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ELECTRIC ARC WELDING

The welding in which the electric arc isproduced


to give heat for the purpose of joining two
surfaces is called electric arc welding.

The joining by fusing of two ormore pieces of


metal together by using the heat produced
from an electric arc.
How an arc is formed?
• The arc is like a flame of
intense heat that is
generated as the
electrical current passes
through a highly
resistant air gap.
ELECTRIC ARC WELDING
Arc Welding
• It is a fusion welding processes which usesan
electric arc to produce the heat required for
melting the metal.
• The welder creates an electric arc that melts the base metals
and filler metal (consumable) together so that they all fuse
into one solid piece of metal
Arc Welding

• Many things around us are welded …


– Pipelines that bring fresh water
– Towers that carry electricity to houses
– Cars and buses that take people where they need to go
Arc Welding
• It is a manual arc welding process that uses a
consumable electrode coated in flux to lay the
weld.
• An electric current, in the form of either
alternating current or direct current from a
welding power supply, is used to form an electric
arc between the electrode and the metals to be
joined.
• As the weld is laid, the flux coating of the electrode
disintegrates, giving off vapors that serve as a
shielding gas and providing a layer of slag, both of
which protect the weld area from atmospheric
contamination.
Arc Welding
• Arc welding is a process that melts and joins metals by
heating them with an arc established between a stick
like covered electrode and the metals.
• The core wire conducts the electric current tothe arc and
provides filler metal for thejoint.
• The electrode holder is essentially a metal clamp with an
electrically insulated outside shell for the welder to hold
safely.
• The heat of the arc melts the core wire and the flux
covering at the electrode tip into metal droplets.
• Molten metal in the weld pool solidifies into the weld metal
while the lighter molten flux floats on the top surface and
solidifies as a slag layer.
Arc Welding
Arc Welding
• Also known as “stick welding”
• Uses an arc between a covered electrode
and a workpiece
• Shielding is obtained from decomposition
of the electrode cover
• Pressure is not used
• Filler metal is obtained from the electrode
Principle of Arc
• A suitable gap is kept between the work and
electrode
• A high current is passed through the circuit.
• The electric energy is converted into heat
energy, producing a temperature of 3000°Cto
4000°C.
• This heat melts the edges to be weldedand
molten pool is formed.
• On solidification the welding joint isobtained
Arc Welding
• Process:
– Intense heat at the arc melts the tip of the electrode
– Tiny drops of metal enter thearc 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
wirebrush before the next pass.
Arc Welding
• Because of the versatility of the process and
the simplicity of its equipment and operation,
shielded metal arc welding is one of the
world's most popular welding processes.
Basics of ArcWelding
• The arc is struck between the electrode
and the metal.
• It then heats the metal to the melting
point.
• The electrode is then removed, breaking
the arc between the electrode and the
metal. This allows the molten metal to
“freeze” or solidify.
Arc Welding
Arc Welding
Basic Steps of Arc Welding
• Prepare the base materials: remove paint and
rust
• Choose the right welding process
• Choose the right filler material
• Assess and comply with safety requirements
• Use proper welding techniques and be sure to
protect the molten puddle from contaminants in
the air
• Inspect the weld
ARCWELDING
• An electric arc is generated between an
electrode and the parent metal
• The electrode carries the electric current to
form the arc, produces a gas to control the
atmosphere and provides filler metal for the
weld bead
• Electric current may be ACor DC.
Electric Power for Welding
• Current used may be
– 1.AC
– 2. DC

For most purposes, DCis preferred.


Arc Welding Equipments
Metal arcwelding
Arc Welding
• The choice of electrode for SMAW dependson
a number of factors, including
1. The weld material
2. Welding position and
3. The desired weld properties.
Welding Electrodes
• The composition of the electrode core is generally
similar and sometimes identical to that of thebase
material.
• But even though a number of feasible options exist, a
slight difference in alloy composition can strongly impact
the properties of the resulting weld.
Coated Electrodes
• The electrode is coated in a metal mixture
called flux, which gives off gases as it
decomposes to prevent
1.Weld contamination
2.Introduces deoxidizers to purify the weld
3.Causes weld-protecting slag to form
4.Improves the arc stability, and
5.Provides alloying elements to improve the weld
quality.
Functions of electrode (flux) covering
• Provides the gaseous shield to protect the
molten metal from air.
– Cellulose-type electrode (C6H10O5)x , providing
gas mixture of H2, CO, H2O and CO2.
– Limestone-type electrode (CaCO3) – low in
hydrogen and it is used for welding metals that
are susceptible to hydrogen cracking such as high-
strength steels.
Functions of electrode (flux) covering
• Deoxidation - Provide deoxidizers and fluxing agentto
deoxidize and cleanse the weld metal. The solid slag
also protects the weld metal fromoxidation.
• Arc stabilization - Provide arc stabilizers which are
compounds such as potassium oxalate and lithium
carbonate. They readily decompose into ions in an
arc, which increase electrical conductivity.
• Metal addition - Provide alloying elements (for
composition control) and metal powder(increase
deposition rate) tothe weld pool.
Arc Welding Power Supplies
• The current for arc welder can be suppliedby
line current or by analternator/generator.
– The amount of heat is determined by the current flow(amps)
– The ease of starting and harshness of the arc is determined by the electrical
potential (volts).
Amperage Output
• Current setting formula is 4 * Dia of Rod
• 185 to 225 amps is a common size.
• For an individual weld, the optimum output
amperage is determined by
– thickness of the metal
– type of joint and
– type of electrode
DC Arc Welding
• D.C. machines are made up to the capacityrange
of 600 amperes.
• 45 to 95 volts
• D.C. can be given in two ways:
(a) Straight polarity
(b) Reverse polarity
The polarity will affect the weld size andapplication
Direct Current
• Direct current: The type of current where the flow of
electrons (polarity) is in onedirection.
• Controlling the polarity allows the welder to influence the
location of the heat.
• When the electrode is positive (+) DCRP,it will be slightly
hotter than the basemetal.
• When the base metal is positive (+), DCSP,the basemetal
will be slightly hotterthan the electrode.
• DCis required for GMAW
• It is frequently used for SMAW
Ampere
• Electricity passing through a resistancecauses heat.
• An air gap is ahigh resistance
• The greater the amperage flowing through the
resistance (air gap)  the greater the heat.
• The electrode also has resistance.
• Excessive amperage for the diameter of the
electrode (current density) over heats the
electrode.
• Insufficient amperage for the diameter of
electrode makes the electrode hard to start.
Arc Welding Defects
The most common quality problems associated with SMAW include
• 1. Weld spatter
Weld spatter, while not affecting the integrity of the weld, damages
its appearance and increases cleaning costs. It can be caused by
excessively high current.

• 2. Porosity
Porosity, often not visible without the use of advanced
nondestructive testing methods, is a serious concern because it can
potentially weaken the weld.
Arc Welding Defects
• 3. Poor fusion
Another defect affecting the strength of the weld is poor
fusion, though it is often easily visible. It is caused by low
current, contaminated joint surfaces, or the use ofan
improper electrode.
• 4. Shallow penetration
Shallow penetration, another detriment to weld strength, can be
addressed by decreasing welding speed, increasing the
current or using a smaller electrode.
• 5. Cracking.
Any of these weld-strength-related defects can make the weld
prone to cracking, but other factors are involved as well. High
carbon, alloy or sulfur content in the base material can lead to
cracking, especially if low-hydrogen electrodes and
preheatingare not employed. Furthermore, the workpieces
should not be excessively restrained, as this introduces residual
stresses into the weld and can cause cracking as the weld cools
and contracts.
Advantages of arc welding
• 1. Simple welding equipment
• 2. Portable
• 3. Inexpensive power source
• 4. Relatively inexpensive equipment
• 5. Welders use standard domestic current.
• 6. Process is fast and reliable
• 7. Short learning curve
• 8. Equipment can be used for multiple functions
• 9. Electric arc is about 5,000 oC
• 10. Used for maintenance, repair, and fieldconstruction
Disadvantages
• Not clean enough for reactive metals suchas
aluminium and titanium.
• The deposition rate is limited because the
electrode covering tends to overheat andfall off.
• The electrode length is ~ 35 mm and requires
electrode changing lower the overall production
rate.
Arc Welding
Arc Welding
ASME SEC IX WELDING CODES FOR PLATES

S.No WELDING POSITION CODE

1 FLAT WELDING 1G

2 HORIZONTAL WELDING 2G

3 VERTICAL WELDING 3G

4 OVERHEAD WELDING 4G
ASME SEC IX WELDING CODES FOR PIPES

S.No WELDING POSITION CODE

1 When pipe can rotated 1G

2 If pipe is at front and cannot be rotated 2G

3 If pipe is horizontal, we have To move while 5G


it cannot be rotated

4 If pipes are at angle of 45 degree or less or 6G


more between 0 and 90 means they are at
an angle and cannot be rotated
Joint Types
1) Butt joint

2) Corner Joint

3) T-Joint

4) Lap Joint

5) Edge Joint
Factors
Plate/Pipe
Current
Root Gap
Arc Voltage
Weld Joints Design (V , U , Double V , Double U)
Materials (Steel Types)
Post Weld Heat Treatment (PWHT) (Yes/No)
Angle
Electrode Diameter (3.2mm,4mm,5mm)
Electrode Pre-Heat (Yes/No)
Welding Position (Flat , Horizontal , Vertical , Overhead)
Response
Variables
Hardness
Impact Strength
Tensile Strength
Micro-Structure
Fatigue
Bend
Minimizing defects ( Cracks, Pin Holes, Under Cut, Slag
Intrusions)
Weld Bead (Width/Height)

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