welding Operator
See A3.0-94 for AWS definitions.

Am
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Module 3 - 138
Brazing
Am
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Brazing vs Welding vs
Soldering
Module 3 - 139
Base metal not melted in brazing or

soldering
Brazing filler metals melt above 840 0 F
(4500 C)
Soldering filler metals melt below 8400 F
Strong joints possible with all processes
if designed properly
Am
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Module 3 - 140
Brazing Aspects
Large surface area
Very small clearance
Clean surfaces
Flux often used
Capillary action
Am
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Module 3 - 141
Braze Joint Configurations
Am
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Module 3 - 142
Brazing Filler Metals

Wire
Strip
Foil
Paste
Preforms
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AWS Brazing Filler

Metals
Designation
BAlSi
BCuP
BAg
BAu
BCu
RBCuZn
BMg
BNi
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Module 3 - 143
Primary Element
Aluminum-Silicon
Copper-Phosphorus
Silver
Gold
Copper
Copper-Zinc
Magnesium
Nickel
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Brazing Methods
Module 3 - 144
Named after heating method

Torch
Furnace
Induction
Resistance
Dip
Infrared
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Module 3 - 145
Brazing Advantages
Strong joints
Joins dissimilar metals
Joins metals to nonmetals
Joins unweldable metals
Less heat, less distortion
Am
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Module 3 - 146
Brazing Limitations
Cleanliness requirements
Joint design requirements
Difficult to inspect
Am
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Module 3 - 147
Brazing Discontinuities
Voids, unbonded areas
Base metal erosion
Corrosion by flux
Trapped flux
Am
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Module 3 - 148
Cutting Processes
We will be discussing:
Oxyfuel Cutting
Air Carbon Arc Cutting
Plasma Arc Cutting
Mechanical Cutting
Am
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Module 3 - 149
Oxyfuel
Cutting (OFC)
Am
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o c i e t y
Module 3 - 150
Oxyfuel Cutting (OFC)
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Module 3 - 151
OFC - Kerf and Drag
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Oxyfuel Cutting Gases
Module 3 - 152
Commonly used
Acetylene
Methane
Propane
MPS
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OFC Torches
Am
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Module 3 - 153
o c i e t y
Module 3 - 154
OFC Cut
Am
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Module 3 - 155
OFC Advantages
Simple equipment
Very portable
Cuts thin or thick materials
Good accuracy
Manual or mechanized
Am
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o c i e t y

Metal Joining and Cutting Processes

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Metal Joining and Cutting Processes

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Module 3 - 1

Helps spot problems

WIT Coverage of Welding

3 Basic Process Groups

EXX20, EXX24, EXX27

Low Hydrogen Electrodes

Stainless Steel Electrodes

As arc voltage, V, drops, arc current, A, rises

Gas Metal Arc Welding (GMAW)

Constant Potential Power

Constant Potential Source

GMAW Modes of Transfer

GMAW Modes of Transfer

Factors for Transfer Modes

FCAW Guns - Gas & Selfshielded

Stainless Steel Electrodes

AWS Tungsten Electrode

GTAW Filler Metals

ER70S-2, ER70S-3, etc.

ER308, ER308L, ER316, etc.

Impact Test Temperature

Width vs Depth Ratio

Plasma Arc Welding

Electroslag Welding (ESW)

OAW Filler Metals

SW Studs and Fasteners

Stud Welding - Studs

A fusion welding process

Cross Section of LB Weld

Low heat input

High D/W ratios of 10:1 attainable

Welds thin metals or small diameter wires

Electron Beam Welding

Heat obtained from resistance of

Welding Applications &

See A3.0-94 for AWS definitions.

Base metal not melted in brazing or

Braze Joint Configurations

Brazing Filler Metals

AWS Brazing Filler

Named after heating method

Oxyfuel Cutting (OFC)

OFC - Kerf and Drag

Oxyfuel Cutting Gases

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