In JBES( Jay Bharat Exhaust Systems) four types of welding take place:
1. TIG
2. MIG( Actually MAG welding is used here)
3. Spot
4. Projection welding
The plant has around 62 MAG (Metal Active Gas ) stations , 7 Spot welding stations , 3 Projection
welding stations and 1 TIG welding station. The welding is done on the sheets ranging from 1.2 m to 10
mm in thickness.
Projection Welding
It is an example of resistance welding that produces coalescence of the material by the heat
obtained due to the resistance in the flow of the [Link] current used here is in kiloamperes .
The resulting welds are formed at the predetermined places by projections , embossments etc.
Spot Welding
It is a resistance welding process that produces coalescence at the faying surfaces of a joint by the
heat obtained from resistance to the flow of the welding current to the workpieces from the
electrode that serve to concentrate the welding current and the pressure at the welded area.
Various components required for spot welding:
[Link] transformer
2. A means of applying pressure
3. A controller/contractor
4. Electrode tips for conducting welding current to the work
Gas Tungsten Arc Welding ( TIG)
GTAW is an arc welding process which produces coalescence of materials by heating them with an
arc between a tungsten electrode and the work . Please note that the tungsten electrode here is a
non consumable. Shielding is obtained by the use of some gas or a mixture of gases . Both pressure
and filler material can or cannot be used. In Europe it is called WIG welding.
Gas metal arc welding
It is a meathod in which an arc is used between the filler material electrode and the weld [Link]
process is done by shielding the weld pool with the help of the gas.
General Description
A welding process where the necessary heat for welding is produced by an electric arc
maintained between a consumable electrode wire and the part to be welded.
The heat affected zone, the molten metal and the electrode are all shielded from the
atmosphere by a blanket of shielding gas fed through the GMAW torch.
Principle of Operation
The gas metal arc welding process utilizes the heat of the arc between a continuously fed
consumable electrode and the work piece to be welded. The heat of the arc melts the surface of the
workpiece and the end of the electrode. The metal melted odd the electrode then deposits on the
workpiece in form of a weld deposit. The shielding is obtained by the use of various gases which may
be inert , active, ora mixture of both .The gas protects the weld pool from the external atmosphere .
The electrode is fed automatically and the travel and guidance can be both manual or automatic.
The metal being welded determines the composition of the electrode and the shield gas.
Setup
The GMAW requires the following parts:
[Link] feeder
[Link] source
[Link] gas
[Link] gun
[Link] metal
[Link] material
Various shield gases used:
• Argon ( Ar )
• Carbon Dioxide ( CO2 )
• Oxygen ( O2 )
• Helium ( He )
• Hydrogen ( H2 )
• Nitrogen ( N2 )
CO2 is a low cost gas thus making MAG welding cost efficient . It also supports high travel
speeds and has very good penetration. The deposition is also quite high.
Argon is used in the cases when we require good weld finish.
Setting Variables
Wire Feed Speed (Amperage)
Voltage
Electrical Stick-out
Travel Speed
Gun Angle
Gas Flow Rate
[Link] Feed Speed (WFS) or Amperage
Wire Feed Speed (WFS) is generally set at the wire feeder
The WFS is proportional to the average amperage
WFS is measured in :
• meters / minute
• meters / minute
WFS is generally determined by size of weld, weld position, and thickness of material
[Link]
Voltage is generally set at the power source
Changes in voltage affect :
• heat input
• arc length
• type of transfer mode
• bead width
• bead profile
• penetration
[Link] Speed
For a given WFS and voltage setting an optimum travel speed is obtained for different
weld sizes
Increases in travel speed will :
• decrease penetration
• reduces weld size
• reduces heat input
[Link] Angle
Gun angle is used to control bead appearance and weld quality
As seen on following slide, gun angle affects bead width, bead profile and penetration
Incorrect gun angle can cause weld defects such as :
• undercut on fillet welds
• lack of penetration
[Link] Flow
Proper shielding gas flows must be maintained to ensure that the molten weld puddle is
protected from the atmosphere
Too low or too high of a gas flow can have detrimental effects on the weld quality
• too low can cause lack of proper shielding
• too high can cause turbulence which pulls in outside air
Care should be taken to protect the weld area from external drafts
Wire Feeders types
There are two types of wire feeders that can be used in GMAW :
Constant speed feeder
• most common type used
• used with CV power supplies
Variable Speed (voltage sensing) feeder
• limited application
• usually used with CC power sources
• generally limited to larger
diameter wires in flat positio
Advantages of GMAW
Able to weld a large number of commercially available metals
High deposition rates / deposition efficiency
High travel speeds
Low hydrogen deposits are attainable
Reduced chances of cracking
No slag covering on the weld
Easy to clean weld
Only silicate islands present
Low fume generation
Safer environment for the welder
Disadvantages of GMAW
Equipment generally more expensive
Out of position welding may require specialized equipment
Limitations on extremely thin or intricate welding
More sensitive to porosity caused by air drafts
Can be more sensitive to operating parameters versus other processes