WELDING PROCESS

Disadvantages: 2. Aglomerated: granular appearance, good properties,

MMA (MANUAL METAL ARC) Low productivity, low operating factors, high skill Variable: 4. Pulsed Transfer: addition od additive, good recycling, very hugroscopic.
 Also known as SMAW (Shielded Metal Arc Welding) required, required oven to bake the electrode, not Current, voltage, T. Speed, electrode extension, Low Heat input, low distortion, better fusion (Co2 for
 MMA is an Arc Welding Process uses an arc suitable for reactive materials polarity, gas flow rate deep penetration but make many spatter) Function of flux: to provide shielding to avoid atmospheric
between a contamination, to stabilize the arc, to add deoxidant, to
melting tip of covered electrode to the base metal Safety: Materials: improve the properties of weld metal
 he type of Power Source characteristic is constant Arc rays, electric shock, burn skin, fumes, fire, S: Min 1.0 mm ~ max 15.0 mm
current or drooping arc explosion (ledakan) T: Suitable for most materials including the reactive Current controls the depth of penetration
Figure: V materials such as titanium
TIG (TUNGSTEN INERT GAS) C: Must be very cleaned Voltage controls the weld bead shape:
 Also known as GTAW (Gas Tungsten Arc Welding) Current control; the depth of penetration (WFS) – wire High voltage = flatter bead shape
Consumable: feed speed combined with current Low voltage = change properties, high flux melting
I  TIG as an arc welding process uses an arc between S: Min 0.8 mm ~ Max 4.0 mm Voltage controls; the weld bead profile, high voltage =
Type of welding machine: Transformer, DC Rectifier, a non consumable electrode to the base metal T: As Per parent metal flatter weld bead shape Welding head arrangement: single head single wire, single
Engine Driver, Inverter  Filler metal may or may not be added to the molten C: Store at clean and dry area head twin wire, tandem wire
pool (autogenously) Type of torch:
Type of polarity: DC + (Reverse Polarity)  Deepest  The type of power source is constant or drooping Gases: Air cooled, water cooled – Al, mg Variables: current (H. Current – H. deep penetration),
Penetration, Ar, He, Ar+He, Ar + H2 (Austenitic Stainless Steel) Voltage, T. Speed (L. T. speed – H. deepest and weld
DC – (Straight Polarity)  the hair deposit high, AC Arc Characteristic: Type of roller: V’ Groove, U’ Groove, Knurled (FCAW) bead), wire size (Small wire – H. deepest penetration),
Figure: V Typical Defects: electrode extension, flux depth (not depth will be result
Type of Flux Covering: Rutile (Co2)  General Tungsten Inclusion, Silica inclusion (ferritic steel), Equipment Set-up: porosity).
purpose nothing spatter and slag inclusion
Cellulose (H2)  Deepest penetration, Basic (Low H2) Materials:
I Advantages: S: min 6.0 mm ~ Max 150.0 mm
Function of Flux Covering: Type of welding machine: Very high quality welding process, very smooth and T: C. Steel, S. Steel, Alloy
 To provide shielding to avoid atmospheric Transformer / rectifier, inverter clean, easily automated, suitable for thin mat’l, suitable C: Moderated Cleaning
- +
contamination for any welding positions, versatile, low H2 welding
 To provide deoxidant to avoid surface Type of polarity: process (<3 ml / 100 gr) Consumable:
contamination DC+, DC-  Steel, AC  Al, mg S: min 2.4 mm ~ max 6.0 mm
 To improve smoothness of weld metal and to Disadvantages: T: as per parent metal
produce slow cooling by slag layer Table: Low productivity, expensive, need gas for shielding, not C: store at clean and dry area
 To improve the properties of weld metal Effect of DC - DC + AC suitable for thick mat’l, ozone levels, high frequency
 To aid arc ignition polarity start will interfere the usage of electronic devices, Variables: current (WFS), Voltage, T. Speed, Stick out Fluxes:
 To stabilize the arc Electrical complex welding machine length, nozzle to work distance, contract tube to work  fused (high resistance to moisture)
characteristic distance  Agglomerated = need to bake prior to their used, 500°
MMA is a manual welding process, welder control: Safety: C ~ 1H or as per manufactuter instructions
Arc length, Travel speed, Electrode angle Electron Arc rays, electric shock, burn skin Materials:
Flow or heat S: Min 1.0 mm ~ max 50.0 mm Typical defects: solidification crack, slag inclusion, burn
Equipment set-up MMA: MIG (Metal Inert Gas)  Ar, He, Ar + He T: C. Steel, Stainless steel, Al, Alloy, copper through, porosity
distribution
Figure MAG (Metal Active Gas)  Co2, Ar + Co2 C: Moderate cleaning  for avoid porosity it’s cover at
(2% - Austenitic stainless steel) antideoxidant Advantages: high quality, smooth profile, easily automated,
Penetration
suitable for thick mat’l, no visible arc
 Also known as GMAW (Gas Metal Arc Welding) Consumable:
Cleaning No Yes Yes,
 MIG/MAG is an arc welding process uses an arc S: Min 0.8 mm ~ Max 1.6 mm Disadvantages: bulky (besar sekali), not so portable,
action every
between a melting tip of ‘solid wire’ to the base T: As per parent metal difficult control the depth of penetration, H. heat Input,
half
- + metal C: Store at clean and dry area limited welding position, expensive
cycle
 The type of power source is constant voltage or flat
Gases: Ar, He, Ar +he, O2, Ar + O2, Co2 Safety: electric shock
Type of shielding gas: Note: Ar can not for steel, stainless steel and alloy
Characteristic:
 Argon: easy to initiate the arc, stable arc
Figure:
 Helium: hotter arc, high heat input, deeper Typical Defects:
Variables: penetration Spatter, lack of sidewall fusion (DIP), solidification crack,
Current, arc voltage (arc length), travel speed,  Ar + He, Ar + He ~ (2%) : austenitic stainless steel silica inclusion (ferritic Steel), Copper inclusion (15 dent
electrode angle, O.C.V (Open Circuit Voltage), polarity metallic)
Type of tungsten:
Materials:  Thoriated ~ 1% or 2% - Steel Advantages:
S: Min 3.0 mm ~ max 25 mm  Zirconiated – Al, mg High productivity, easily mechanized, low H2 welding
T: Carbon Steel, Stainless Steel, Copper, Alloy  Ceriated – AC and DC process (<3 ml/100 gr), suitable for all welding positions
Type of welding machine:
C: Some tolerance on the surface preparation  Lanthanum - AC and DC
Transformer rectifier, inverter
Type of polarity normally: DC + (Reverse polarity) Disadvantages: complex set-up, expensive, need gas for
Consumable: Technique to initiate the arc: shielding, high ‘ozone’ level, not suitable for restricted
S: Min 2.4 mm ~ max 6.0 mm Scratch start, high freq start, pulsed arc start access, need proper protection when use on site
Type of metal modes of transfer:
T: Basic, Rutile and Cellulose 1. Short circuiting or dip transfer :
C: Chip, Crack, Concentricity Type of welding torch: Safety: arc rays, electric shock, fumes, fire, burn skin
I < 200 A, V < 20 V, all welding positions, lack of
Air cooled, water cooled  al, mg, and thick materials
sidewall fusion, spatter
Treatment: SUB – ARC
Basic (low H2): Bake at 350° C ~ 1H or as per Equipment set-up:
manufactures instruction, holding oven at 150° C, Figure:  SAW (Submerged Arc Welding) also known
Quiver at 70° C ~ 80° C  Sub-arc is an arc welding process uses an arc
Rutile: My be oried at max 120°C ~ 1H 2. Spray Transfer: between a melting of ‘bare wire’ to the base metal.
Cellulose: Never Bake or what so ever Flat and HV, Al, mg, high dilution, solidification The arc is shielded by fused or agglomerated fluxes.
crack, Ar 85%
Typical defects: Type of power sources:
Slag inclusion, porosity, lack of side wall fusion, lack of - + Constant voltage < 1000 V, Constant Current > 1000 A
root penetration
Type of Flux:
Advantages: 3. Globular transfer:  in between dip and spray 1. Fused: flaky or shiny appearance, good recycling,
Simple to operate, portable, versatile, cheap and easy smooth profile, limited composition, high resistance to
maintenance, suitable for restricted access, low H2 moisture absorbtion
possible, not require gas for shielding.