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Arc Welding Power Sources

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Athay Halder
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21 views

Arc Welding Power Sources

Uploaded by

Athay Halder
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Arc Welding Power Sources:

The main requirement of a power source is to deliver controllable current at a voltage according to
the demands of the welding process being used. Each welding process has distinct differences from
one another, both in the form of process controls required to accomplish a given operating condition
and the consequent demands on the power source. Therefore, arc welding power sources are
playing very important role in welding. The conventional welding power sources are:
Power Source Supply

Power Source Supply

(i) Welding
AC
Transformer
(ii) Welding Rectifier DC
(iii) Welding AC or DC (Depending on
Generators generator)
Welding transformers, rectifiers and DC generators are being used in shop while engine coupled AC
generators as well as sometimes DC generators are used at site where line supply is not available.
Normally rectifiers and transformers are preferred because of low noise, higher efficiency and lower
maintenance as compared to generators. Selection of power source is mainly dependent on welding
process and consumable. The open circuit voltage normally ranges between 70-90 V in case of
welding transformers while in case of rectifiers it is 50-80 V. However, welding voltages are lower as
compared to open circuit voltage of the power source.
Based on the static characteristics power sources can be classified in two categories
• Constant current or drooping or falling characteristic power source.
• Constant potential or constant voltage or flat characteristic power source.
Constant voltage power source does not have true constant voltage output. It has a slightly
downward or negative slope because of sufficient internal electrical resistance and inductance in the
welding circuit to cause a minor droop in the output volt ampere characteristics.
With constant voltage power supply the arc voltage is established by setting the output voltage on
the source. The power source shall supply necessary current to melt the electrode at the rate
required to maintain the preset voltage or relative arc length. The speed of electrode drive is used to
control the average welding current. The use of such power source in conjunction with a constant
electrode wire feed results in a self regulating or self adjusting arc length system. Due to some
internal or external fluctuation if the change in welding current occurs, it will automatically increase
or decrease the electrode melting rate to regain the desired arc length.
The volt ampere output curves for constant current power source are called ‘drooper' because of
substantial downward or negative slope of the curves. The power source may have open circuit
voltage adjustment in addition to output current control. A change in either control will change the
slope of the volt ampere curve. With a change in arc voltage, the change in current is small and,
therefore, with a consumable electrode welding process, electrode melting rate would remain fairly
constant with a change in arc length. These power sources are required for processes using relatively
thicker consumable electrodes which may sometimes get stubbed to workpiece or with
nonconsumable tungsten electrode where during touching of electrode for starting of arc may lead
to damage of electrode if current is unlimited. Under these conditions the short circuiting current
shall be limited leading to safety of power source and the electrode.
Some power sources need high frequency unit to start the arc, which may be requirement of
processes like TIG and plasma arc. High frequency unit is introduced in the welding circuit but in
between the control circuit and HF unit, filters are required so that high frequency may not flow
through control circuit and damage it. High frequency unit is a device which supplies high voltage of
the order of few KV along with high frequency of few KHz with low current. This high voltage ionizes
the medium between electrode and workpiece/nozzle starting pilot arc which ultimately leads to the
start of main arc. Although high voltage may be fatal for the operator but when it is associated with
high frequencies then current does not enter body but it causes only skin effect i.e. current passes
through the skin of operator causing no damage to the operator.
Duty Cycle:
Duty cycle is the ratio of arcing time to the weld cycle time multiplied by 100. Welding cycle time is
either 5 minutes as per European standards or 10 minutes as per American standard and accordingly
power sources are designed. It arcing time is continuously 5 minutes then as per European standard
it is 100% duty cycle and 50% as per American standard. At 100% duty cycle minimum current is to
be drawn i.e. with the reduction of duty cycle current drawn can be of higher level. The welding
current which can be drawn at a duty cycle can be evaluated from the following equation;

Duty cycle and associated currents are important as it ensures that power source remains safe and
its windings are not getting damaged due to increase in temperature beyond specified limit. The
maximum current which can be drawn from a power source depends upon its size of winding wire,
type of insulation and cooling system of the power source.
Table 4.1: Welding Processes, Type of Current and Static Characteristic
Type of Static Characteristic of The
Welding Process
Current Power Source
Manual Metal Arc Welding Constant Current

Tungsten Inert Gas Welding Constant Current

Plasma Arc Welding Constant Current


Constant Current (if
electrode F = 2.4 mm )
Submerged Arc Welding
Constant Potential (if
electrode F = 2.4 mm )
Gas Metal Arc Welding / Metal Inert Gas
Constant Potential
Welding / Metal Active Gas Welding

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