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Assignment_welding

Training welding

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Md Al Amin Patwary
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10 views

Assignment_welding

Training welding

Uploaded by

Md Al Amin Patwary
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Welding Training Program (Assignment)

1. What is Spatter?
Spatter refers to tiny droplets of molten metal or flux that are expelled from the welding arc,
scattering around the weld area. It is considered a defect as it results in a rough surface and requires
cleaning.

2. What is Slag?
Slag is the non-metallic residue formed when flux melts and combines with impurities during
welding. It solidifies over the weld bead and must be removed to ensure a clean and smooth weld.
3. Types of Weld Beads
• Stringer Bead: A straight weld with minimal side-to-side movement.
• Weave Bead: A wider weld created with side-to-side oscillation for better coverage.

4. Standard Bead Size


The bead width is typically two to three times the diameter of the core wire. This ensures a
consistent ripple pattern and complete penetration.

5. What is an Arc?
An arc is created when the electrode and the workpiece make contact to complete the electrical
circuit.
• Arc Characteristics:
o Generates a temperature of up to 6500°C.
o Melts the electrode and base metal.
o Emits light to aid welders in positioning and directing the weld.

6. What is Electrode Size?


Electrode size refers to the diameter of the electrode's core wire.
• Common Sizes: 2.5 mm to 8 mm in diameter, 330 mm to 460 mm in length.
7. What is a Core Wire?
The core wire is the metal wire inside an electrode that melts to form the weld bead.

8. What is a Base Metal?


Base metal is the primary material being welded, either ferrous (steel) or non-ferrous (aluminum,
copper).

9. What is Filler Metal?


Filler metal is additional material added to the weld to fill gaps and ensure a strong joint.
10. Common Sizes of ESAB BD Electrodes
The common available sizes of ESAB BD electrodes, based on the wire diameter, typically range
from 1.6 mm to 5.6 mm, including 1.6 mm, 2.0 mm, 2.4 mm, 3.2 mm, 4.0 mm, 4.8 mm, and 5.6
mm. The tolerance for these diameters is typically ± 0.05 mm. However, other sizes may be made
upon agreement between the purchaser and the manufacturer.

11. Conversion Between Gauge and Millimeters (mm)


Gauge values describe thickness; smaller gauges indicate thicker materials.
American Wire Gauge (AWG)

Gauge (AWG) Diameter (mm)

10 2.588

12 2.052

Standard Wire Gauge (SWG)

Gauge (SWG) Diameter (mm)

10 3.251

12 2.642

12. What is Reinforcement?


Reinforcement is the excess weld material deposited above the joint surface to strengthen the weld
and ensure durability under stress.

13. Electrode Classification (E6013)


• E: Electrode for arc welding.
• 60: Tensile strength of 60,000 psi.
• 1: All-position welding.
• 3: Rutile-based flux for smooth welding.
14. What is Polarity?
Polarity refers to the direction of current in welding.
• Types:
o DCEP: Direct Current Electrode Positive.
o DCEN: Direct Current Electrode Negative.
o AC: Alternating Current.

15. Types of Welding Machines


• Transformer welding machines
• Rectifier welding machines
• Inverter welding machines
• Engine-driven welding machines

16. Welding Positions (Flat Plate)


• Flat (1G)
• Horizontal (2G)
• Vertical (3G)
• Overhead (4G)

17. Types of Weld Joints


• Butt joint
• Lap joint
• Corner joint
• Edge joint
• Tee-joint
18. Face, Root, and Root Gap
• Face: Exposed surface of the weld.
• Root: Deepest penetration points of the weld.
• Root Gap: Distance between base metals at the joint root.

19. Types of Weld Passes


• Root Pass: First pass for joint penetration.
• Fill Pass: Adds material to strengthen the joint.
• Cover Pass: Provides the final surface finish.

20. AC and DC in Welding


• AC (Alternating Current): Current reverses direction periodically.
• DC (Direct Current): Current flows in a single direction.

21. Standard Electrode Sizes


Nominal Diameter of Core Wire (AWS 5.1):
o The standard diameters include: 1.6 mm, 2.0 mm, 2.4 mm, 3.2 mm, 4.0 mm, 4.8
mm, 5.6 mm, 6.4 mm, and 8.0 mm.
o Tolerance: ± 0.05 mm.
o Other sizes can be produced as agreed between the purchaser and manufacturer.
Nominal Length of Core Wire (AWS 5.1):
o The standard lengths are: 230 mm, 300 mm, 350 mm, 450 mm, and 460 mm.
o Tolerance: ± 10 mm.
o Other lengths can be made as agreed between the purchaser and manufacturer.
These measurements guide the selection of appropriate electrode sizes for different welding
applications.

22. Tack Weld vs. Run Weld


• Tack Weld: Short, temporary welds to hold components in place.
• Run Weld: Continuous weld along the joint.

23. Define Arc Welding


Arc welding is a process that uses an electric arc to generate heat, melting the metals to form a
joint. It involves a power source, electrode, and shielding to protect the weld.
24. Welding Current and Arc Voltage
• Welding Current: Flow of electric charge, measured in amperes (A).
• Arc Voltage: Voltage across the arc, measured in volts (V).

25. Preparation Before Welding


1. Surface Cleaning: Remove rust, oil, and debris.
2. Parameter Setup: Adjust current and voltage based on material.
3. Equipment Check: Inspect cables, machine, and grounding.
4. PPE: Use welding helmets, gloves, and flame-resistant clothing.
5. Clamping: Secure the workpiece for stability.

26. Difference Between Sheet and Plate


Property Sheet Plate
Thickness Typically less than 6 mm Generally 6 mm or more
Flexibility Easier to bend and form due Rigid and less flexible
to lower thickness
Applications Automotive body panels, Structural applications,
appliances shipbuilding

27. Common Weld Defects


Porosity
• Appearance: Small gas bubbles trapped in the weld.
• Causes: Contaminated surface, improper shielding gas, excessive welding speed.
Undercut
• Appearance: A groove along the weld edge.
• Causes: Excessive current, high welding speed, incorrect angle.

Cracks
• Appearance: Long, linear fractures in the weld or adjacent material.
• Causes: Rapid cooling, improper filler material, residual stress.

Lack of Fusion
• Appearance: Incomplete joining between base material and filler.
• Causes: Insufficient heat, incorrect electrode angle, low current.
6. Slag Inclusions
• Appearance: Non-metallic material trapped in the weld.
• Causes: Improper cleaning between passes, insufficient electrode manipulation.

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