Department of Industrial and Production Engineering
Welding Technology
Unit - 2
Arc Welding Processes
Shrivardhan Bhargava
Assistant Professor
IPE Department, SGSITS, Indore
Arc Welding Process
What is arc welding?
Arc welding is a type of welding process using an electric arc to create heat to melt and join metals. A
power supply creates an electric arc between a consumable or non-consumable electrode and the base
material using either direct (DC) or alternating (AC) currents.
How Does it Work?
▪ Arc welding is a fusion welding process used to join metals.
▪ An electric arc from an AC or DC power supply creates an intense heat of around 6500°F which melts
the metal at the joint between two work pieces.
Arc Welding Process
▪ The arc can be either manually or mechanically guided
along the line of the join, while the electrode either simply
carries the current or conducts the current and melts into
the weld pool at the same time to supply filler metal to the
join.
▪ Because the metals react chemically to oxygen and
nitrogen in the air when heated to high temperatures by
the arc, a protective shielding gas or slag is used to
minimize the contact of the molten metal with the
air. Once cooled, the molten metals solidify to form a
metallurgical bond.
Arc Welding Process
Mechanism of arc welding:
• Arc welding uses an electric phenomenon called arc discharge. An arc discharge is an electric discharge
phenomenon of a gas and refers to current released in air.
• When the voltage applied to two spatially separated electrodes is gradually increased, the air insulation
finally breaks and current flows between the electrodes, emitting bright light and high heat at the same
time. The generated arc-shaped light is called an electric arc or arc.
• Arc welding is using the heat of an arc as a heat source. In arc welding, positive voltage is applied to the
electrode (welding rod or wire) and negative voltage is applied to the base material. This makes an arc
occur from the base material to the electrode.
Arc Welding Process
• The output current of the arc is about 5 to 1000 A and the output voltage is about 8 to 40 V. The
temperature of the arc is about 5000°C to 20000°C. The melting temperature of iron is about 1500°C.
Consequently, the base material and electrode are heated to a high temperature and fuse together.
Arc Welding Process
Electrode consumption Welding method
Consumable (fusible) electrode type ▪ Manual Metal Arc Welding (MMAW)
▪ Metal Inert Gas welding (MIG)
▪ Pulsed MIG Welding
▪ Submerged arc welding (SAW)
▪ Flux Cored Arc Welding (FCAW)
▪ Electroslag arc welding (ESW)
Non-consumable (non-fusible) electrode type ▪ Tungsten Inert Gas welding (TIG)
▪ Plasma arc welding (PAW)
Arc Welding Process
Manual metal arc welding (MMA or MMAW):
▪ It is also known as shielded metal arc welding (SMAW) or
flux shielded arc welding or stick welding.
▪ Shielded metal arc welding (SMAW) is a process that melts
and joins metals by heating them with an arc established
between a sticklike flux coated metal electrode and the
metals.
▪ The core wire conducts the electric current to the arc and
provides filler metal for the joint.
▪ The electrode holder is essentially a metal clamp with an
electrically insulated outside shell for the welder to hold
safely.
Arc Welding Process
▪ 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.
▪ Shielding gas is a mixture of H2 , CO, H2O and CO2.
Arc Welding Process
Functions of electrode (flux) covering:
➢ Protection: Provide the gaseous shield to protect the molten metal from air.
1) Cellulose-type electrode (C6H10O5)x - It is providing gas mixture of H2 , CO, H2O and CO2.
2) Limestone-type electrode (CaCO3) - It is low in hydrogen and used for welding metals that are
susceptible to hydrogen cracking such as high-strength steels.
➢ Deoxidation: Provide deoxidizers and fluxing agent to deoxidize and cleanse the weld metal. The solid
slag also protects the weld metal from oxidation.
➢ 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) to the weld pool.
Arc Welding Process
Advantages:
▪ Simple welding equipment.
▪ Portable.
▪ Inexpensive.
▪ Used for maintenance, repair, and field construction.
Disadvantages:
▪ Not clean enough for reactive metals such as aluminium and titanium.
▪ The deposition rate is limited because the electrode covering tends to overheat and fall off.
▪ The electrode length is ~ 35 mm and requires electrode changing and lower the overall production rate.
Arc Welding Process
Metal Inert Gas welding (MIG):
▪ Metal inert gas (MIG) welding is a process that melts
and joins metals by heating them with an arc
established between a continuously fed filler wire
electrode and the metals.
▪ Argon (Ar) and Helium (He) are also used as inert
shielding gases to protect the molten weld pool. It is
often called Gas metal arc welding (GMAW).
However, non-inert gases i.e. CO2 are also used for
carbon and low alloy steels.
Arc Welding Process
▪ Mixtures of Argon (25%) and Helium (75%) are
used for non-ferrous (mostly Al) as well as stainless
steels and alloy steels.
▪ The Argon arc plasma is stable and beneficial for
transferring metal droplets through the arc plasma.
Arc Welding Process
Modes of metal transfer: The molten metal at the electrode tip can be transferred to the weld pool by
▪ Globular transfer:
✓ Metal droplets travel across the arc gap under the influence of gravity.
✓ Often not smooth and cause spatter (i.e. the splashing and scattering of metal droplets).
✓ Low welding current (180 A).
▪ Spray transfer:
✓ Occur above a critical current level (280 – 320 A).
✓ Small metal droplets travel across the gap under the influence of the electromagnetic force at much
higher frequency and speed than in the globular mode.
✓ More stable and spatter free.
Arc Welding Process
▪ Short-circuit transfer:
✓ Molten metal droplets are transferred from electrode tip to the
weld pool when it touches the pool surface (short-circuit).
✓ Require very low current and electrode diameter, giving small
Globular transfer
and fast - freezing weld pool desirable for welding thin
section or out of position welding.
Spray transfer
Short circuit transfer
Arc Welding Process
Advantages:
▪ Very clean due to inert shielding gas used.
▪ Much higher deposition rate.
▪ Can weld thicker weld sections at higher weld speeds.
▪ Can use dual-touch and twin-wire processes to further increase the deposition rate.
▪ Short and stable arc make it easier to weld (skill is not required).
Disadvantages:
▪ The GMAW gun is quite bulky and difficult to reach small areas or corners.
Arc Welding Process
Pulsed MIG Welding:
▪ It is the modified spray transfer MIG welding.
▪ It is based on the principle of pulsation of welding current between a high and a low level at regular
time intervals.
▪ The low level welding current, also called background current is mainly expected just to maintain
welding arc.
▪ The high level welding current, also called peak current is primarily used for,
a) Melting of faying surfaces with desired penetration of the base metal. A faying surface is one of the
surfaces that are in contact at a joint e.g. steel pipe flanges.
b) High melting rate of electrode.
c) Detachment of molten droplets hanging to the tip of the electrode to facilitate spray transfer.
Arc Welding Process
▪ An optimum combination of pulse
parameters results in transfer of one
molten metal drop per peak pulse.
▪ Pulsed MIG welding is possible only if
power source is able to supply a pulsed
current.
▪ Unlike spray transfer the stream is not
continues due to pulsation welding
current between low level and high
level current.
Heating mechanism of pulsed MIG welding and continuous MIG welding:
(a) sketch map of MIG welding process, (b) forming process of molten pool
in pulsed MIG welding and (c) forming process of molten pool in continuous
MIG welding.
Arc Welding Process
Advantages:
▪ Wire and gas savings: Since Pulsed MIG machines offer a wider operating range, rather than having
two or three different sized wires, an operator would only require one. Having one wire type minimizes
inventory costs and reduces changeover times.
▪ Spatter reduction:
▪ Heat reduction: Pulsing offers controlled heat input leading to less distortion.
▪ Improved productivity: Pulsed MIG offers high deposition rates. It is easier to weld with pulsed MIG
than other transfer methods with the new machines which are simpler and more adaptive.
▪ Out of position welding:
▪ Larger diameter wire possible:
▪ Low and high reactive metals can be welded:
Arc Welding Process
Limitations:
▪ Equipment is typically more expensive than conventional step-down transformer power sources.
▪ Gas blends required are more expensive than the commonly used 100% CO₂ or 75% Argon & 25% CO₂
gas.
▪ Higher arc energy produces higher levels of radiated heat and a brighter arc, this requires more
protection for the welder (usually gloves with heat shield).
Arc Welding Process
Submerged arc welding (SAW):
▪ Submerged arc welding (SAW) is a process that melt and
join metals by heating them with an arc established
between a consumable wire electrode and the metals, with
the arc being shielded by a molten slag and granular flux.
▪ The arc is submerged and invisible.
▪ The flux is supplied from a hopper, which travel with the
torch.
▪ The shielding gas may not be required because the molten
metal is separated from the air by the molten slag and
granular flux.
Arc Welding Process
Advantages:
▪ Clean welds are obtained due to protecting and refining action of the slag.
▪ At high welding current, spatter and heat loss are eliminated because the arc is submerged.
▪ Alloying elements and metal powders can be added to the granular flux to control the composition and
increase the deposition rate respectively.
▪ The deposition rate can be increased by using two or more electrodes.
▪ It can weld thick section.
Disadvantages:
▪ Cannot weld in a flat-position and circumferential (pipe).
▪ High heat input can reduce the weld quality and increase distortions.
Arc Welding Process
Flux Cored Arc Welding (FCAW):
▪ Flux cored arc welding (FCAW) is a semi-automatic arc welding process.
▪ FCAW uses a continuous wire fed electrode and a constant-voltage welding power supply.
▪ Flux cored arc welding uses heat generated by an electric arc to fuse base metal in the weld joint area.
▪ This arc is struck between the metallic workpiece and the continuously-fed tubular cored consumable
filler wire, with both the wire and the metallic workpiece melting together to form a weld joint.
▪ FCAW welding uses a hollow, tubular electrode filled with flux rather than a solid metal electrode.
Arc Welding Process
Advantages:
▪ FCAW is preferable for outdoor use as well as for joining of thicker materials.
▪ The built-in shielding provided by the filler wire can endure strong breezes and, if used without an
external shielding gas, FCAW is portable and convenient.
▪ This welding process also provides more flexibility with alloy compositions.
▪ It also offers higher wire deposition rates and improved arc stability, allowing for high speed
applications without adversely affecting good quality weld.
▪ Flux cored arc welding can be an ‘all position’ process and also requires less skill among operators.
▪ It also requires less pre-cleaning of metals than other processes.
▪ The chances of porosity are also very low if FCAW is applied correctly.
Arc Welding Process
Disadvantages:
▪ Production of noxious smoke that can make it difficult to see the weld pool. FCAW generates more
smoke than other processes.
▪ Porosity can also be a problem if the gases from the weld metal are not able to escape out before the
weld metal solidifies.
▪ FCAW electrodes require better handling and storage procedures compared with solid wire electrodes.
Because of tubular nature, filler material can be sometimes more expensive than the solid counter parts.
▪ The correct filler metal needs to be chosen to ensure the required mechanical properties. Also,
consistent wire feeding needs to be ensured to avoid related weld problems.
▪ Another disadvantage is the slag formation that needs to be removed prior depositing each subsequent
layer. Finally, while FCAW is excellent for joining thicker metals, it is not recommended for use on
materials thinner than 20 gauge.
Arc Welding Process
Electroslag arc welding (ESW):
▪ Electroslag welding (ESW) is a process that melt and join
metals by heating them with a pool of molten slag held
between the metals and continuously feeding a filler wire
electrode into it.
▪ The weld pool is covered with molten slag and move upward
as welding progresses.
▪ A pair of water-cooled copper shoes keeps the weld pool and
the molten slag from breaking out.
▪ The molten slag protects the weld metal from air and refine it.
▪ The arc is only used during the initiation process.
Arc Welding Process
Advantages:
▪ Extremely high deposition rate.
▪ One single pass is required, no matter how thick the workpiece is.
▪ No angular distortion because the weld is symmetrical with respect to its axis.
Disadvantages:
▪ Very high heat input.
▪ Weld quality could be poor due to coarse grain in the fusion zone or heat affected zone.
▪ Strict to vertical position due to very large weld pools.
Arc Welding Process
Tungsten Inert Gas welding (TIG):
▪ It is also called Gas-tungsten arc welding (GTAW).
▪ It is a process that melt and join metals by heating them
with an arc established between a non-consumable
tungsten electrode and the metals.
▪ The tungsten electrode is normally contacted with a water
cooled copper tube, which is connected to the welding
cable prevent overheating.
▪ The shielding gas (Ar, He) goes through the torch body
and nozzle toward the weld pool to protect it from air.
▪ Filler metal (for joining of thicker materials) can be fed
manually or automatically to the arc.
Arc Welding Process
Electrodes and shielding gases:
▪ Electrode: Tungsten electrodes with 2% cerium or thorium give better electron emissivity, current -
carrying capacity, and resistance to contamination than pure electrodes and the arc is more stable.
▪ Shielding gas:
Note: Ar is heavier and
offers more effective
shielding and cheaper than
He.
Arc Welding Process
Advantages:
▪ Suitable for joining thin section due to its limited heat inputs.
▪ Can weld metals without fillers (autogenous welding).
▪ Very clean welding process, which can be used for welding reactive metals such as titanium, zirconium,
aluminium and magnesium.
Disadvantages:
▪ Deposition rate is low.
▪ Excessive welding current causes melting of the tungsten electrode and results in brittle tungsten in the
weld pool.
▪ Multiple passes required.
▪ Low welding speed.
Arc Welding Process
Plasma arc welding (PAW):
What is Plasma?
Plasma is a gaseous mixture of positive ions, electrons and neutral gas molecules. It is nothing but a high
temperature ionized gas. It is generally a mixture of positively charged atoms and neutral charged atoms
and free elements. When this high temperature plasma is passed through the orifice, the proportion of the
ionized gas is increased and the plasma arc welding is formed. It is the basic principle of PAW.
What is PAW?
Plasma arc welding (PAW) is a process that melt and join metals by heating them with a constricted arc
established between a tungsten non-consumable electrode and either the work piece (transferred arc
process) or water cooled constricting nozzle (non-transferred arc process). It is similar to TIG but an
orifice gas and an shielding gas is used.
Arc Welding Process
Working:
▪ When the high heat content plasma gas is forced through the
torch orifice surrounding by negative tungsten electrode in
the form of jet.
▪ The plasma cutting force imposes a swirl on the orifice gas
flow. The arc is initiated in the beginning by supplying
electrical energy between nozzle and tungsten electrode.
▪ This will release high energy and heat. This heat is normally
in between 10,000°C to 30,000°C. This high amount of heat
energy is used to weld the metal.
Arc Welding Process
▪ The arc is constricted due to the covering action of the orifice
gas nozzle.
▪ The tungsten electrode is recessed in the orifice gas nozzle
and the arc is initiated by a high frequency generator between
the electrode tip and the water - cooled orifice gas nozzle.
▪ The arc is then transferred to, between the electrode tip and
the workpiece.
Arc Welding Process
Keyholing: Keyholing is a positive indication of
full penetration and allow higher welding speed
(for thickness 2.5 - 6.4 mm).
▪ Requires proper combinations of the orifice
gas flow, the travel speed, and the welding
current.
▪ A wine cup shape is common in PAW.
Arc Welding Process
Advantages:
▪ The electrode is recessed in the nozzle, therefore no contamination to the weld metal.
▪ Less sensitive to arc length variation.
▪ Full penetration (keyhole effect).
▪ High welding speed.
Disadvantages:
▪ More complicated.
▪ Require proper electrode tip configuration and positioning and orifice selection.
▪ Equipment is more expensive.
Arc Welding Process
There are two types Plasma Arc Welding used practically.
Transferred arc process:
▪ In transferred arc process, the workpiece is made an integral part of the electrical circuit. Therefore, the
positive terminal of the DC power source is connected to the workpiece (while the electrode remains
connected with the negative terminal).
▪ The workpiece must be electrically conductive. When sufficient voltage (around 200 V) is applied
across two terminals, a long electrical arc forms between the electrode and workpiece through the small
nozzle opening.
▪ As it is difficult to establish the arc directly between the electrode and workpiece (because of 5 – 10
mm gap), an auxiliary arc is established between the electrode and nozzle at the beginning of the work
for a very short period.
Arc Welding Process
▪ The plasma-forming gas that is pumped into the gas-chamber comes out through the small nozzle
opening surrounding the electric arc.
▪ Owing to the high arc temperature, the gas automatically gets converted to plasma and emerges out of
the nozzle in the form of a jet to finally strike the workpiece and produces plasma jet of high energy
density
▪ The transferred arc plasma torch is also known as direct arc plasma torch as electrical connection is
made directly between the electrode and workpiece. Both the arc and plasma are transferred to the
workpiece to increase the heating processes.
▪ It may be used for high speed welding and cutting of Ceramics, Steels, Aluminum alloys, Copper
alloys, Titanium alloys, Nickel alloys etc.
Arc Welding Process
Application of Transferred Plasma Arc Welding:
This process is suitable for work pieces that are subject to wear and tear or corrosion. Transferred plasma
arc welding is applied in the following processes;
▪ Forging matrix dies.
▪ Plasticizing screw.
▪ Making hydraulic cylinders.
▪ Making molds and accessories for the glass industry.
▪ Forging industrial blades and knives.
▪ Making automotive valves.
Arc Welding Process
Non-transferred arc process:
▪ The problem with transferred arc process arrangement arises when the workpiece is not electrically
conductive. In such cases, the copper nozzle is connected to the positive terminal of the DC power
source, while no connection is made with the workpiece. Such an arrangement is known as non-
transferred arc process or indirect arc plasma torch.
▪ Here electric arc forms between the electrode and the nozzle. However, the plasma-forming gas
forcefully directs the arc into the small nozzle opening, while itself gets converted to plasma and comes
out of the nozzle as a high temperature high velocity jet.
▪ It produces plasma of relatively low energy density. It is used for welding of various metals and for
plasma spraying (coating).
▪ Since the work piece in non-transferred plasma arc welding is not a part of electric circuit, the plasma
arc torch may move from one work piece to other without extinguishing the arc.
Arc Welding Process
▪ The heat generated from non-transferred plasma arc welding is more dispersed than the transferred
plasma arc. This makes the non-transferred arc welding process suitable for a wide range of
applications. Current flows from the electrode inside the torch to the orifice-containing nozzle and back
to the power supply.
Application of Non-Transferred Plasma Arc Welding:
▪ The primary purpose of this process is plasma spraying.
▪ This is a thermal coating process whereby heat-softened particles that form a coating are applied onto a
substrate. This reduces corrosion damage and gives materials a longer life.
Arc Welding Process
Difference Between Transferred Arc and Non-Transferred Arc Plasma Torch