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Welding Inspection
Part 2
Course Reference WIS 5
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Welding
BS 499 prt 1 Welding terms
A union between pieces of metal at faces
rendered plastic or liquid by heat,pressure or
both.
Possible energy sources
Ultrasonics
Electron beam
Friction
Electric resistance
Electric arc
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Welds
An ideal weld must give a strong bond
between materials with the interfaces
disappearing
To achieve this
• Smooth,flat or matching surfaces
• Surfaces shall be free from contaminants
• Metals shall be free from impurities
• Metals shall have identical crystalline
structures
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Welding Processes
Welding is regarded as a joining process in which the
work pieces are in atomic contact
Solid state processes Fusion welding processes
• Forge welding • Oxy-acetylene
• Friction welding • MMA (SMAW)
• MIG/MAG (GMAW)
• TIG/TAG (GTAW)
• Sub-arc (SAW)
• Electro-slag (ESW)
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Fusion Welding Factors
The four essential factors for fusion welding
1. Fusion is achieved by melting using a high
intensity heat source
2. The welding process must be capable of
removing any oxide and contamination from the
joint
3. Atmosphere contamination must be avoided
4. The welded joint must possess the mechanical
properties required by the specification being
adapted
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Electric Arc Welding
Arc Welding Processes
Manual metal arc
Tungsten Inert Gas
Metal Inert Gas
Submerged Arc
Differences between them
Methods of shielding the arc
Consumable or Non-consumable electrode
Degree of automation
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Manual Metal Arc Process (MMA)
Electrode covering
Electrode
core wire
Electric Arc
Solidified slag
Molten weld pool
Gas shield
Build up of weld metal
Penetration
Parent material
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Manual Metal Arc (MMA)
Shielding provided Welder controls
by decomposition of Arc length
flux covering Angle of electrode
Electrode Speed of travel
consumable
Amperage
Manual process settings
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Welding Power Sources
Drooping or Constant Current Characteristic
Large arc gap
Requires more volts
As the welder increases the arc gap, more volts are
required for the arc to bridge the increased arc gap.
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Welding Power Sources
Drooping or Constant Current Characteristic
Small arc gap
Requires less volts
As the welder reduces the arc gap, less volts are
required for the arc to bridge the reduced arc gap.
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Welding Power Sources
Drooping or Constant Current Characteristic
100
O.C.V. Striking voltage (typical) for arc
90
initiation
80
70
Required for: MMA, TIG, Plasma
60 arc and SAW > 1000 AMPS
Voltage
50
40 Large voltage variation, e.g. +
Normal Operating 10v (due to changes in arc
30 Voltage Range length)
Small amperage change
20
resulting in virtually constant
current e.g. + 5A.
10
20 40 60 80 100 120 130 140 160 180 200
Amperage
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Welding Plant
• Transformer:
Changes mains supply voltage to a voltage suitable for
welding. Has no moving parts and is often termed static
plant.
• Rectifier:
Changes a.c. to d.c., can be mechanically or statically
achieved.
• Generator:
Produces welding current. The generator consists of an
armature rotating in a magnetic field, the armature must be
rotated at a constant speed either by a motor unit or, in the
absence of electrical power, by an internal combustion
engine.
• Inverter:
An inverter changes d.c. to a.c. at a higher frequency.
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Manual Metal Arc (MMA)
Weld metal Weld metal
HAZ
HAZ
DC +ve DC -ve
• Wide shallow weld pool • Narrow deep weld pool
• Wide heat affected zone • Narrow heat affected zone
• Lower hardness • Increased hardness
• Slower cooling • Faster cooling
• Improved mechanical • Deep penetration
properties • May be used for the
• May be used for fillers and application of the root run
cap runs
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Manual Metal Arc (MMA)
The three main electrode covering types used
in MMA welding
• Rutile - general purpose
• Basic - low hydrogen
• Cellulose - deep penetration/fusion
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Tungsten Inert Gas (TIG)
Cap
Switch Switch
Handle power cable
Filler wire
Collet
Deposited weld metal
Non-consumable electrode
Shielding gas Gas inlet
& power
cable
Molten weld pool
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Tungsten Electrodes
• Old types
Thoriated: DC -ve electrode - steels and most metals
1% thoriated + tungsten for higher current values
2% thoriated for lower current values
Zirconiated: AC - aluminum alloys and magnesium
• New types
Cerium: DC -ve elctrode - steels and most metals
Lanthanum: AC - Aluminum alloys and magnesium
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Tungsten Inert Gas Welding
1. 2. 3. 4. 5.
1. Pre-flow timer control 4. Crater fill control
Adjusts the time the gas and Current down slope (slope out)
water valves are open 5. Post-flow timer control
3. Start current control Adjusts the time the gas flows
Current up slope (slope-in) after welding
3. Output control
Welding current control
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Metal Active/Inert Gas (MAG/MIG)
Wire electrode
Current conductor
Wire feed
rolls
Gas nozzle Shielding gas in
Gas shield
Electric Arc Contact tip and
electrode wire guild
Molten weld pool Build up of weld metal
Penetration
Parent material
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Flat or constant voltage characteristic
3 mm
Correct arc gap
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Flat or constant voltage characteristic
2 mm
The welder moves the welding torch nearer to the work
piece. The current must increase to increase the burn off
rate, which allows the arc gap to return back to the correct
distance.
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Flat or constant voltage characteristic
4 mm
The welder moves the welding torch further away from
the work piece. The current must be reduced to slow
down the burn of rate to allow the arc gap to return to
the correct distance
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Welding Power Sources
Flat or Constant Voltage Characteristic
Flat or Constant Voltage Characteristic Used With MIG/MAG, ESW &
SAW < 1000 amps
O.C.V. Arc Voltage
Virtually no Change.
33
32
31
Small Voltage
Change.
Voltage
Large Current Change
100 200 300
Amperage
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Metal Transfer Modes for MAG/MIG
• Dip Transfer:
Voltage ~ < 21 Amperage ~ < 200
• Spray Transfer:
Voltage ~ > 27 Amperage ~ > 220
• Globular Transfer:
Between Dip & Spray Transfer Modes.
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Inductance or Choke
• Applicable to MIG/MAG process in dip transfer mode.
• The electrode is fed slowly through the arc until it
touches the weld pool, at this point the output from the
power supply is short circuited and a very high current
flows through the electrode. If this was allowed to
continue, the wire would melt and eject excessive
amounts of spatter.
• The inclusion of the choke in the welding circuit controls
the rate at which the current rises so that the electrode
tip is melted uniformly without excessive spatter
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Electro-slag (ESW)
Consumable-Guide Non Consumable-Guide
Electrode
Feed Rolls Electrode Wire
Electrode Wire
Electrode
Feed Rolls
Guide Tube
Drive Unit
Molten Slag
Bath Electrode
Guide
Copper
Shoe Copper Shoe
Solid Weld Solid Weld
Metal Metal
More suitable for short weld lengths and More suitable for longer weld lengths and
mechanically simpler. Can also be used in mechanically more complicated.
portable models.
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Sub-arc (SAW)
Filler wire spool Flux hopper
Power supply Slide rail
- +
Wire electrode
Flux
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Process Comparisons
Process Electrical characteristic Electrode current type
MMA Drooping / constant current DC+ve, DC-ve, AC
TIG Drooping / constant current DC-ve, AC
MIG/MAG Flat / constant voltage DC+ve,
MAG FCAW Flat / constant voltage DC+ve, DC-ve,
Drooping / constant current > 500amps
Sub-arc DC+ve, DC-ve, AC
Flat / constant voltage < 500amps
Electro-slag Flat / constant voltage DC+ve,