Welding and Cutting Processes

Module 2

Module 2 Welding and Cutting Processes

Module 2 Welding and Cutting Processes

2A Introduction to Arc Welding Processes 2B Introduction to Non-Arc Welding Processes 2C Brazing and Soldering 2D Introduction to Cutting Processes 2E Welding Process Applications

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Module 2 Welding and Cutting Processes

Module 2 Learning Objectives

Definitions and terminology associated with arc welding

Description of welding arcs Arc welding power supply types and characteristics

Basic operational concepts of SMAW, GTAW, GMAW,

FCAW, SAW, ESW, and EGW welding Overview of specialized p welding gp processes including g narrow groove welding, low hydrogen practices, overlays (HFWMO, CRWMO, structural) and stud welding Code requirements (essential, supplementary essentials, and non-essential variables) Welding Safety Practical Experience (SMAW, GTAW, and GMAW) Welding Process Demonstrations
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Module 2 Welding and Cutting Processes

Module 2 Learning Objectives

Definitions and terminology associated with non-arc welding
processes Descriptions and capabilities of non-arc welding processes Advantages, disadvantages, and applications of non-arc welding processes Important operating parameters of non-arc non arc welding processes Safety issues Applicable codes, standards, and specifications Demonstrations

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Introduction to Arc Welding Processes

Module 2A

Module 2 Welding and Cutting Processes

Arc Welding Introduction

Process Definition
Forms of arc welding vary by means of:

Controlling the arc Shielding of the molten metal Filler metal addition (if used)

Upper: Standard terminology - AWS Lower: Commonly y used trade names

SMAW Stick GMAW MIG FCAW Flux Core SAW FUSION WELDING EGW

ARC WELDING

ESW PAW

GTAW TIG
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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Basic Arc Welding Circuit

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Welding Arc

Welding Electrode Region

Work Electrode Region

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Electrode Types
Consumable Electrodes

Melt and transfer to the weld for filling joint

Carbon steel Low-alloy steel Stainless steel Aluminum Magnesium Copper Titanium

Filler metal Provide electrode for arc and do not melt

Tungsten Carbon

Nonconsumable Electrodes

Filler material, when used, is provided separately

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Consumable Electrode Classification (Filler Metal)

Prefix

E = Electrode, R = Rod First 2 or 3 digits indicate minimum UTS in KSI Examples ER70S-1, E-7018 are 70 KSI UTS Chemistry (ex. Cr, Mo, Mn, and Ni additions) Process information (ex. S: solid, F: flux, T: tubular) Primary welding positions

Carbon and Low Alloy Steels

Other information maybe y specified p

Stainless Steels Use AISI Numbers Specific details contained in the electrode designation are
dependent on the process

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Arc Welding Power Sources

Two types: constant voltage (CV) and constant current (CC)

Some power supplies are capable of both CC and CV operation

Constant voltage

Generally used with welding processes that employ a continuously ti l f fed d consumable bl electrode, typically in the form of wire (ex. GMAW, FCAW)

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Arc Welding Power Sources

Constant current

Slight variations in voltage due to changes in arc length have a minimal effect on current Generally used for manual welding with a covered electrode or a tungsten electrode, where variations in arc length are unavoidable (ex. SMAW, GTAW)
When used in a semi-automated or automated application, external control devices are needed (ex. GMAW, FCAW)

(CC)

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Primary Operating Parameters

Arc Voltage/Arc Length Arc Current Electrode Feed Rate
(Consumable) Welding Travel Speed Polarity

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Arc Voltage
Mainly related to arc length Affects concentration of arc heat

Shorter arc, more heat concentration Longer arc, less heat concentration

Voltage can be regulated to control arc length Varies little with arc current and welding speed

Has little affect on energy input and amount of melting

Typical arc voltages: 8- to 40-volts

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Arc Current
Mainly affects amount of arc heat Determines electrode melting rate (consumable) Directly affects energy input to work and melting

More current, more melting Less current, less melting

Often regulated to control arc and energy input Arc currents: 1- to 1000-amperes

More typically, 50- to 500-amperes

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Electrode Feed Rate

Directly determines amount of metal deposited Closely related to current

Current must provide equal melt-off rate

May be supplied manually or via an automatic feed system Typically, 10s to 100s of inches-per-minute (ipm)

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Welding Travel Speed

Has little affect on arc and electrode melting Directly affects metal deposition per length of weld Mainly affects energy input to work

Faster travel, less energy input and base metal melting Slower travel, more energy input and base metal melting

An important parameter to productivity May be provided manually or mechanized Typical range is 5- to 100-in/min

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Energy Input

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Electrical Polarity
Electrical polarity is important to arc operation Electrode positive

DCEP DCRP (reverse polarity) DCEN C DCSP (straight polarity) AC VP (variable polarity)

Electrode negative

Alternating polarity

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

The DCEN Arc

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

The DCEP Arc

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Need for Shielding from Atmosphere

Molten metal reacts with the atmosphere to form oxides and
nitrides

Porosity can result Metallurgical changes can occur

Weld mechanical properties are generally reduced Note that the weld should be free of dirt, grease, paint, scale,
and other foreign objects to ensure weld quality

Fluxes and shielding gasses are not designed to scavenge these components from the solidifying weld metal

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Flux Shielding
Provides a gas to shield the arc and prevent excessive
atmospheric contamination of the molten filler metal and weld pool. Provides scavengers, deoxidizers, and fluxing agents to cleanse the weld and prevent excessive grain growth in the weld metal. Establishes the electrical characteristics of the electrode. Provides a slag blanket to protect the hot weld metal from the air and enhance the mechanical properties, bead shape, and surface cleanliness of the weld metal. Provides a means of adding alloying elements to change the mechanical properties of the weld metal.

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Welding Fluxes
Ingredient Iron oxide Titanium oxide Calcium fluoride Magnesium oxide Potassium silicate Other silicates Calcium carbonates Cellulose Ferro-chrome Other carbonates Ferro-manganese Ferro-silicon Function Slag former, arc stabilizer Alloy Slag former, arc stabilizer Fluxing agent Slag binder, Slag, binder fluxing agent Gas former, arc stabilizer Gas former Alloy, deoxidizer Alloy Gas former Alloy Deoxidizer
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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Gas Shielding
Mainly purges the weld area to shield it from the atmosphere Argon is the most common inert gas Carbon dioxide is sometimes used

Less expensive Similar to gases produced from fluxes Oxidation stabilizes arc and metal transfer Improves weld bead wetting

CO2 and O2 are commonly mixed with argon

H2 can be added to increase arc heat in some cases Helium may also be used to increase arc heat Require addition of deoxidizers to filler materials

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Module 2 Welding and Cutting Processes

Arc Welding Introduction

Sources of Shielding

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Module 2 Welding and Cutting Processes

Arc Welding Safety

Arc Welding Hazards

Arc Radiation

UV damage to skin and eyes Welding voltages are generally safe Anomalous conditions can arise Suffocation Long term breathing of fume Explosion of cylinders

Electrical Shock

Fumes and Gases

Compressed Gases

Burns - Hot Metal Fire - Ignition of Nearby Flammable Materials

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Module 2 Welding and Cutting Processes

Arc Welding Safety

Arc Welding Safety

AWS Z49.1: 2005

Safety in Welding, Cutting, and Allied processes Training (mandated under provisions of the U.S. Occupational Safety and Health Act (OSHA), especially those of the Hazard Communication Standard, 29 CFR 1910.1200)

Management Support Ventilation V til ti General Housekeeping Eye and Skin Protection from Radiation Hot Work Permit System

Reference: AWS Z49-1 or WHB, V1, Ch16

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Module 2 Welding and Cutting Processes

Arc Welding Safety

ANSI/ASC Z49.1 Safety in Welding, Cutting and Allied Processes

A document outlining safe
practices for welding and cutting operations Is referenced almost in all AWS welding codes When the code is mandated by y the contract or laws, ANSI/ASC Z49.1 is also invoked.

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Module 2 Welding and Cutting Processes

Arc Welding Safety

Management Support
Evidenced by:

Stating clear safety objectives Showing commitment to safety Designating safe work areas Developing safety procedures Providing safe equipment Implementing safety training

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Module 2 Welding and Cutting Processes

Arc Welding Safety

Personal Protective Equipment

Sturdy boots, no laces Clean clothing Woolen is best Treated cotton acceptable No synthetics Pants P t without ith t cuffs ff Pants outside boots Flaps on shirt pockets Cap Gloves Leathers

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Module 2 Welding and Cutting Processes

Arc Welding Safety

Eye, Ear, Face, and Head Protection

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Module 2 Welding and Cutting Processes

Arc Welding Safety

Lens Shade Selector

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Module 2 Welding and Cutting Processes

Arc Welding Safety

Fume Exposure and Ventilation

Fume Plume

note head position

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Module 2 Welding and Cutting Processes

Arc Welding Safety

Welding in Confined Space

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Module 2 Welding and Cutting Processes

Arc Welding Safety

Shield Gases
Argon, Helium Inert Nitrogen, Carbon dioxide Reactive Odorless Colorless Can displace oxygen

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Module 2 Welding and Cutting Processes

Arc Welding Safety

Safe Welding and Cutting of Containers

Manifold/Piping System

Compressed Gas

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Module 2 Welding and Cutting Processes

Arc Welding Safety

Compressed Gases Cylinder Safety

Oxygen Manifold System - Oxygen Supports Combustion

Acetylene Manifold System A Fuel Gas

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Arc Welding Power Sources

Module 2A.1

Module 2 Welding and Cutting Processes

Arc Welding Power Sources

Arc Welding Power Source

Provide suitably conditioned electrical power for the arc

Reduce line voltage to arc voltage Provide suitable output characteristic for a stable arc

Allow operator input of weld parameters/sequences Interfaces to/from other equipment

Wire feeders Controllers Robot systems

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Module 2 Welding and Cutting Processes

Arc Welding Power Sources

Sources of Electricity
Engine driven generator/alternator Utility power

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Module 2 Welding and Cutting Processes

Arc Welding Power Sources

Usable Arc Welding Voltage, Current Range

Industrial line voltages are 208VAC to 480VAC Voltage range for a welding arc is 20V to 80V Welding power sources need a transformer to convert line

voltage to welding voltage Motor driven generators (for field use) directly output voltages that are usable for arc welding Typical welding arc currents range from 100A to 1000A 2kVA to 80kVA of electrical power is needed

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Module 2 Welding and Cutting Processes

Arc Welding Power Sources

Arc Welding Power Source Characteristics

Type of current

Transformers - AC Transformers with rectifiers - AC/DC

Welding current rating Duty cycle Service classification Input power requirements Special features

Remote control High frequency Pulsation Start and finish schedules Wave balancing and line voltage compensation
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Module 2 Welding and Cutting Processes

Arc Welding Power Sources

Line-Powered Welding Power Source Components

Arc Welding Power Source

Fused Disconnect Switch (open)

Input AC

Reduce Voltage Chassis Ground Connections

Control Output Characteristics

Earth Ground

Electrode
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Module 2 Welding and Cutting Processes

Arc Welding Power Sources

Basic Characteristics of Power Sources

Constant Current
VOLTAGE

Transistor switching inverter supplies provide a relatively constant current at a given setting

Constant Voltage

CURRENT

Arc Force Adjustment

VOLTAGE

Voltage remains relatively stable and current varies to maintain an arc voltage

CURRENT
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Module 2 Welding and Cutting Processes

Arc Welding Power Sources

Output Control Methods

Transformers

Tapped secondary Movable coil or shunt Movable reactor core Saturable reactor (magnetic amplifier)

Reactor (inductor, older technology)

Silicon Controlled Rectifier (SCR, newer technology) Transistor (newest technology)

Linear Switching - inverter

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Module 2 Welding and Cutting Processes

Arc Welding Power Sources

Other Features
Single phase Three phase Remote control Pulsation Variable polarity AC High Hi h f frequency Synergic controls Start control Arc force control Finish - down slope

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Shielded Metal Arc Welding (SMAW)

Module 2A.2

Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

Elements of a Typical Welding Circuit for SMAW

Source: AWS Handbook, 9th ed., Vol. 2

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

Definition of SMAW
An arc welding process in
which coalescence of metals is produced by heat from an electric arc that is maintained between the tip of a covered electrode and the surface of the base metal in the joint being welded

Source: AWS Handbook 9th ed. Vol. 2

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

SMAW

Medium arc length

Long arc length

170A, 12V, T=5.5 IPM

170A, 14V, T=5.5 IPM

6012 electrode was used Recording rate was 125 frames per second
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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

Electrode Covering
Depending on the type, the covering performs one or more of
the following:

Provide a gas cover to shield the arc and prevent excessive atmospheric contamination of the molten filler metal Provide scavengers, deoxidizers, and fluxing agents to cleanse the weld and (potentially) prevent excessive grain growth in the weld metal Establishes the electrical characteristics of the arc. Provides a slag blanket to protect the hot weld metal from the air and enhance the mechanical properties, bead shape, and surface cleanliness of the weld metal Provides a means of adding alloying elements to weld metal to alter the microstructure and mechanical properties of the weld metal

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

Characteristics of SMAW
Outgrowth of original welding process developed in the early
20th century Most widely used process worldwide Normally performed manually by skilled welders Equipment and consumable costs are low Extremely versatile Productivity is low Fume generation rates are high Generally considered low tech

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

SMAW Advantages
Most widely used process worldwide broad skill-base Equipment and consumable costs are low low-tech Extremely versatile Easily implemented for field
welding Relatively adaptable to part fit-up variances

Operator skill is required

Underwater welding with SMAW 2-54

Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

Limitations
Requires relatively highskilled manual welder Deposition rate is low Defect rates are relatively high Fume generation rates are high

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

Effect of Welding Parameters on Bead Profile

A) Proper amperage, arc length, and travel speed B) Amperage too low C) Amperage too high D) Arc length too short E) Arc length too long F) Travel speed too slow G) Travel speed too fast

Courtesy AWS Handbook, 8th Edition, Volume 2, page 64

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

Orientation of the Electrode

Courtesy AWS Handbook, 8th Edition, Volume 2, page 66

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

Typical Electrode Orientation and Welding Technique for Carbon Steel Electrodes

* Travel angle may be 10- to 30-degrees for electrodes with heavy iron powder coatings

From AWS Handbook, 8th Edition, Volume 2, page 65

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

Recommended Dimensions of Grooves for Shielded Metal Arc Welding of Steel

From AWS Handbook, 8th Edition, Volume 2, page 59

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

AWS A5.1 Specification for Carbon Steel Electrodes for SMAW

E-XXXX

E = Electrode (coated) First 2 digits = Ultimate tensile strength (UTS) in ksi Third digit = position
1 is all positions 2 is flat or horizontal 4 is flat flat, overhead, overhead horizontal or vertical vertical-down down

Fourth digit = type of coating

0 is DCEP Cellulose-sodium silicate 1 is AC/DCEP, Cellulose, potassium 2 is AC/DCEN, Rutile, sodium 3 is AC/DC, Rutile, potassium 4 is AC/DC, Rutile/iron powder 5 is DCEP, Lime, sodium 6 is AC/DCEP, Lime, potassium 7 is AC/DC, Iron oxide/iron powder 8 is AC/DCEP, lime/iron powder

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

SMAW Electrode Classification Example

E7018

E indicates stick electrode 70 indicates nominal tensile strength of 70-ksi 1 indicates use for welding in all positions 8 indicates low hydrogen coating E indicates stick electrode 60 indicates nominal tensile strength of 60-ksi 1 indicates use for welding in all positions 0 indicates cellulose coating

E6010

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

AWS A5.4 Specification for Stainless Steel Electrodes for SMAW

Uses AISI number to denote alloy and suffix for coating type

-15 = DCEP -16 = AC/DC E-308-15 is a 308 alloy with DCEP lime coating E-312-16 is a 312 alloy with AC/DC rutile coating

Examples

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

AWS A5.5 Specification for Low Alloy Steel Covered Electrodes

Similar to AWS A5.1 May be five digits Suffix denotes type of alloy

A B C D E G M W

C-Mo Cr-Mo Ni Mn-Mo Ni-Mo General Military Weathering

E-8018-B2

80,000-ksi UTS All positions Alloyed with Cr-Mo Lime, AC/DC

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

ASME Classifications
ASME classifies electrodes by F-No. and ASME Specification

The same F-No. are electrodes with the same usability characteristics
All cellulosic electrodes are F-No. 3 All low-hydrogen electrodes are F-No. 4

ASME specifications are the same as AWS specifications with the addition of SF
AWS Specification A5.1 A5 1 is ASME Specification SFA SFA-5 5.1 1

Electrodes can be in the same ASME specifications but in

different F-no. groups and vice versa

E6010 is SFA-5.1 and F-No. 3 E7018 is SFA-5.1 and F-No. 4 E8018-B2 is SFA-5.5 and F-No. 4

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

Quality Issues
Discontinuities associated with
manual welding process that utilizes flux for pool shielding

Slag inclusions Lack of fusion

Other possible effects on quality

are porosity and hydrogen cracking

Lack-of-fusion defects in two-sided SMA weld

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

Low Hydrogen Practice

Hydrogen embrittlement is a common problem in mediumand high-carbon steel alloys

Causes delayed cracking in HAZ Worse in thick sections, restrained parts

Low hydrogen welding practices keep

electrodes and weldment dry, prevent introduction of hydrogen into the weld metal
Preheat, minimum interpass temperatures

Rod ovens and portable rod

containers prevent moisture from being absorbed in electrode coatings

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

ASME Section IX SMAW Process Procedure Variables

Paragraph .4 .5 .6 .7 QW-404 Filler Metals .12 12 .30 .33 Brief of Variables F-Number A-Number Diameter Diameter > 1/4 in. Classification t Classification X X X X Supplementary Essential Essential X X X Nonessential

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Module 2 Welding and Cutting Processes

Shielded Metal Arc Welding

ASME Section IX SMAW Process Procedure Variables

Paragraph .1 QW-405 Positions QW-409 Electrical Characteristics QW-410 Technique .2 .3 .1 4 .4 .8 .5 .25 Brief of Variables + Position Position Vertical Welding > Heat Input Current or Polarity I & E Range Method of Cleaning Manual or Automatic X X X X X X X Essential Supplementary Essential Nonessential X

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Gas Tungsten Arc Welding (GTAW)

Module 2A.3

Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

GTAW Process Description

An arc is formed between a nonconsumable (tungsten)
electrode and the workpiece electrode The energy from the arc melts the workpiece, and the molten metal solidifies to form a weld bead Shielding gas provides the medium for arc formation and protects the molten p p pool and electrode from oxidation

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Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

Basic Components of GTAW

Source: AWS Handbook 9th ed. Vol. 1

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Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

Autogeneous GTAW

Recording rate was 125 Hz

250A 11.5V 10 IPM

170A 10.5V, T=5.5 IPM

170A 11.5V, T=5.5 IPM 2-72

Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

GTAW Filler Metal

Good wire position

Recording rate: 250 Hz

170A 14.5V 5.5 IPM 35.4 IPM

Bad wire position off target

Bad wire position too high

170A 12.5V 5.5IPM 35.4 IPM

170A 16.5V 5.5 IPM 35.4 IPM

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Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

GTAW - Range of Operation

Current: <1- to 500-amps, typically 30 to 150 Voltage: 9- to 20-volts, typically 10- to 12-volts for argon Arc Gap: 0.02- to -in., typically 1/16-in. Welding Speed: 1- to 40-in/min, typically 3- to 6-in/min. Shielding Gas: argon, argon hydrogen mixtures, helium,

argon helium mixtures Thickness: 0.004-in. upwards, typically up to 0.1-in. in a single pass or -in. with multiple passes May be without filler (autogenous) or with added filler, usually as wire, 1/32- to 3/32-in. diameter

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Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

GTAW Process Description: Terminology

Gas Tungsten Arc Welding: GTAW - AWS Definition Tungsten Inert Gas Welding: TIG - Europe and worldwide,
also often used in the U.S. Wolfram Inert Gas Welding: WIG - Used in Germany Heliarc: Original name in U.S. Argonarc: Original name in U U.K. K

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Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

GTAW Applications
Full penetration welds, typically up to 0.1-in. Root runs, particularly in pipe welds Autogenous welds (no filler) High quality welds Fill runs, typically up to 0.5-in. Most M t metals t l

Stainless steels and nickel-based alloys Carbon and low alloy steels Aluminum and magnesium alloys Titanium and reactive metals

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Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

GTAW Applications
Small components - sensors, medical and electronic Tube to tube welds, orbital or rotated tube Tube to tube plate welds, condensers, heat exchangers Repairs, all industries (e.g., aerospace) Process equipment, food industry Cladding, Cl ddi overlays l Sheet metal applications

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Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

GTAW Process Advantages

Can be used in all positions, manual or mechanized Provides excellent control on thin and intricate parts No slag or spatter; post weld cleaning often not required Use with or without filler wire Welds almost all metals Precise P i control t l of f weld ld h heat t High quality

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Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

GTAW Process Limitations

Lower deposition rates than consumable electrode processes Requires more dexterity and coordination for manual welding
than consumable electrode processes Requires high gas purity, low tolerance for drafty environments means it cannot be used outdoors without special p p precautions Low tolerance to contaminants Generally requires arc starting system Requires precise positioning of electrode

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Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

Characteristics of Current Types for GTAW

Current type Electrode polarity DC Negative DC positive AC (balanced) balanced

Electrode and ion flow

Penetration characteristics Oxide cleaning action Heat balance in the arc (approx.) penetration Electrode capacity

No 70% at work end; 30% at electrode end Deep; narrow Excellent e.g.1/8in-400A

Yes 30% at work end; 70% at electrode end Shallow; wide Poor e.g.1/4-120A

Yes-once every half cycle 50% at work end; 50% at electrode end medium Good e.g.1/8in-225A

Courtesy of the AWS Welding Handbook Volume 2, 7th Edition

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Gas Tungsten Arc Welding

Shielding Gas for GTAW

Argon is used most extensively

Lower cost and flow rate than helium Easier arc starting Better cross draft resistance Transfers more heat to workpiece - useful for metals with high thermal conductivity and for high speed welding Argon-helium mixtures are used to gain advantages of both gases Used to increase penetration on stainless steels, along with up to 15% hydrogen

Helium is preferred for some applications

Argon-Helium mixtures

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Gas Tungsten Arc Welding

Pulsed Gas Tungsten Arc Welding

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Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

Hot Wire GTAW

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Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

High Frequency (HF) Arc Starting

Spark gap oscillator generates HF (VRMS ~ 3500 V, f ~

10kHz) Air core transformer couples HF to welding electrode HF bypass filter prevents HF current from passing back into welding machine (and causing possible damage to electronics

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Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

Specifications and Practices

Electrode and filler metal specifications

AWS A5.12, Specification for Tungsten and Tungsten Alloy Electrodes for Metal Arc Welding and Cutting AWS A5.18, Specification for Carbon Steel Filler Metals for Gas Shielded Arc Welding ASME uses the same labeling system for GTAW filler metals as SMAW electrodes
SF labeling

Recommended practice documents C5.5, Recommended Practices for Gas Tungsten Arc

Welding C5.10, Recommended Practices for Shielding Gases for Arc Welding and Cutting

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Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

ASME Section IX GTAW Process Procedure Variables

Paragraph .3 .4 .5 .12 .14 14 .22 .23 QW-404 Filler Metals .30 .33 .50 Brief of Variables Size F-Number A-Number Classification Filler Consumable Insert Filler Metal Product Form t Classification Flux X X X X X X X X X Essential Supplementary Essential Nonessential X

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Gas Tungsten Arc Welding

ASME Section IX GTAW Process Procedure Variables

Paragraph .1 QW-405 Positions .2 .3 .1 2 .2 .3 .5 QW-408 Gas .9 .10 Brief of Variables + Position Position Vertical Welding Trail or Composition Single Single, Mixture Mixture, or % Flow Rate or Backing Flow - Backing or Composition Shielding or Trailing X X X X X X X X Essential Supplementary Essential Nonessential X

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Module 2 Welding and Cutting Processes

Gas Tungsten Arc Welding

ASME Section IX GTAW Process Procedure Variables

Paragraph .1 .3 QW-409 Electrical Characteristic .4 .8 .12 .3 .5 .10 .11 QW-410 Technique .15 .25 Brief of Variables > Heat Input Pulsing I Current or Polarity I & E Range Tugsten Electrode Orifice, Cup, or Nozzle Size Method of Cleaning Single to Multi Electrodes Closed to Out Chamber Electrode Spacing Manual to Automatic X X X X X Essential Supplementary Essential X X X X X X X X Nonessential

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Plasma Arc Welding (PAW)

Module 2A.4

Module 2 Welding and Cutting Processes

Plasma Arc Welding

Plasma Arc Welding (PAW) Definition

Nonconsumable electrode Heat is produced from a plasma jet

Arc can be transferred or nontransferred Usually supplemented by an auxiliary source of shielding gas

Shielding is obtained from the ionized gas

Filler metal may of may not be used Pressure is not used Variables

Plasma current Orifice diameter and shape Type of orifice gas Flow rate of orifice gas Type of shielding gas
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Module 2 Welding and Cutting Processes

Plasma Arc Welding

Plasma Arc Torch

Source: AWS Handbook 9th ed. Vol. 1

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Module 2 Welding and Cutting Processes

Plasma Arc Welding

Why Arc Constriction?

Columnar shaped plasma jet

Significantly reduces sensitivity to variations in arc length More stable plasma jet Permits the use of longer arc lengths Less welder skill is required (compared to GTAW) Increased penetration and travel speeds

Higher energy density

Courtesy of the AWS Welding Handbook, Volume 2, 8th Edition

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Module 2 Welding and Cutting Processes

Plasma Arc Welding

Transferred and Nontransferred Plasma Arc Modes

CONSTRICTING NOZZLE ORIFICE GAS SHIELDING GAS

WORK

TRANSFERRED

NONTRANSFERRED

Courtesy of the AWS Welding Handbook, Volume 2, 8th Edition

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Module 2 Welding and Cutting Processes

Plasma Arc Welding

Consumables
Techniques for adding filler metal

Cold wire feed

Filler wire is introduced at the leading edge of the weld pool May be done manually or by conventional GTAW wirefeeders

Hot wire feed

Wirefeeder introduces wire at the trailing edge of the weld pool

Dabber technique
Filler wire feed is pulsed in synchronization with the pulsing of the plasma arc current

AWS specifications for consumables used for PAW are the

same as those used for GTAW

Filler wires, electrodes, and shielding gases

2-94

Module 2 Welding and Cutting Processes

Plasma Arc Welding

Advantages and Disadvantages

Advantages

Columnar plasma jet

Higher energy density enables faster welding speeds, lower heat input, and less distortion Improved arc stability and tolerance to variations in torch-to-work distance Permits the use of longer torch-to-work distances q ( (compared p to GTAW) ) Less welder skill is required

Disadvantages

Higher equipment cost Lower tolerance to variations in fit-up Manual PAW torches are more difficult to manipulate than manual GTAW torches

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Module 2 Welding and Cutting Processes

Plasma Arc Welding

Applications
Process techniques

Keyhole mode Melt-in mode All metals except aluminum and magnesium are welded with DCEN Build-ups for aerospace components Medical pacemakers Electronic components Bellows and seals Motors and transformers Tube mills Cladding, wire mesh, process piping

Applicable to all metals weldable by the GTAW process

Applications pp

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Module 2 Welding and Cutting Processes

Plasma Arc Welding

ASME Section IX PAW Process Procedure Variables

Paragraph .3 .4 .5 .12 .14 14 .22 .23 QW-404 Filler Metals .27 .30 .33 Brief of Variables Size F-Number A-Number Classification Filler Consumable Insert Filler Metal Product Form Alloy Elements t Classification X X X X X X X X X Essential Supplementary Essential Nonessential X

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Module 2 Welding and Cutting Processes

Plasma Arc Welding

ASME Section IX PAW Process Procedure Variables

Paragraph .1 QW-405 Positions .2 .3 .1 4 .4 .5 .9 QW-408 Gas .10 .21 Brief of Variables + Position Position Vertical Welding Trail or Composition Composition or Backing Flow - Backing or Composition Shielding or Trailing Flow Rate X X X X X X X X Essential Supplementary Essential Nonessential X

2-98

Module 2 Welding and Cutting Processes

Plasma Arc Welding

ASME Section IX PAW Process Procedure Variables

Paragraph .1 QW-409 .8 Electrical Characteristics .12 .3 .5 .10 .11 QW-410 Technique .12 .15 .4 Brief of Variables > Heat Input Current or Polarity I & E Range Tugsten Electrode Orifice Orifice, Cup Cup, or Nozzle Size Method of Cleaning Single to Multi Electrodes Closed to Out Chamber Melt-in to Keyhole Electrode Spacing X X X X Essential Supplementary Essential X X X X X X X X Nonessential

2-99

Submerged Arc Welding (SAW)

Module 2A.5

Module 2 Welding and Cutting Processes

Submerged Arc Welding

SAW Definition
At least one consumable bare metal electrode Arc(s) produce heat Shielded by granular, fusible material on workpieces Used without the application of pressure

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Module 2 Welding and Cutting Processes

Submerged Arc Welding

SAW Components

Source: AWS Handbook 9th ed. Vol. 1

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Module 2 Welding and Cutting Processes

Submerged Arc Welding

SAW Definitions and Variables

Definitions
Machine Automatic Semiautomatic Tandem arc Flux Flux recovery units Tractors Manipulators Positioners

Variables
Welding amperage Welding voltage Travel speed Electrode size Electrode extension Width and depth of flux

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Module 2 Welding and Cutting Processes

Submerged Arc Welding

Consumables for SAW

AWS A5.17, Specification for Carbon Steel Electrodes and
Fluxes for Submerged Arc Welding

F7A6-EM12K - 70,000 psi UTS, Charpy toughness of 20 ft-lb @ -60F, with EM12K Medium Mn, 0.12%C, Killed
F - Flux 7 - Tensile Strength in 10,000 psi A - Condition of heat treatment 6 - Lowest temperature (x -10C) with Charpy toughness of 20ft-lb E - Solid electrode, EC - cored electrode M - Classification of manganese content L - Low, M - Medium, H - High 12 - Carbon content in hundredths of a percent K - Killed

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Module 2 Welding and Cutting Processes

Submerged Arc Welding

Selection and Application Criteria for SAW

Advantages

Superior weld quality Often self cleaning High deposition rates Minimum edge preparation No radiant energy Minimum fume problem Flux housekeeping Usable only in flat position

Disadvantages

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Module 2 Welding and Cutting Processes

Submerged Arc Welding

Effect of Amperage Variation on Weld Bead Shape and Penetration

Semiautomatic welding 3/32 in. wire, 35V, 24in./s

Machine welding 7/32 in. wire, 34V, 30in./s

350 A

500 A

650 A

700 A

1000 A

850 A

Welding Processes -- Arc and Gas Welding and Cutting, Brazing and Soldering, AWS Welding Handbook, 7th Ed, Vol. 2, p. 203, fig. 6.5.

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Module 2 Welding and Cutting Processes

Submerged Arc Welding

Effect of Arc Voltage Variations on Weld Bead Shape and Penetration

Semiautomatic welding 3/32 in. wire, 500A, 24in./s Machine welding 7/32 in. wire, 850A, 30in./s

25V

35V

45V

27V

45V

34V

Welding Processes -- Arc and Gas Welding and Cutting, Brazing and Soldering, AWS Welding Handbook, 7th Ed, Vol. 2, p. 203, fig. 6.6.

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Module 2 Welding and Cutting Processes

Submerged Arc Welding

Effect of Travel Speed Variation on Weld Bead Shape and Penetration

Semiautomatic welding 3/32 in. wire, 500A, 35V Machine welding 7/32 in. wire, 850A, 34V

12 in./min

24 in./min

48 in./min

60 in./min

15 in./min

30 in./min

Welding Processes -- Arc and Gas Welding and Cutting, Brazing and Soldering, AWS Welding Handbook, 7th Ed, Vol. 2, p. 204, fig. 6.7.

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Module 2 Welding and Cutting Processes

Submerged Arc Welding

Effect of Electrode Size on Weld Bead Shape and Penetration

Machine welding 600A, 30V 30in./min

Electrode size 1/8in. 5/32in. 7/32in.

Welding Processes -- Arc and Gas Welding and Cutting, Brazing and Soldering, AWS Welding Handbook, 7th Ed, Vol. 2, p. 205, fig. 6.8.

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Module 2 Welding and Cutting Processes

Submerged Arc Welding

Effect of Work Inclination on Weld Bead Shape in 13-mm (1/2 in.) Plate

Flat position weld

Downhill weld (1/8 slope)

Uphill weld (1/8 slope)

Lateral weld (1/19 slope)

Welding Processes -- Arc and Gas Welding and Cutting, Brazing and Soldering, AWS Welding Handbook, 7th Ed, Vol. 2, p. 215, fig. 6.12.

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Module 2 Welding and Cutting Processes

Submerged Arc Welding

ASME Section IX SAW Process Procedure Variables

Paragraph .4 .5 .6 .9 .10 10 .24 .27 .29 .30 .33 QW-404 Filler Metals .34 .35 .36 Brief of Variables F-Number A-Number Diameter Flux/Wire Classification Alloy Flux or Supplemental Alloy Elements Flux Designation t Classification Flux Type Flux/Wire Classification Recrushed Slag X
2-111

Essential X X

Supplementary Essential

Nonessential

X X X X X X X X X X X

Module 2 Welding and Cutting Processes

Submerged Arc Welding

ASME Section IX SAW Process Procedure Variables

Paragraph QW-405 Positions QW-409 Electrical Characteristics .1 .1 .4 .8 .5 .8 .10 QW-410 Technique .15 .25 Brief of Variables + Position > Heat Input Current or Polarity I & E Range Method of Cleaning Tube-Work Distance Single to Multi Electrodes Electrode Spacing Manual or Automatic X X X X X X X X X X Essential Supplementary Essential Nonessential X

2-112

Gas Metal Arc Welding and Flux Cored Arc Welding (GMAW & FCAW)
Module 2A.6

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

Gas Metal Arc Welding

Source: AWS Handbook 9th ed. Vol. 1

2-114

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

Flux Cored Arc Welding

Self-Shielded FCAW
Courtesy of the AWS Welding Handbook, Volume 2, 8th Edition

Gas-Shielded FCAW

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Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

GMAW/FCAW Equipment
SHIELDING GAS REGULATOR ELECTRODE SUPPLY ELECTRODE FEED UNIT 7 SHIELDING GAS SUPPLY

3 2 6 WELDING GUN WATER CIRCULATOR 1 WORKPIECE 1 2 3 4 5 WORK LEAD WATER TO GUN WATER FROM GUN GUN SWITCH CIRCUIT SHIELDING GAS TO GUN 6 7 8 9 10 CABLE ASSEMBLY SHIELDING GAS FROM CYLINDER WELDING CONTACTOR CONTROL POWER CABLE PRIMARY INPUT POWER 10 4 5 POWER SOURCE 8

Courtesy of the AWS Welding Handbook, Volume 2, 8th Edition

2-116

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

Consumables for GMAW

Primary consumables are the wire and the shielding gas A5.18 Specification for Carbon Steel Electrodes and Rods for
Gas Shielded Arc Welding C5.10 Recommended Practices for Shielding Gases for Arc Welding and Plasma Cutting ERxxS ERxxS-y y

ER Electrode or rod xx - Two or three digits for tensile strength in KSI S - Solid wire y - Suffix for specifying chemistry and other details

2-117

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

Consumables for FCAW

A5.20 Specification for Carbon Steel Electrodes for Flux
Cored Arc Welding C5.10 Recommended Practices for Shielding Gases for Arc Welding and Plasma Cutting ExyT-ab

E - Electrode x One or two digits for tensile strength in 10s of KSI y - Welding position (0 = flat or horizontal, 1 all) T - Tubular a - Usability, performance

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Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

GMAW/FCAW Variables
Wire feed speed (WFS)

Controls the welding current

Arc voltage Polarity Travel speed Electrode extension Torch angles

Work and travel angles

Joint design Electrode diameter Shielding gas

2-119

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

WFS, Voltage, and CTWD

WFS

Primary variable that controls heating and melting power to the electrode Increasing the WFS increases the deposition rate and weld penetration Impacts I t the th melting lti efficiency ffi i at t th the workpiece k i and d th the weld ld shape h Improper voltage can result in arc instabilities and inadequate welds Longer CTWDs result in greater preheating in the electrode stick-out, lower heat input into the workpiece, and a more crowned weld bead
Secondary affect on heat input to the workpiece compared to current, voltage, and travel speed

Voltage

Contact Tip to Word Distance (CTWD)

2-120

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

Modes of Metal Transfer

Spray

Globular

Short-circuiting

Pulse-spray

2-121

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

GMAW (transfer mode)

Globular mode Spray mode

T Travel l di direction ti WFS=200 IPM, 29V, T=10 IPM

ER70S-3, 0.052 welding wire was used Ar-10%CO2 shielding gas was used Recording rate 125 Hz for globular and spray modes
Stainless Wire ER308L

2-122

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

FCAW

WFS= 225 IPM, V= 29V , T= 10 IPM

0.045 welding wire was used Ar-10%CO2 shielding gas was used Recording rate was 1125 Hz

2-123

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

Short Circuit Transfer

Wire shorts to plate

Arc reignites Metal transfer

2-124

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

Globular Transfer
Drop short circuits and explodes producing spatter

Irregular droplet size

Random transfer

2-125

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

Spray Transfer

2-126

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

Pulse Spray Transfer

Synergic control: in modern supplies, pulse waveforms are

automatically adjusted to accommodate a wire feed rate set by the user

2-127

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

GMAW (transfer mode)

Pulsed mode

2-128

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

Typical Weld Cycle

Electrode contacts workpiece (short circuit current) Start current Current, voltage, wire feed sp peed, and travel speed Welding current

Crater fill current Open circuit voltage Start wire feed speed Welding wire feed speed Burnback voltage Crater fill wire feed speed

Run-in wire feed speed

Welding voltage Start voltage

Travel speed Crater fill voltage

Preflow time

Run-in time

Start time

Weld time Welding cycle time

Crater fill Burnback time time

Postflow time

2-129

Module 2 Welding and Cutting Processes

Gas Metal Arc Welding Advancements

Reciprocating Wire Feed GMAW

2-130

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

Selection and Application Criteria for GMAW

Advantages

Welds all commercial metals All positions High deposition rates compared to GTAW and SMAW
Continuously fed filler wire

Long welds without stops and starts Mi i l post-weld Minimal t ld and di inter-pass t cleaning l i Welding equipment is more complex than that for SMAW
More difficult to use in hard to reach places Welding torch size

Limitations

Welding torch must be kept in close proximity to the workpieces in order to achieve adequate shielding Arc must be protected against air drafts

2-131

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

Selection and Application Criteria for FCAW

Advantages

High deposition rates Deeper penetration than SMAW High quality welds Less pre-cleaning than GMAW Slag covering helps with out-of-position welds Self-shielded FCAW is draft tolerant Slag must be removed Higher fume generation than GMAW and SAW Spatter Equipment is more expensive and complex than SMAW FCAW wire is more expensive

Disadvantages

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Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

ASME Section IX GMAW & FCAW Process Procedure Variables

Paragraph .4 .5 .6 .12 .23 23 .24 .27 QW-404 Filler Metals .30 .32 .33 Brief of Variables F-Number A-Number Diameter Classification Filler Metal Product Form or Supplemental Alloy Elements t t Limits (S.Cir. Arc) Classification X X X X X X X Essential X X X Supplementary Essential Nonessential

2-133

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

ASME Section IX GMAW & FCAW Process Procedure Variables

Paragraph .1 QW-405 Positions .2 .3 .1 2 .2 .3 .5 QW-408 Gas .9 .10 Brief of Variables + Position Position Vertical Welding Trail or Composition Single Single, Mixture Mixture, or % Flow Rate or Backing Flow - Backing or Composition Shielding or Trailing X X X X X X X X Essential Supplementary Essential Nonessential X

2-134

Module 2 Welding and Cutting Processes

Gas Metal and Flux Cored Arc Welding

ASME Section IX GMAW & FCAW Process Procedure Variables

Paragraph .1 .2 QW-409 .4 Electrical Characteristics .8 .3 .5 .8 .10 QW-410 Technique .15 .25 Brief of Variables > Heat Input Transfer Mode Current or Polarity I & E Range Orifice Orifice, Cup Cup, or Nozzle Size Method of Cleaning Tube-Work Distance Single to Multi Electrodes Electrode Spacing Manual or Automatic X X X X X X X X X X X Essential Supplementary Essential X Nonessential

2-135

Other Arc Welding Processes

Module 2A.7

Module 2 Welding and Cutting Processes

Electroslag Welding

Electroslag Welding (ESW) Definition

Pieces welded by molten slag that
melts the filler metal and the surfaces of the workpieces to be welded ESW is not a true arc process

Source: AWS Handbook 9th ed. Vol. 1

2-137

Module 2 Welding and Cutting Processes

Electroslag Welding

Advantages of ESW
Deposition rates of 35- to 45-lbs/hr Sections with thicknesses -in Preheating and post-heating are normally not required Long molten time allows gas and slag to escape High duty cycle with little operator fatigue Minimum Mi i material t i lh handling dli Minimum distortion No spatter

100% of filler metal is transferred to the weld

Fastest welding process for large, thick materials

2-138

Module 2 Welding and Cutting Processes

Electroslag Welding

Limitations of ESW
Limited to carbon, low alloy, and some stainless steels Only applicable to vertically positioned joints Single pass welding only

Process cannot be interrupted, or else weld will contain discontinuities and flaws

Minimum base metal thickness of approximately pp y -in Complex material shapes may be difficult or impossible to
weld

2-139

Module 2 Welding and Cutting Processes

Electroslag Welding

Application of ESW
Used for welding carbon, low alloy, and some stainless steels
in a single pass Recognized by all of the important national codes

Several have requirements that differ from other welding processes Transition j joint between different flange g thicknesses Stiffeners in box columns and wide flanges

Widely used for structural applications

Large presses and machinery with large, heavy plate Pressure vessels

2-140

Module 2 Welding and Cutting Processes

Electroslag Welding

Safety and Health of ESW

Refer to Z49.1 of AWS and OSHA Title 29 Part 1910 for
details Safety glasses with side shields are recommended Electrical safety due to all parts of operation being electrically "HOT" Stay away from fumes Slag leakage may be a problem Be cautious with hot shoes, sumps, and run-off blocks

2-141

Module 2 Welding and Cutting Processes

Electroslag Welding

ASME Section IX ESW Process Procedure Variables

Paragraph .4 .5 .6 .12 .17 17 QW-404 Filler Metals .18 .19 .33 Brief of Variables F-Number A-Number Diameter Classification Flux Type or Composition Wire to Plate Consumable Guide Classification X X X X X Essential X X X Supplementary Essential Nonessential

QW-409 Electrical Characteristics .5 .5 QW-410 Technique .10 .15

15% I & E Range Method of Cleaning Single to Multi Electrodes Electrode Spacing

X X X X X
2-142

Module 2 Welding and Cutting Processes

Electrogas Welding

Electrogas Welding (EGW) Definition

Arc welding process that uses an arc between a continuous
filler metal electrode and the weld pool Employs vertical position welding with backing to confine the molten weld pool Externally applied shielding gas may or may not be used

No granular flux

Courtesy of the AWS Welding Handbook, Volume 2, 9th Ed.

2-143

Module 2 Welding and Cutting Processes

Electrogas Welding

Application of EGW
Storage tanks, ship hulls, structural members, and
pressure vessels

High heat input gives large grain size Used for 3/8- to 4-in. thicknesses Reduced need for preheat Reduced need for PWHT Reduced distortion

Problem may be low notch toughness High voltages are needed to melt into sidewalls

2-144

Module 2 Welding and Cutting Processes

Electrogas Welding

ASME Section IX EGW Process Procedure Variables

Paragraph .4 .5 .6 QW-404 Fill Filler Metals QW-408 Gas .12 23 .23 .33 .2 .4 Brief of Variables F-Number A-Number Diameter Classification Filler Metal Product Form Classification Single, Mixture, or % Flow Rate X X X X X Essential X X X Supplementary Essential Nonessential

2-145

Module 2 Welding and Cutting Processes

Electrogas Welding

ASME Section IX EGW Process Procedure Variables

Paragraph QW-409 .4 Electrical Characteristics .8 .5 .8 8 QW-410 Technique .10 .15 .1 Brief of Variables > Heat Input Current or Polarity I & E Range Method of Cleaning Tube Tube-Work Work Distance Single to Multi Electrodes Electrode Spacing X Essential Supplementary Essential X X X X X X X X Nonessential

2-146

Module 2 Welding and Cutting Processes

Arc Stud Welding

Arc Stud Welding Definition

Attachment of threaded studs to
base plate Local melting at interface by ~0.1-2 second arc Metal expulsion during plunging Capacitor discharge is a less common process for stud welding

Source: AWS Handbook 9th ed. Vol. 1

2-147

Module 2 Welding and Cutting Processes

Arc Stud Welding

ASME Section IX Arc Stud Process Procedure Variables

Paragraph QW-402 Joints QW-405 Positions QW-408 Gas .8 .9 .1 .2 .4 .8 QW-409 .10 Electrical Characteristics .11 QW-410 Technique .22 .9 Brief of Variables Stud Shape Size - Flux or Ferrule + Position Single, Mixture, or % Current or Polarity I & E Range Arc Timing Amperage Power Source Gun Model or Lift X X X X Essential X X X X X X Supplementary Essential Nonessential

2-148