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Welding
direction
Edge preparation
Filler material and weld metal
Weld metal (fusion zone)
Heat-affected zone (HAZ)
Unaffected parent material
Manual, semi-automatic and automatic welding
Welding positions: Flat, horizontal, vertical,
overhead
Heat-affected zone
(HAZ)
Weld metal
(Fusion zone)
Unaffected
parent material
Ionization potentials
Element
Argon
15.7
CO2
14.4
Helium
24.9
Hydrogen
15.6
Nitrogen
14.5
Oxygen
13.6
Ion density:
ne ni /no = [2 Zi (2mkT)3/2 exp(-V/kt)]/ Zoh3
where ne, ni and no= particle densities
for electrons, ions and neutral atoms,
V = ionization potential,
T= Temperature in 0K,
Zi , Zo=Partition functions, h=Plancks const. ,
m = Mass of electron, k = Boltzmanns const.
Particle densities of order of 1011 to 1014/mm3
Power source
characteristic
Arc
characteristic
OCV
Voltage
Operating
point
SCC
Current
Pinch effect
Pinch effect:
Radial component of magnetic field around arc
squeezes the axial conductor (plasma, droplet &c)
- assisted by
release of gases from the metal;
explosive evaporation due to high current
through remaining thin filament
Detachment of droplet from consumable electrode
Plasma jet:
Detached droplet accelerated by plasma jet
towards weld pool, sucked in by surface tension
on contact with weld puddle
Metal Transfer
Consumable electrode processes for
higher efficiency need for metal transfer
Requirement of smooth transfer:
Avoid spatter, uncontrolled short circuit,
arc instability due to erratic transfer,
possibility of drawing air into the arc
Types of transfer: Globular, spray,
short circuit types
Globular transfer
(Axial) spray transfer
Short circuit (or dip) transfer
Pulsed transfer
Welding processes
Fusion welding
Pressure welding
Cold pressure
welding
Diffusion
Explosive
bonding
welding
Hot pressure
welding
Chemical reaction
Gas
welding
Ultrasonic
welding
Thermit
welding
Electroslag
welding
Electric arc
Friction welding
Gas shielded
Flux-shielded
SMAW
SAW
PAW
GTAW
GMAW
Including
FCAW