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Welding Training Program

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Md Al Amin Patwary
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15 views

Welding Training Program

Uploaded by

Md Al Amin Patwary
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Welding Training Program: Essential Concepts

Understanding Spatter
Spatter consists of tiny molten metal or flux droplets scattered from the welding arc. These
particles often result in surface imperfections and require post-weld cleaning.

What is Slag?
Slag forms when flux melts and interacts with impurities during welding. It solidifies atop
the weld bead and must be removed to achieve a clean finish.

Types of Weld Beads


- Stringer Bead: A straight weld with minimal lateral movement.
- Weave Bead: A broader weld achieved through side-to-side motion for enhanced coverage.

Standard Bead Dimensions


The bead width is usually two to three times the electrode's core diameter, promoting
consistent penetration and a uniform appearance.

What is an Arc?
An arc forms when the electrode contacts the workpiece, closing the electrical circuit.
- Key Characteristics:
- Reaches temperatures of up to 6500°C.
- Melts both electrode and base material.
- Produces light, assisting in weld placement.

Electrode Size
This refers to the diameter of the electrode's core wire, typically ranging from 2.5 mm to 8
mm in diameter and 330 mm to 460 mm in length.

Core Wire Defined


The core wire is the metallic component within the electrode that melts during welding to
form the weld bead.

Base Metal
The material being welded, which can be ferrous (e.g., steel) or non-ferrous (e.g., aluminum,
copper).

Filler Metal
This is the material added to fill gaps and reinforce the welded joint.
Sizes of ESAB BD Electrodes
Common sizes range between 1.6 mm and 5.6 mm, with a tolerance of ±0.05 mm. Custom
sizes are available upon request.

Gauge vs. Millimeter Conversion


- Smaller gauge numbers indicate thicker materials.
- Examples:
- AWG 10: 2.588 mm
- SWG 10: 3.251 mm

Reinforcement in Welding
Excess material added above the joint surface to enhance strength and durability.

Electrode Classification (E6013)


- E: Electrode.
- 60: Tensile strength (60,000 psi).
- 1: Usable in all positions.
- 3: Rutile-based flux for smoother welding.

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