Professional Documents
Culture Documents
OF OCEAN ENGINEERING-ITS
Welding Processes
Nur Syahroni, ST., MT., Ph.D.
Outline
Teknologi dan Inspeksi Las (MO-141323) 2
The American Welding Society (AWS) defines a
welding process as:
• a joining process that produces coallescence of
materials
• by heating them to the welding temperature
• with or without the application of pressure or
by the application of pressure alone, and
• with or without the use of filler materials
Definition
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Classification of Welding Processes (AWS)
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Welder & Welding Operator:
• Welder is: a person who performs a manual or a
semiautomatic welding
• Welding operator is: a person who performs a
mechanized or an automatic welding
Methods of Application
Teknologi dan Inspeksi Las (MO-141323) 5
Methods of Application
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1. Shielded Metal Arc Welding (SMAW)
The Shielded Metal Arc Welding (SMAW) is also known as
the Manual Metal Arc Welding (MMAW) or sometimes
informally termed as the Stick Welding
• The SMA welding Process was first developed in the late
19th century using bare wire consumables.
• SMAW is a simple process in terms of equipment
• The process can by used in AC, DC+ or DC-
• The process is a manual process and demands a high skill
from the welder.
• The process is the most widely used throughout the
welding industry both for shop and site working
conditions
Introduction
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1. Shielded Metal Arc Welding (SMAW)
Principle of Operation
Teknologi dan Inspeksi Las (MO-141323) 8
1. Shielded Metal Arc Welding (SMAW)
Basic Equipments
Teknologi dan Inspeksi Las (MO-141323) 9
1. Shielded Metal Arc Welding (SMAW)
Electrode Holder
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1. Shielded Metal Arc Welding (SMAW)
SMAW - Electrodes
Teknologi dan Inspeksi Las (MO-141323) 13
1. Shielded Metal Arc Welding (SMAW)
Electrode Functions
Teknologi dan Inspeksi Las (MO-141323) 15
1. Shielded Metal Arc Welding (SMAW)
SMAW - Troubleshooting
Teknologi dan Inspeksi Las (MO-141323) 16
1. Shielded Metal Arc Welding (SMAW)
Advantages:
• Field or shop use
• Range of consumables
• All positions
• Portable
• Simple equipment
Disadvantages:
• High welder skill required
• High levels of fume
• Hydrogen control (flux)
• Stop/start problems
• Comparatively uneconomic when compared with some other
processes i.e MAG, SAW and FCAW
Introduction
Teknologi dan Inspeksi Las (MO-141323) 18
2. Gas Tungsten Arc Welding (GTAW)
Principle of Operation
Teknologi dan Inspeksi Las (MO-141323) 19
2. Gas Tungsten Arc Welding (GTAW)
Basic Equipments
Teknologi dan Inspeksi Las (MO-141323) 20
2. Gas Tungsten Arc Welding (GTAW)
Welding Variables
Welding Technology & Inspection (MO-091333) 23
2. Gas Tungsten Arc Welding (GTAW)
Voltage
The voltage of the TIG welding process is variable only by the type of
gas being used, and changes in the arc length
Current
The current is adjusted proportionally to the tungsten electrodes
diameter being used. The higher the current the deeper the
penetration and fusion
Polarity
The polarity used for steels is always DC –ve as most of the heat is
concentrated at the +ve pole, this is required to keep the tungsten
electrode at the cool end of the arc. When welding aluminium and its
alloys AC current is used
Welding Variables
Welding Technology & Inspection (MO-091333) 24
2. Gas Tungsten Arc Welding (GTAW)
DC • can be DCEN or DCEP
• DCEN gives deep penetration
Types of current
Welding Technology & Inspection (MO-091333) 25
2. Gas Tungsten Arc Welding (GTAW)
+ - + - + -
+ - + - + -
+ - + - + -
Heat balance 70% at work 30% 50% at work 50% 35% at work 65%
at electrode at electrode at electrode
Penetration Deep, narrow Medium Shallow, wide
Oxide cleaning action No Yes - every half cycle Yes
Electrode capacity Excellent (e.g. Good (e.g. Poor (e.g.
3,2 mm/400A) 3,2 mm/225A) 6,4 mm/120A)
Increase
Vertex
diameter
angle
Decrease
Bead width
increase
Electrode tip prepared for low Electrode tip prepared for high
current welding current welding
Electrode tip for DCEN
Welding Technology & Inspection (MO-091333) 28
2. Gas Tungsten Arc Welding (GTAW)
DC -ve AC
Introduction
Welding Technology & Inspection (MO-091333) 31
3. Gas Metal Arc Welding (GMAW)
Principle of Operation
Welding Technology & Inspection (MO-091333) 32
3. Gas Metal Arc Welding (GMAW)
Basic Equipments
Welding Technology & Inspection (MO-091333) 33
4. Gas Metal Arc Welding (GMAW)
Electrode
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3. Gas Metal Arc Welding (GMAW)
Dip Transfer (Short-circuit): (Voltage < 22) / (Amperage < 200)
Voltage
• Thin materials positional welding
• Polarity
Process Variables
Welding Technology & Inspection (MO-091333) 38
3. Gas Metal Arc Welding (GMAW)
• Arc voltage
• Travel speed
•Increasing travel speed
•Reduced penetration and width, undercut
Process Variables
Welding Technology & Inspection (MO-091333) 39
3. Gas Metal Arc Welding (GMAW)
Advantages Disadvantages
High productivity Lack of fusion (dip)
Easily automated Small range of consumables
All positional (dip & pulse) Protection on site
Material thickness Complex equipment
range Not so portable
Continuous electrode
Wide range of application
Flux powder
Arc shield composed of
vaporized and slag forming
Flux core compounds
wires
Molten
weld Metal droplets covered with
Solidified weld pool
thin slag coating
metal and slag
Principle of Operation
Welding Technology & Inspection (MO-091333) 41
4. Flux-Cored Arc Welding (FCAW)
Basic Equipments
Welding Technology & Inspection (MO-091333) 44
4. Flux-Cored Arc Welding (FCAW)
Flux Metal wire
Electrode
Welding Technology & Inspection (MO-091333) 45
4. Flux-Cored Arc Welding (FCAW)
Electrode
Welding Technology & Inspection (MO-091333) 46
4. Flux-Cored Arc Welding (FCAW)
Advantages Disadvantages
Field or shop use High skill factor
High productivity Slag inclusions
All positional Cored wire is Expensive
Slag supports and shapes High level of fume (Inner-
the weld Bead shield)
No need for shielding gas Limited to steels and nickel
alloys
Introduction
Welding Technology & Inspection (MO-091333) 48
5. Submerged Arc Welding (SAW)
Principle of Operation
Welding Technology & Inspection (MO-091333) 49
5. Submerged Arc Welding (SAW)
Filler wire spool
Flux hopper
Power
supply
- +
Slide rail
Wire electrode
Flux
Basic Equipments
Welding Technology & Inspection (MO-091333) 50
5. Submerged Arc Welding (SAW)
Courtesy of ESAB AB
Courtesy of ESAB AB
Basic Equipments
Welding Technology & Inspection (MO-091333) 51
5. Submerged Arc Welding (SAW)