Module 3

Joining Cutting Metal

and Processes

Cairo Inspection Company

Eng. Ibrahim Eldesoky
ASNT –NDT-LEVEL III
ASME AUTHORIZED INSPECTOR
 Introduction
There are certain aspects of the various joining
and cutting processes which the successful
welding inspector must understand in order to
perform most effectively.
 The inspector should realize the important
advantages and limitations of each process.
 The inspector should be aware of those
discontinuities which may result when a
particular process is used.
 The welding inspector should have some
knowledge of the equipment requirements for
each process.

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 2

 Introduction
 The inspector should be familiar with the
various machine controls and what effect their
adjustment will have on the resulting weld
quality.
 This knowledge will aid in the discovery of
problems when they occur rather than later
when the cost of correction is greater.
 Another benefit of having experience with
these welding methods is that the production
welders will have greater respect for the
inspector and resulting decisions

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 3

 Introduction

The processes discussed here can be divided

into three basic groups: welding, brazing
and cutting.
There are numerous joining and cutting
processes available for use in the
fabrication of metal products. These are
shown by the American Welding Society's
Master Chart of Welding and Allied
Processes, shown in Figure 3.1

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 4

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 5
 Welding Processes

A weld is, "a localized coalescence of

metals or nonmetals produced either by
heating the materials 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 metal."
Coalescence means "joining together."

6
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Shielded Metal Arc Welding (SMAW)
Method Description
 This process operates by heating the
metal with an electric arc between a
covered metal electrode and the metals to
be joined.
 Figure 3.2 shows the various elements
of the shielded metal arc welding process.
This illustration shows that the arc is
created between the electrode and the
work piece due to the flow of electricity.

7
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Shielded Metal Arc Welding (SMAW)

 This arc provides heat, or energy, to melt

the base metal, filler metal and electrode
coating. As the welding arc progresses to
the right, it leaves behind solidified weld
metal covered by a layer of converted flux,
referred to as slag. This slag tends to float
to the outside of the metal since it solidifies
after the molten metal has solidified.

8
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Shielded Metal Arc Welding (SMAW)

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 9

 Shielded Metal Arc Welding (SMAW)

 Another feature noted in Figure 3.2 is

the presence of shielding gas which is
produced when the electrode coating is
heated and decomposed. These gases
assist the flux in the shielding of the
molten metal in the arc region.

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 10

The primary element of the shielded metal
arc welding process is the electrode itself.
The sizes and types of electrodes for
shielded metal arc welding define the arc
voltage requirements (within the overall
range of 16 to 40 V) and the amperage
requirements (within the overall range of
20 to 550 A). It is made up of a metal core
wire covered with a layer of granular flux
held in place by some type of bonding
agent.

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 11

 Shielded Metal Arc Welding (SMAW)
 All carbon and low alloy steel electrodes use
essentially the same type of steel core wire, a
low carbon, rimmed steel. Any alloying is
provided from the coating, since it is more
economical to achieve alloying in this way.
Most SMAW electrodes have a solid metal core.
Some are made with a fabricated or composite
core consisting of metal powders encased in a
metallic sheath. In this latter case, the purpose
of some or even all of the metal powders is to
produce an alloy weld deposit.

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 12

electrode coverings can be designed for
welding with alternating current (ac)
Gases that readily ionize are available
from a variety of compounds, including
those that contain potassium To increase
the deposition rate, the coverings of some
carbon and low alloy steel electrodes
contain iron powder.

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 13

The presence of iron powder in the covering
also makes more efficient use of the arc energy
When iron or other metal powders are added in
relatively large amounts, the deposition rate
and welding speed usually increase Iron
powder electrodes with thick coverings reduce
the level of skill needed to weld. The tip of the
electrode can be dragged along the surface of
the work while maintaining a welding arc. For
this reason, heavy iron powder electrodes
frequently are called drag electrodes.
Deposition
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 14
 Arc Shielding
Electrodes which produce a heavy slag can carry
high amperage and provide high deposition
rates, making them ideal for heavy weldments
in the flat position.
Electrodes which produce a light slag layer are
used with lower amperage and provide lower
deposition rates. These electrodes produce a
smaller weld pool and are suitable for making
welds in all positions. Because of the differences
in their welding characteristics, one type of
covered electrode usually will be best suited for
a given application
 Shielded Metal Arc Welding (SMAW)
 The electrode coating is the feature which classifies
the various types of electrodes. It actually serves five
separate functions:
 Shielding- the coating decomposes to form a
gaseous shield for the molten metal.
 Deoxidation- the coating provides a fluxing
action to remove oxygen and other atmospheric gases.
 Alloying- the coating provides additional
alloying elements for the weld deposit.
 Ionizing- the coating improves electrical
characteristics to increase arc stability.
 Insulating- the solidified slag provides an insulating
blanket to slow down the weld metal
cooling rate (minor effect).

16
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 The identification
 consists of an "E," which stands for
electrode, followed by four or five digits.
 The first two, or three, numbers refer to the
minimum tensile strength of the deposited
weld metal. These numbers state the
minimum tensile strength in thousands of
pounds per square inch. For example, "70"
means that the tensile strength of the
deposited weld metal is at least 70,000 psi.
 The next number refers to the positions in
which the electrode can be used. A "1"
indicates the electrode is suitable for use in
any position.

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 17

 Shielded Metal Arc Welding (SMAW)
A "2" means that the molten metal is so fluid
that the electrode can only be used in the flat
position for all welding types and in the
horizontal position for fillet welds only.
A "4" means the electrode is suitable for
welding in a downhill progression.
The number "3" is no longer used as a
designation.
 The last number in the designation
describes other characteristics which are
determined by the composition of the coating
present on the electrode.

18
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Shielded Metal Arc Welding (SMAW)
 It is important to note that those electrodes
ending in "5," "6," or "8" are classified as "low
hydrogen" types. To maintain this low
hydrogen (moisture) content, they must be
stored in their original factory-sealed metal
container or an acceptable storage oven.
 This oven should be heated electrically and
have a temperature control capability in the
range of 150° to 350°F. Since this device will
assist in the maintenance of a low moisture
content (less than 0.2%) it must be suitably
vented.

19
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 20
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
SMAW electrodes are available to weld carbon
and low alloy steels, stainless steels, cast irons,
copper, and nickel and their alloys, and for
some aluminum applications. Low melting
metals, such as lead, tin, and zinc, and their
alloys, are not welded with SMAW because the
intense heat of the arc is too high for them.
SMAW is not suitable for reactive metals such
as titanium, zirconium, tantalum, and
columbium because the shielding provided is
inadequate to prevent oxygen contamination of
the weld.
21
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Shielded Metal Arc Welding (SMAW)

 Any low hydrogen electrodes which are

not to be used immediately should be
placed into the holding oven as soon as
their airtight container is opened. Most
codes require that low hydrogen electrodes
be held at a minimum oven temperature of
250°F (120°C) after removal from their
sealed container.

22
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Shielded Metal Arc Welding (SMAW)

 Some electrode types are designed to

have a certain moisture level. If this
moisture is eliminated, the operating
characteristics of the electrode will
deteriorate significantly.

23
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Electrode Coating Classification
F #s

 F1 - EXX20, EXX24, EXX27

 F2 - EXXX2, EXXX3, EXXX4
 F3 - EXX10, EXXX1
 F4 - EXXX5, EXXX6, EXXX8

24
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 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

25
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Electrode Suffixes - 1 of 2

- A1 0.5% Mo
- B1 0.5% Mo 0.5% Cr
- B2 0.5% Mo 1.25% Cr
- B3 1.0% Mo 2.25% Cr
- B4 0.5% Mo 2.0% Cr
-W Weathering

26
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Electrode Suffixes - 2 of 2

- C1 2.5% Ni
- C2 3.5% Ni
- C3 1.0% Ni
- D1 0.3% Mo 1.5% Mn
- D2 0.3% Mo 1.75% Mn
-G 0.2% Mo 0.3% Cr 0.5% Ni
1% Mn 0.1% V

27
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Stainless Steel Electrodes

 E308, E308L - Weld 304 and 304L

 E316, E316L - Weld 316 and 316L
 E309 - Weld Stainless to Carbon Steel

28
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
The electrode diameter selected for use
depends largely on the thickness of the
material to be welded, the position in
which welding is to be performed, and the
type of joint to be welded. In general,
larger electrodes will be selected for
applications involving thicker materials
and for welding in the flat position in
order to take advantage of their higher
deposition rates.

29
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Weld groove design must also be considered
when electrode size is selected. The electrode
used in the first few passes must be small
enough for easy manipulation in the root of
the joint. Small diameter electrodes are
frequently used for the initial pass to control
melt through and bead shape. Larger
electrodes can be used to complete the weld,
taking advantage of their deeper
penetration and higher deposition rates

30
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 SMAW Equipment

31
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Shielded Metal Arc Welding (SMAW)
The Equipment
 Shielded metal arc welding equipment is
relatively simple, as can be seen in Figure
3.6. One lead from the welding power source
is connected to the piece to be welded and the
opposite lead goes to the electrode holder
into which the welder places the welding
electrode to be consumed.
 The electrode and base metal are melted
by the heat produced from the welding arc
created between the end of the electrode and
the work piece when they are brought close
together.
32
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Shielded Metal Arc Welding (SMAW)

 The power source for shielded metal

arc welding is a constant current power
source, having a "drooping"
characteristic. This terminology can be
more easily understood by looking at the
characteristic volt-ampere (V-A) curve for
this type of power source.

33
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 34
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 35
 Shielded Metal Arc Welding (SMAW)
 long arc length will result in more heat
produced than a short arc length
 the welder can increase or decrease the
fluidity of the weld pool simply by changing
the arc length. However, an extremely long
arc length will cause a loss of heat in the weld
pool due to loss of arc concentration. An
excessively long arc length will also result in a
loss of arc stability and weld pool shielding
gases.

36
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Shielded Metal Arc Welding (SMAW)

 An experienced welder might choose a

flat slope setting to gain more control,
while an inexperienced welder might
need a steeper slope setting for less
change in weld pool characteristics due
to an inconsistent arc length.

37
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Voltage Drop.
Voltage drop in the welding cables is lower
with ac. This makes ac more suitable if the
welding is to be done at long distances from
the power supply
Low Current.
With small diameter electrodes and low
welding currents, dc provides better
operating characteristics and a more stable
arc.

38
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Arc Starting.
Striking the arc is generally easier with dc,
particularly if small diameter electrodes are
used.
Arc Length.
Welding with a short arc length (low arc
voltage) is easier with dc than with ac.
Welding Position.
Direct current is somewhat better than ac for
vertical and overhead welds because lower
amperage can be used.

39
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Metal Thickness.
Both sheet metal and heavy sections can
be welded using dc. The welding of sheet
metal with ac is less desirable than with
dc. Arc conditions at low current levels
required for thin materials are less
stable on ac power than on dc power.

40
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 41
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
OPEN CIRCUIT VOLTAGE, WHICH is the voltage set on the
power source, does not refer to arc voltage. Arc voltage is
the voltage between the electrode and the work during
welding and is determined by arc length for any given
electrode. Open circuit voltage, on the other hand, is the
voltage generated by the welding machine when no
welding is being done. Open circuit voltages generally
run between 50 and 10 V, whereas arc voltages are
between 17 and 40 V. The open circuit voltage drops to
the arc voltage when the arc is struck and the welding
load comes on the machine. The arc length type of
electrode being used determine just what this arc voltage
will be. If the arc is lengthened, the arc voltage will
increase and the welding curent wil decrease.

42
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
HEATING THE AREA to be welded before and during
welding is required in order to achieve desired
properties in the weld or the adjacent base metal, or
both. Unnecessary preheat should be avoided as it takes
time and energy. Excessive preheat temperatures are not
cost effective and could degrade the properties and the
quality of the joint. A welder's discomfort increases with
higher preheats and tends to reduce the quality of the
work. Preheat temperatures employed would be based
upon welding code requirements, competent technical
evaluation, or the results of tests. In general, the
temperature will depend on the material to be welded,
the electrodes to be used, and the degree of restraint in
the joint.

43
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Hardenable steels, high-strength steels, and
use of electrodes other than low hydrogen
types normally require application of
preheat.
Preheat is sometimes used when welding
materials having high thermal conductivity,
such as copper and aluminum alloys, to
reduce the welding amperage required,
improve penetration, and aid in fusing the
weld metal to the base metal.

44
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
THE CORRECT ELECTRODE diameter is one that,
when used with the proper amperage and travel
speed, produces a weld of the required size in the
least amount of time. The electrode diameter
selected for use depends largely on the thickness of
the material to be welded, the position in which
welding is to be performed, and the type of joint to
be welded. In general, larger electrodes will be
selected for applications involving thicker materials
and for welding in the flat position in order to take
advantage of their higher deposition rates.

45
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
For welding in the horizontal, vertical and overhead
positions, the molten weld metal tends to flow out of
the joint due to gravitational forces. This tendency
can be controlled by using small electrodes to reduce
the weld pool size. Electrode manipulation and
increased travel speed along the joint also aid in
controlling weld pool size. Weld groove design must
also be considered when electrode size is selected.
The electrode used in the first few passes must be
small enough for easy manipulation in the root of
the joint.

46
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
In V-grooves, small diameter electrodes are
frequently used for the initial pass to control melt
through and bead shape. Larger electrodes can be
used to complete the weld, taking advantage of
their deeper penetration and higher deposition
rates. Finally, the experience of the welder often
has a bearing on the electrode size. This is
particularly true for out-of position welding, since
the welder's skill governs the size of the molten
puddle that the welder can control.

47
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
The largest possible electrode that does not violate
any pertinent heat input limitations or deposit too
large a weld should be used. Welds that are larger
than necessary are more costly and, in some
instances, actually are harmful. Any sudden change
in section size or in the contour of a weld, such as
that caused by over welding, creates stress
concentrations. It is obvious that the correct
electrode size is the one that, when used with the
proper amperage and travel speed, produces a weld
of the required size in the least amount of time.

48
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Direct Current
provides a steadier arc and smoother metal transfer
than ac does. Most covered electrodes operate better
on reverse polarity (electrode positive), Reverse
polarity produces deeper penetration, but straight
polarity produces a higher electrode melting rate.
The dc arc produces good wetting action by the molten
weld metal and uniform weld bead size even at low
amperage. For this reason, dc is particularly suited to
welding thin sections. Direct current is preferred for
vertical and overhead welding and for welding with a
short arc.
Arc blow may be a problem when magnetic metals
(iron and nickel) are welded with dc

49
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
FOR SMAW, ALTERNATING current offers two advantages
over dc. One is the absence of arc blow and the other is
the cost of the power source. Without arc blow, larger
electrodes and higher welding currents can be used.
Certain electrodes (specifically, those with iron powder in
their coverings) are designed for operation at higher
amperages with ac. The highest welding speeds for
SMAW can be obtained in the drag technique with these
electrodes on ac. Fixturing materials, fixture design, and
workpiece connection location may not be as critical with
ac. An ac transformer costs less than an equivalent dc
power source

50
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Amperage
Deposition rates increase as the amperage increases.
With a specific type and size of electrode, the optimum
amperage depends on several factors such as the
position of welding and the type of joint. The amperage
must be sufficient to obtain good fusion and penetration
yet permit proper control of the molten weld pool. For
vertical and overhead welding, the optimum amperages
would likely be on the low end of the allowable range.
Amperage beyond the recommended range should not be
used. It can overheat the electrode and cause excessive
spatter, arc blow, undercut, and weld metal cracking.
Figure 2.11(A), (B), and (C) show the effect of amperage
on bead shape.

51
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Excessive amperage overheats the electrode
and breaks down the covering. This, in turn,
changes the arc characteristics and the
shielding that is obtained. Because of this
limitation, deposition rates are generally
lower than for a welding process such as
GMAW.

52
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 ARC LENGTH
THE ARC LENGTH is the distance from the molten tip of
the electrode core wire to the surface of the molten
weld pool. Proper arc length is important in obtaining
a sound welded joint. The correct arc length varies
according to the electrode classification, diameter, and
covering composition; it also varies with amperage
and welding position. Arc length increases with
increasing electrode diameter and amperage. As a
general rule, the arc length should not exceed the
diameter of the core wire of the electrode. Too short an
arc will be erratic and may short circuit during metal
transfer.

53
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Too long an arc will lack direction and intensity,
which will tend to scatter the molten metal as it
moves from the electrode to the weld. The spatter
may be heavy and the deposition efficiency low.
Also, the gas and flux generated by the electrode
covering are not so effective in shielding the arc
and weld metal. This can result in porosity and
contamination of the weld metal by oxygen or
nitrogen, or both. When arc blow is encountered,
the arc length should be shortened as much as
possible.

54
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
TRAVEL SPEED
TRAVEL SPEED IS the rate at which the electrode moves
along the joint. The proper travel speed is the one which
produces a weld bead of proper contour and appearance,
as shown in Figure 2.11(A). Travel speed is influenced by
several factors:
(1) Type of welding current, amperage, and polarity
(2) Position of welding
(3) Melting rate of the electrode
(4) Thickness of material
(5) Surface condition of the base metal
(6) Type of joint
(7) Joint fit-up
(8) Electrode manipulation

55
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
When welding, the travel speed should be adjusted so
that the arc slightly leads the molten weld pool. Up to
a point, increasing the travel speed will narrow the
weld bead and increase penetration. Beyond this
point, higher travel speeds can decrease penetration,
cause the surface of the bead to deteriorate and
produce undercutting at the edges of the weld, make
slag removal difficult, and entrap gas (porosity) in
the weld metal. The effect of high travel speed on
bead appearance is shown in Figure 2.11 (G).

56
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
With low travel speed, the weld bead will be wide and
convex with shallow penetration, as illustrated in
Figure 2.11 (F). The shallow penetration is caused by
the arc dwelling on the molten weld pool instead of
leading it and concentrating on the base metal. Travel
speed also influences heat input, and this affects the
metallurgical structures of the weld metal and the
heat affected zone. Low travel speed increases heat
input and this, in turn, increases the size of the heat-
affected zone and reduces the cooling rate of the weld.

57
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Higher travel speed reduces the size of the heat-
affected zone and increases the cooling rate of
the weld. The increase in the cooling rate can
increase the strength and hardness of a weld in
a hardenable steel, unless preheat of a level
sufficient to prevent hardening is used.

58
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Shielded Metal Arc Welding (SMAW)
Advantages
 The equipment is relatively simple and
inexpensive.
Limitations
 Slow
 Solidified slag which must be removed
 Low hydrogen electrodes require storage

59
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Shielded Metal Arc Welding (SMAW)
Discontinuities
 Porosity in the finished weld
Which is a result of the presence of moisture or
contamination in the weld region could be present
in the electrode coating, on the surface of the
material, or come from the atmosphere
surrounding the welding operation. Or "long
arcing" or arc blow.
 Slag inclusions can also occur with SMAW
simply because it relies on a flux system for weld
protection.

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 60

 Shielded Metal Arc Welding (SMAW)
 Incomplete fusion, incomplete joint
penetration, cracking, undercut, overlap,
incorrect weld size, and improper weld profile.
 Arc blow

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 61

 Gas Metal Arc Welding (GMAW)
Introduction

 we also hear it commonly referred to as

"MIG" it is semiautomatic process; however, it is
also used in mechanized and automatic
applications as well.
 Gas metal arc welding is characterized by a
solid wire electrode which is fed continuously
through a welding gun. An arc is created
between this wire and the work piece to heat
and melt the base and filler materials.

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 62

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 63
 Gas Metal Arc Welding (GMAW)
 The shielding for welding is provided by a
protective gas which is also emitted from the
welding gun from some external source.
 Gases used include both inert and reactive
types. Inert gases such as argon and helium are
used for some applications. They can be applied
singly, or in combination with each other, or mixed
with other reactive gases such as nitrogen, oxygen
or carbon dioxide
 The electrodes used for this process are solid
wires which are supplied on spools or reels of
various sizes.

64
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 ER XXS-X
 They are denoted by the letters "ER," followed
by two or three numbers, the letter "S," a
hyphen, and finally, another number,
 The ER means Electrode , Rod.
 The next two or three numbers state the
minimum tensile strength of the deposited weld
metal in thousands of pounds per square inch. a
"70" denotes a filler metal whose tensile
strength is at least 70,000 psi. The letter "S"
stands for a Solid wire. Finally, the number after
the hyphen refers to the particular chemistry of
the electrode

65
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Gas metal arc electrodes have increased
amounts of deoxidizers such as manganese,
silicon, and aluminum to help avoid the
formation of porosity. The most critical factor
here is that the wire must be kept clean
 power source
 gas metal arc welding uses a constant
voltage, or constant potential, power source.
That is, welding is accomplished using a pre-
set value of voltage over the range of welding
currents.

66
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 67
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Gas metal arc welding is normally accomplished
using direct current, electrode positive (DCEP).
When this type of power source is combined with a
wire feeder, the result is a welding process which
can be either semiautomatic, mechanized or fully
automatic.
 To set up for welding, the welder will adjust the
voltage at the power source and the wire feed speed
at the wire feeder. As the wire feed speed is
increased, the welding current increases as well.
The melt-off rate of the electrode is proportional to
the arc current, so the wire feed speed actually
controls this feature as well

68
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 This feature allows the process to
function as a semiautomatic type,
meaning that the welder does not have to
control the feeding of the filler metal as
was the case for manual shielded metal
arc welding. "Self-Regulating Constant
Potential"

69
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 70
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Looking at Figure 3.13, it can be seen
that moving the gun closer to the
workpiece will reduce the electrical
resistance and produce an instantaneous
increase in current. This, in turn,
instantaneously burns off the additional
electrode to bring the arc length and
current back to their original values

71
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 72
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Metal Transfer
 There are four basic modes of metal
transfer. They are spray, globular, pulsed
arc, and short circuiting.
 The type of metal transfer depends upon
several factors, including shielding gas,
current and voltage levels, and power source
characteristics.

73
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
1-Spray transfer is considered to be the
hottest, followed by pulsed arc, globular, and
finally short circuiting. Therefore, spray
transfer is the best for heavier sections and
full penetration weld joints, as long as they
can be positioned in the flat position.
Spray transfer can be achieved only when
there is at least 80% argon present in the gas
mixture.
2-Globular transfer provides almost as much
heating and weld metal deposition, but its
operating characteristics tend to be less
stable, resulting in increased spatter.

74
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
3-Pulsed arc requires a welding power
source capable of producing a pulsing direct
current output which allows for improved
heat control and process flexibility
4-Short circuiting transfer results in the least
amount of heating to the base metal, making
it an excellent choice for welding of sheet
metal and joints having excessive gaps due to
poor fit up. “for heavier section welding,
incomplete fusion can result from insufficient
heating of the base metal”.

75
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 CO2 is probably the most popular gas for
GMAW of carbon steel, primarily due to its
relatively low cost and its excellent
penetration characteristics. One drawback,
however, is that there will be more spatter
which may require removal, reducing
operator productivity.

76
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Spray Globular
77
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Short-Circuiting Transfer

78
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Advantages:
 GMAW can be effectively used to join or
overlay many types of ferrous and nonferrous
metals.
 GMAW can be used successfully in situations
where the presence of hydrogen could cause
problems.
 GMAW is well suited for automatic and
robotic welding or other high production
situations.
 The efficiency is further increased by the
fact that the continuous spool of wire doesn't
require changing nearly as often as the
individual electrodes used in SMAW.
79
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 High lbs/hr of metal deposited, which
reduces labor costs
 It is a relatively clean process because
less smoke is generated
 The visibility of the process ,welder
can more easily observe the action of the
arc and molten puddle to improve
control since no slag is present

80
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Limitation
 If the base metal is excessively
contaminated, the shielding gas alone may
not be sufficient to prevent the occurrence
of porosity.
 GMAW is also very sensitive to drafts or
wind which tend to blow the shielding gas
away and leave the metal unprotected. For
this reason, gas metal arc welding is not
well suited for field welding.
 The equipment required is complex

81
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Inherent Problems
 porosity due to contamination or loss of
shielding,
 Incomplete fusion due to the use of
short circuiting transfer on heavy sections,
and arc instability caused by worn liners
and contact tips.

82
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Flux Cored Arc Welding (FCAW)
 This is very similar to gas metal arc welding except
that the electrode is tubular and contains a granular
flux instead of the solid wire used for gas metal arc
welding
 The tubular electrode being fed through the contact
tube of the welding gun to produce an arc between the
electrode and the work piece.
 As the welding progresses, a bead of solidified weld
metal is deposited Covered by a layer of slag, as occurs
for shielded metal arc welding.
 With flux cored arc welding, there may or may not be
an externally-supplied shielding gas, depending upon
what type of electrode is used

83
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 84
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 EXXT-X
 An identification begins with the letter "E" which
stands for electrode.
 The first number refers to the minimum tensile
strength of the deposited weld metal in ten
thousands of pounds per square inch, so a "7"
means that the weld metal tensile strength is at
least 70,000 psi.
 The second digit is either a "0" or a "1." A "0"
means that the electrode is suitable for use in the
flat or horizontal fillet positions only, while a "1"
describes an electrode which can be used in any
position

85
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Following these numbers is the letter "T" which
refers to a tubular electrode.
 This is followed by a hyphen and then another
number which denotes the particular grouping
based upon the chemical composition of deposited
weld metal, type of current, polarity of operation.
 Some electrodes are to be used without any
additional shielding . They are designated by the
suffixes 3, 4, 6, 7, 8, 10, 11, 13, and 14.
 However, those electrodes having the numerical
suffixes 1, 2, 5, 9, or 12 require some external
shielding to aid in protecting the molten metal

86
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 87
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Gases typically used for flux cored arc
welding are CO2,or 75%Argon-25%CO2 or
other combination
 Depending on the type of electrode, the
operation may be DCEP (1, 2, 3, 4, 6, 9, 12)
or DCEN (7, 8, 10, 11, 13, 14) or both DCEN
or DCEP (5).

88
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Advantages
 High productivity in terms of the
amount of weld metal that can be
deposited in a given period of time.
 Requires less skills
 FCAW is capable of tolerating a greater
degree of base metal contamination than
is GMAW
 FCAW lends itself well to field situations

89
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Limitations
 The smoke reduces the welder's visibility to
the point where it may be difficult to properly
manipulate the arc in the joint , and their will
be a need for ventilation
 The equipment required for FCAW is more
complex than that for SMAW
 There exists a possibility that the solidified
slag could become trapped in the finished
weld.
 Lake of maintenance can cause the wire
feeding problems
 incomplete joint penetration, slag
inclusions, and porosity.

90
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Gas Tungsten Arc Welding (GTAW)

 The most significant feature of GTAW is

that the electrode used is not intended to be
consumed during the welding operation. It is
made of pure or alloyed tungsten which has
the ability to withstand very high
temperatures, even those of the welding arc.
 The presence of the thoria or zirconia aids
in improving the electrical characteristics by
making the tungsten slightly more emissive.

91
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 92
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Class Alloy Color
 EWP Pure tungsten Green
 EWCe-2 1.8-2.2% cerium Orange
 EWLa-1 1% lanthanum Black
 EWLa-1.5 1.5% lanthanum Gold
 EWLa-2 2.0% lanthanum Blue
 EWTh-1 0.8 -1.2% thorium Yellow
 EWTh-2 1.7-2.2% thorium Red
 EWZr 0.15-0.40% zirconium Brown

93
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 The EWTh-2 type is most commonly used
for the joining of ferrous materials.
 GTAW can be performed using DCEP, DCEN
or AC. The DCEP will result in more heating of
the electrode, while the DCEN will tend to heat
the base metal more. AC alternately heats the
electrode and base metal. AC is typically used
for the welding of aluminum because the
alternating current will increase the cleaning
action to improve weld quality. DCEN is most
commonly used for the welding of steels.

94
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Effect of DCEN
Current on
GTAW

95
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Effect of DCEP
Current on
GTAW

96
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Effect of AC
Current on
GTAW

97
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 GTAW uses inert gases for shielding. Argon
and helium are the two inert gases used in
GTAW. Some mechanized stainless steel
welding applications use a shielding gas
consisting of argon and a small amount of
hydrogen
The equipment
 required for GTAW has as its primary
element a power source like the one used for
SMAW, that is, a constant current type. Since
there is a gas present, it is now necessary to
have apparatus for its control and
transmission. Figure 3.22 shows a typical gas
tungsten arc welding setup.
98
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 99
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 An added feature of this welding system,
which is not shown, is a high frequency
generator which aids in the initiation of the
welding arc
 There are numerous applications for GTAW
in many industries. It is capable of welding
virtually all materials, because the electrode
is not melted during the welding operation.
Its ability to weld at extremely low currents
makes gas tungsten arc welding suitable for
use on the thinnest (down to 0.005 in.) of
metals.

100
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Its typically clean and controllable operation
causes it to be the perfect choice for extremely
critical applications such as those found in the
aerospace, food and drug processing,
petrochemical, and power piping industries.
Advantages
 The principal advantage of GTAW lies in the
fact that it can produce welds of high quality
and excellent visual appearance
 the process is quite clean and there is no slag
 it is suitable for welding most metals

101
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 where there is no commercially-available
wire for a particular metal alloy, it is possible
to produce a suitable filler metal by simply
shearing a piece of identical base metal to
produce a narrow piece which can be hand-fed
into the weld zone just as if it were a wire.
 disadvantages.
 GTAW is among the slowest of the available
welding processes
 low tolerance for contamination
 gas tungsten arc welding requires a high
skill level

102
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Problems
 porosity in the deposited weld.
 tungsten inclusions

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 103
 Submerged Arc Welding (SAW)
 the most efficient one mentioned so
far in terms of the rate of weld metal
deposition. SAW is characterized by the
use of a continuously-fed solid wire
electrode which provides an arc that is
totally covered by a layer of granular
flux; hence the name "submerged" arc.

104
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Submerged
Arc Welding
(SAW)

105
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 106
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Submerged Arc Welding (SAW)
 uses a separate electrode and flux, there
are numerous combinations available for
specific applications. There are two general
types of combinations which can be used to
provide an
alloyed weld deposit: an alloy electrode with
a neutral flux, or a mild steel electrode with
an alloy flux.

107
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Identification
FXXX-EXXX
 Examples
 F7A6-EM12K is a complete designation. It
refers to a flux that will produce weld metal
which, in the as-welded condition, will have a
tensile strength no lower than 70,000 psi (480
MPa) and Charpy V-notch impact strength of a
least 20 ft-lb (27 J) at -60°F (-51 °C) when
produced with an EM12K electrode under the
conditions called for in this specification.

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky

 F7A4-EC1 is a complete designation for a
flux when the trade name of the electrode
used in the classification is indi-cated as well.
It refers to a flux that will produce weld metal
with that electrode, which in the as-welded
condition, will have a tensile strength no
lower than 70,000 psi (480 MPa) and Charpy
V-notch of at least 20 ft-lb (27 J) at -40°F (-
40°C) under the conditions called for in this
specification.

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky

 The equipment
 used for submerged arc welding consists of
several components a power source is
required. most submerged arc welding is
performed with a constant voltage power
source, there are certain applications where a
constant current type is preferred.
 the flux is generally placed into a hopper
above the welding torch and fed by gravity so
that it is distributed either slightly ahead of
the arc or around the arc from a nozzle
surrounding the contact tip.

110
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 For some applications, multiple
electrodes can be used. The electrodes
may be energized by a single power
source, or multiple power sources may be
necessary
 Due to the high rate of weld metal
deposition, it has shown to be quite
effective for overlaying or building up
material surfaces

111
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Advantages
1-High deposition rate
2-High operator appeal
3-less smoke generated
4-Ability to penetrate deeply
limitation
1-flat or horizontal fillet positions only
2-extensive fixturing and positioning equipment
3-slag must be removed
4-the flux prevents the welder from seeing the
arc

112
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Width vs Depth Ratio

113
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Inherent problems
 porosity .
 underbead cracking .
 solidification cracking .

114
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Plasma Arc
Welding
(PAW)

115
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Plasma Arc Welding (PAW)

 A plasma is defined as an ionized

gas. With any process using an arc, a
plasma is created.
 Both GTAW and PAW use the same
type of power source
 Both the PAW and GTAW torches
use a tungsten electrode for the
creation of the arc

116
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 117
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 There is a "plasma" gas which is forced
through this orifice and past the welding arc
resulting in the constriction of the arc.
 This constriction, or squeezing, of the arc
causes it to be more concentrated, and
therefore more intense.
 There are two categories of plasma arc
operation, the transferred and nontransferred
arc.
 The transferred arc is generally used for
both welding and cutting of conductive
materials,

118
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
  The no transferred arc is preferred
for the cutting of nonconductive
materials and for welding of
materials when the amount of
heating of the work piece must be
minimized.

119
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Transferred vs Nontransferred Arc

120
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 two separate gases are required: the
shielding gas and the orifice (or plasma) gas.
Argon is most commonly employed for both
types
 PAW is used for full penetration welds in
material up to 1/2 in. thick by employing a
technique referred to as "keyhole welding."
Figure 3.32 shows the typical appearance of a
keyhole weld.
 Keyhole welding is performed on a square
butt joint with no root opening.

121
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Keyhole
Welding
Technique

122
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Advantages
 It provides a very localized heat source.
 Faster welding speeds and less distortion
 The welder has better visibility
 The welder is less likely to contact the
molten metal and produce a tungsten
inclusion.
Limitations
 possibility of getting incomplete fusion
 small amounts of mistracking can produce
incomplete fusion along the joint.

123
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Electroslag Welding (ESW)
 ESW is characterized by the joining of
members which are placed edge to edge so
that the joint is vertical. The welding is done
in a single pass such that the progression is
from the bottom to the top of the joint
 ESW is that it is not an arc welding
process. It relies on heating from the
electrical resistance of the molten flux to
melt the base and filler metals.

124
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Electroslag
Welding
Equipment
----
Conventional

125
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Electroslag
Welding
Equipment
---
Consumable
Guide

126
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 ESW Advantages

 Joins heavy sections

 High deposition rates
 Single or multiple electrodes
 Minimum joint preparation
 Low distortion

127
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 ESW Limitations
 Vertical ‘casting’ process
 Very extensive setup time
 Uses water-cooled shoes
 Flux storage
 Largely confined to vertical
orientation and flat position only

128
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 ESW Discontinuities

 Gross porosity
 Slag inclusions
 Large grains
 Gross shrinkage
 Cracks

129
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Advantages
 high deposition rate
limitation
 the extensive time required to set up
and get ready to weld.
 not economical for thinner sections
inherent problems
 Gross porosity
 centerline cracks due to weld metal
shrinkage grain growth in the weld metal
Inherent problems
 weld metal properties could be
degraded

130
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Oxyacetylene
Welding
(OAW)

131
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Oxyacetylene Welding (OAW)
 acetylene is the only fuel gas capable of
producing high enough temperatures for effective
welding.
 With OAW, the energy for welding is created by a
flame, so this process is considered to be a
chemical welding method.
 the shielding for is accomplished by this flame
therefore no flux or external shielding is necessary
 The equipment
for oxyacetylene welding is relatively simple
 It consists of several parts: oxygen tank,
acetylene tank, pressure regulators, torch, and
connecting hoses.
132
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 A higher amount of oxygen will create an
oxidizing flame and a higher amount of
acetylene will produce a carburizing flame.
 filler material identification
 Two examples are RG-45 and RG-60. The
"R" designates it as a rod, "G" stands for gas
and the 45 and 60 relate to the minimum
tensile strength of the weld deposit in
thousands of pounds per square inch (psi).
 It is used for the welding of thin steel
sheet and small diameter steel piping and
maintenance situations.

133
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Oxyacetylene Welding

134
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 OAW
Equipment

135
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 OAW Filler Metals

RG - 45
RG - 60

‘R’ refers to rod

‘G’ refers to gas

136
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 OAW Advantages

 Simple equipment
 Suitable for thin materials
 Very portable
 No electricity required

137
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 OAW Limitations

 Very slow process

 Manual only
 Less concentrated heat
 Low productivity
 Flame adjustment sensitive

138
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Stud Welding
(SW)

139
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Stud Welding (SW)
 SW is considered to be an arc welding
process
 The process is controlled by a mechanical
gun which is attached to a power supply
through a control panel
 Due to the convenience and simplicity
offered by SW, it has seen tremendous usage in
many industries for a variety of metals.
 SW has two possible discontinuities. They
are lack of 360° flash and incomplete fusion at
the interface
140
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Stud
Welding
Components

141
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Stud
Welding
Cycle

142
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 SW Studs and Fasteners

143
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Stud Welding - Studs

 Flux on tip cleans weld area

 ‘Stand off’ tips also used

144
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 SW Advantages

 Simple
 Fast
 Repetitive
 Automatic stud feeding (option)

145
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 SW Limitations

 Needs clean surface

 Equipment malfunctions

146
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 SW Discontinuities

 Lack of ‘flash’
 Incomplete fusion

147
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Laser Beam
Welding
(LBW)

148
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 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

149
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 LBW - 2 of 2

 Light can be transmitted by

fiber optics or mirrors
 Non-contact process
 Shielding gas often required

150
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Cross Section of LB Weld

151
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 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
152
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 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

153
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 LBW Limitations

 Joints must be accurately positioned

 Surfaces must be forced together
 Alloy reflectivity and thermal
conductivity
 Plasma control device often required
 Cost

154
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 LBW Discontinuities

 Porosity
 Embrittlement

155
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Electron Beam Welding (EBW)

156
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 EBW
 Originally required high vacuum
 Can now operate in low, or no,
vacuum
 A fusion joining process
 Heat applied from stream of
high-energy electrons from gun

157
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 EB
Schematic

158
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Electron
Beam
Welding
Fixture

159
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 EB Weld

160
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 EBW Advantages

 Similar to LBW
 Deeper penetration capability
 High purity, especially for
vacuum environment
 High welding speeds
 Ability to change weld shape

161
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 EB Limitations

 Similar to LBW
 Vacuum chamber may be
required
 Vacuum chamber size can
limit assembly size
 X-Rays generated
 Cost

162
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 EBW Discontinuities

 Cracking
 Root voids
 Porosity

163
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Resistanc
e Welding
- 1 of 3

164
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Resistance Welding
- 2 of 3

165
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Resistance Welding
- 3 of 3

 Heat obtained from resistance

of workpieces as current flows
through them
 Electrodes are usually copper

166
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 RSW Advantages

 Very fast welding times - < 1

sec / spot
 Semiautomatic or automatic
 Good for thin materials
 No flux required

167
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 RSW Limitations

 Inspection of welds may be

difficult
 Primarily a shop process
 Electrodes must be clean
 Metal surfaces must be clean

168
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 RSW Discontinuities

 Non-fusion areas
 Cracks
 Misalignment of RSEW
electrodes

169
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Brazing

170
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Brazing vs Welding vs
Soldering
 Base metal not melted in brazing or
soldering
 Brazing filler metals melt above
8400 F (4500 C)
 Soldering filler metals melt below
8400 F
 Strong joints possible with all
processes if designed properly

171
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Brazing Aspects

 Large surface area

 Very small clearance
 Clean surfaces
 Flux often used
 Capillary action

172
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Braze Joint Configurations

173
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Brazing Filler Metals

 Wire
 Strip
 Foil
 Paste
 Preforms

174
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 AWS Brazing Filler
Metals
Designation Primary Element
BAlSi Aluminum-Silicon
BCuP Copper-Phosphorus
BAg Silver
BAu Gold
BCu Copper
RBCuZn Copper-Zinc
BMg Magnesium
BNi Nickel

175
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Brazing Methods
Named after heating
method
 Torch
 Furnace
 Induction
 Resistance
 Dip
 Infrared

176
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Brazing Advantages

 Strong joints
 Joins dissimilar metals
 Joins metals to nonmetals
 Joins “unweldable” metals
 Less heat, less distortion

177
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Brazing Limitations

 Cleanliness requirements
 Joint design requirements
 Difficult to inspect

178
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Brazing Discontinuities

 Voids, unbonded areas

 Base metal erosion
 Corrosion by flux
 Trapped flux

179
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Cutting Processes

We will be discussing:
 Oxyfuel Cutting
 Air Carbon Arc Cutting
 Plasma Arc Cutting
 Mechanical Cutting

180
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Oxyfuel
Cutting (OFC)

181
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Oxyfuel Cutting (OFC)

182
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 OFC - Kerf and Drag

183
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 Oxyfuel Cutting Gases
Commonly used

 Acetylene
 Methane
 Propane
 MPS

184
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 OFC Torches

185
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 OFC Cut

186
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
 OFC Advantages

 Simple equipment
 Very portable
 Cuts thin or thick materials
 Good accuracy
 Manual or mechanized

187
Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky
Main Content Page Layout•

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 188
 The End …… any questions?

Cairo Inspection Company (CIC) Www. [Link] Eng. Ibrahim Eldesoky 189