CWI Module 3
CWI Module 3
(SMAW)
Manual
We more often hear it referred to as
"Stick Welding"
This process operates by heating the
metal with an electric arc between a
coverd metal electrode and the metals
to be joined.
Electrode
Concept
Type
Problem
Limitation
Advantage
Power Curre
source
nt
Shielding
AC DCEP DCEN
DCEP
DCEP (1,2,3,4,6,9,12) * 5
DCEN (7,8,10,11,13,14) * 5
Slag inclusion
Wire feeding problems
Incomplete joint penetration and
Porosity.
Porosity (Contamination)
Tungsten inclusion
AC DCEP - DCEN
Advantage
Limitation
Problems
Improper manipulation or
adjustment of the flame. If the
flame is adjusted such that an
oxidizing flame or carburizing
flame is produced weld metal
properties could be degraded.
SW is considered to be an arc
welding process.
Brazing Processes
Brazing differs from welding in that brazing is accomplished without any
melting of the base metal. The heat applied is only for melt the filler metal.
*Soldering is also required melting filler metal temperature below 840 F
(450C).
* Brazing required melting filler metal temperature above 840 F (450C).
The braze joint is designed to have a large surface area. The clearance, or
gap, between the tow pieces to be joined is kept to a minimum. Capillary
action is that phenomenon which causes a liquid to be pulled into a tight
space between tow surfaces.
So, if the surfaces are not properly cleaned, the ability of the capillary action
to occur will be reduced to the point that the braze material will not be drawn
sufficiently into the joint.
The braze filler material configuration include wire, strip, foil, paste and
preforms.
Braze alloy designations are preceded by a B followed by abbreviations of
the most prominent chemical elements included. The brazing filler metals
having an R in front of
the B in their designations denotes their chemistry is identical with Copper
and Copper-Alloy Gas Welding Rods.
To maintain the cleanliness of the joint during the application of heat, brazing
fluxes are often used. There are numerous methods of brazing:1-Torch Brazing (TB) heating is accomplished using an oxyfuel flam. It can
be done manually, mechanically or automatically.
2-Furnace Brazing (FB) is performed in a furnace, often with a controlled
atmosphere. The braze filler material and flux are preplaced at or near the
joint.
3-Induction Brazing (IB) relies on the heat produced in a metal when placed
within an induction coil.
4-Resistance Brazing (RB) is accomplished by heating the base metal using
its own inherent electrical resistance.
5-Dip Brazing (DB) differs from the other types in that the parts to be joint
are immersed in some type of molten bath (braze filler metal) to provide the
necessary heating.
6-Infrared Brazing (IRB) relies on heating provided by radiant energy (using
a high intensity infrared light source)
The formatting of voids or unbounded areas within the joint. when too much
localized heat ia applied to the base metal resulting in melting and erosion of
the base metal.
The corrosion of the base metal by some of the extremely reactive fluxes.
Cutting Ptocesses
1-Oxyfuel Gas Cutting (OFC)
We use an oxyfuel flame to heat the material to a
temperature at which it will readily oxidize, or
burn. The temperature needed is referred to as the
kindling temperature, and for steels, it is about
1700F (925C). once that temperature has been
achieved, a high pressure stream of cutting oxygen
is directed on the heated surface to produce an
oxidation reaction. This stream of oxygen also
tends to remove the slag and oxide residue which is
produced by this oxidation. The equipment used
for OFC is essentially the same as that foe OAW
except that, instead of the welding tip, there is now
a cutting attachment which includes an additional
lever or valve to turn on the cutting oxygen.
OFC using several different types of fuel gases
such as acetylene, methane (natural gas), Propane,
gasoline, and methylacetylene-propadiene (MPS).
Karf is the width of the cut produced. Drag is the
amount of offset between the cut edge.
OFC is used extensively by most industries, it is
usually limited to the cutting of carbon and low
alloy steels. In order for OFC to be effectively
accomplished the material must comply with the
following criteria: (1) it must have the capability of
burning in a stream of oxygen. (2) its ignition
temperature for burning must be lower than its
melting temperature. (3) its heat conductivity
should be relatively low. (4) the metal oxide
produced must melt at some temperature below the
melting point of the metal. (5) the formed slag
must be of low viscosity.
Advantage (inexpensive and portable equipment
use in shop and field can mad on thin or thick
section)
Limitation (finish cut may require additional
cleaning or grinding there may be a HAZ
produced having a very high hardness the flame
and hot slag produced result in safety hazards.)
2- Air Carbon Arc Cutting (CAC-A)
This process uses a carbon electrode to create an
arc for heating, along with a high pressure stream
of compressed air to mechanically remove the
molten metal. The equipment used for CAC-A
consists of a special electrode holder which is
attached to a constant current power source and a
compressed air supply.
CAC-A has applications in most industries,
especially since it can be used to cut any material
and alloys. It is important to realize that it can be
used as a weld joint preparation tool.
Advantage (has ability to cut removal) any metal
use the same power source as those used for some
types of welding. )
Limitation (very noisy and dirty process a fire
watch may required to make sure the gouged metal
droplets do not create a fire hazard the finished
cut may require some cleanup prior to additional
welding).
Laser Beam Welding (LBW) & Electron Beam Welding (EBW) Reed from the book.