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Effects of welding

parameters in
Shield Metal Arc
Welding
Welding

Welding is the process of joining of two


similar or dissimilar metal with or without
the application of heat and pressure
Types of welding:

 There are many types of welding used depending upon


their applications. Among all the welding some of the
important and mostly used welding processes are:
 Shield metal arc welding(SMAW)

 Gas shield metal arc welding(GSMAW)


 Tungsten metal inert gas welding(TIG)
 Metal inert gas welding(MIG)
 Plasma arc welding(PAW)
 Sub merged arc welding etc
SMAW Welding
 Shield metal arc welding is one of the mostly used
welding processes. In this a consumable electrodes is
used .
 An arc is created between the electrode and work piece
by striking the electrode on work piece.
 This arc produces heat which is used for melting
electrode and work pieces.

 Shielding of the weld pool during metal transfer from


electrode tip to work piece from the atmosphere is done
by the gases created during the decomposition of
electrode under the heat.
 But this is not enough for shielding molten flux is used. It
protects the pool and also slows down the cooling rate
which is very important in getting good metallic properties
in the weld bead.
Parameters Influencing SMAW
Welding
For any welding processes there many welding
parameters which influence the welding. So to get good
welding we have to care of welding parameters. The
parameters influencing the SMAW welding are

Power source
Constant voltage
Constant current

Open circuit voltage(OCT)

Chemical composition of Flux coatings


Cellulose electrode
Rutile electrode
Basic electrode
Welding current
Arc voltage
Welding speed
Electrode orientation
Electrode diameter
Polarity
Direct current straight polarity(DCSP)
Direct current reverse polarity(DCRP)
Weld thermal cycle
Cooling rates
Residual stress
Details of parameters and its effect on
SMAW Welding
Flux coating
Chemical composition of the flux coating mainly influences :
 Arc stability
 Depth of penetration
 Metal deposition rate
 Positional welding capability

Flux composition serves the following purposes:


 Induce easier arc starting
The flux produces favourable gas, which gets ionized more
easily, such that the electric arc is initiated very easily.
 Stabilize the arc
Stability of the arc depends on the ionization potential of
the gases produced by flux.
 Improves weld appearance and penetration
 Reduce spatters
Types of electrodes based on flux
covering:
• Cellulosic
– Flux rich in cellulose
– Burn to produce hydrogen and carbon monoxide,
provides shielding to the arc
– Suitable with DC power and electrode positive
polarity
– presence of these gases in the arc with high ionization
potential, this hydrogen and carbon monoxide, they
have a high ionizing potential. It results in high arc
voltage and therefore a high arc energy results in in
deeply penetrating arc , higher melting rate which is
favourable for high welding speeds.
• A little slag is left on the welding deposit so
there is less chances for slag inclusion ,also thin
layer of slag produces less annealing effect.
• Produces forceful arc and strong plasma jet
which will help to weld in any position. The
forceful arc will helps to transfer the metal
against the gravity in overhead welding .
• Deep penetration, suitable for all positional
welding and good mechanical properties can
obtained by cellulose flux coating electrode.
• Hydrogen gas produced causes hydrogen
embrittlement in the welding.
RUTILE ELECTODE
This contains the high proposition of titanium
dioxide. The titanium dioxide is another name of
rutile and classified as general purpose electrode.
This titanium oxide promotes,
easy ignition,
smooth arc operation, and
 low spatter.
Easy slag removal.
It can be used with either polarity and in all positions
. We can use either AC or DC.
These electrodes are specially suitable for fillet
welding in horizontal and vertical positions.
Basic electrode
• Basic electrodes, these contains high proportion
of calcium carbonate and calcium fluoride. These
are referred to as low hydrogen electrodes.
• The slag more fluid than that in case of rutile
coating. It is more fluidic slag. Slag is a fast
freezing type, suitable for vertical and overhead
position.
• It makes them suitable for welding low-alloy steels
susceptible to hydrogen heat affective zone
cracking.
• Resistance to hot cracking make suitable for
welding thicker steel and steels with high carbon
content.
WELDING CURRENT
it is one of the imp parameter in welding ,heat
generated for melting the electrode depends on the welding
current ,if the current increases the rate of melting also increases
.To achieve higher welding speed the welding current have to be
increased with speed simultaneously.

The welding current affects penetration and deposition rate. A


high current results in a higher and narrower weld, with a greater
penetration depth. However, too high a welding current can result
in undercuts, an uneven weld convexity, burn-through, thermal
cracking, an inappropriate merging angle with the body material
and undercutting.
Welding voltage
voltage is directly proportional to basically arc
length, if the arc length increases voltage also
increases and This cause widening of the welding arc
and Width of the welding arc increases.
 when the arc length reduce . Voltage drop
reduces, the arc becomes narrower.
 If the arc length become too small, arc may
become so narrow, it becomes unstable. Metal
transfer will not be proper.
 if the arc length increase too much. It becomes so
wide. Again, it becomes unstable. So, that is how it
affects arc length or arc voltage.
Effect of voltage on weld bead:
Welding speed
Welding speed means movement of electrode during welding .
Higher the welding speed lesser be the heat transfer, weld metal
deposition and penetration .
Too high welding speed leads to defects like incomplete filling of
weld bead , undercut, slag inclusion etc.
Low welding speed results in high metal deposition ,penetration
and it also leads to the high thermal stress due to higher the heat
transfer rate.
Welding technique
Welding technique is one of the important parameter
which as effect on size of the weld bead and penetration
.depending upon the angle and movement of the electrode
there are 2 type of techniques are there .
They are :
Fore hand welding :Electrode point in direction of the
travel is called as fore hand welding with lead angle .
Back hand welding : electrode pointing against the
direction of travel is called as back hand welding with drag
angle
Techniques of welding and there effects on the
bead profile and penetration depth
Electrode diameter
Increase in the electrode diameter increases the
Current carrying capacity which in turn increases
the weld deposition.
The effect of electrode dia in weld bead and
penetration for constant amount of current:
polarity
• Polarity play an important role in DC power
supply. High heat is produced at positve
terminal and less will in negative terminal of
the supply .There two types of polarities are
there
• Straight polarity : work piece positive and
electrode negative. Used for thick plates
• Reverse polarity : work piece negative and
electrode positive. Used for thin plates
Effect of polarity in weld bead and
penetration
Residual stress
temperature distribution
• From the above we can see that temperature
distribution is not uniform due this non uniform
volumetric expansion will take place due to this
residual stress will develop in the work piece
Cooling rates

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