Welding Inspection

Welding Processes
Course Reference WIS 5
Section Ref 9,10,11,12,13,
 Welding
BS 499 part 1 Welding terms
A union between pieces of metal at faces
rendered plastic or liquid by heat,pressure or
both.
Possible energy sources
Ultrasonic
Electron beam
Friction
Electric resistance
Electric arc
 Welding Processes
Welding is regarded as a joining process in which the
work pieces are in atomic contact

Solid state processes Fusion welding processes

Forge welding Oxy-acetylene
Friction welding MMA (SMAW)
MIG/MAG (GMAW)
TIG/TAG (GTAW)
Sub-arc (SAW)
Electro-slag (ESW)
 Fusion Welding Factors
The four essential factors for fusion welding

1. Fusion is achieved by melting using a high

intensity heat source
2. The welding process must be capable of
removing any oxide and contamination from
the joint
3. Atmosphere contamination must be avoided
4. The welded joint must possess the
mechanical properties required by the
specification being adapted
 Arc Welding Safety

Before continuing with the welding processes section,

there are 2 safety related terms that should first be
understood

“Duty Cycle” relates to the current carrying capacity of

all conductors, based on a 10 minute cycle i.e. 60% duty
cycle means it can carry the specified current for 6
minutes in 10 then must rest for 4 minutes. A 100% duty
cycle has no rest period requirement. (Explained fully in
the WIS 5 course notes)
 Arc Welding Safety
OEL/MEL (Occupational or Maximum Exposure Limit) which is used in
reference to fume exposure such as that caused in arc welding. The
value may be in PPM or mg/m3 depending on a particulate fume, or a
gas. Typical values in EH/40 are

Fume or gas Exposure Limit Effect on Health

Cadmium 0.025Mg/m3 Extremely toxic

General Welding
5Mg/m3 Low toxicity
Fume
Iron 5Mg/m3 Low toxicity
Aluminium 5Mg/m3 Low toxicity
Ozone 0.20 PPM Extremely toxic
Phosgene 0.02 PPM Extremely toxic

Argon No OEL Value Very low toxicity

O2 air content to be
controlled
Welding Processes
 Manual Metal Arc Process (MMA)

USA: SMAW

Electrode
core wire

Electrode
covering

Electric Arc

Gas shield Solidified slag

Molten weld pool Build up of weld metal
Penetration

Parent material
 Manual Metal Arc Process (MMA)
Welding position has a big affect on weld quality.
More welder skill is required to weld in the overhead position
(4G), when compared to down hand position (1G)
 Manual Metal Arc Process (MMA)
In the down hand position (1G) the welder can drag the tip of
the electrode along the joint. In the case of vertical (3G) and
overhead welding (4G) the welder always gauges the arcs
length
 Manual Metal Arc Process (MMA)
Current (amps) primarily controls depth of penetration, the
higher the current the deeper the penetration. If the current is
too high this may lead to high spatter, undercut and the
possibility of burn throughs
 Manual Metal Arc Process (MMA)
Arc length is another important consideration in weld quality. If
the arc length is too short the arc will be come unstable and my
short circuit. If the arc length is too long this causes high
spatter and incorrect shielding form the atmosphere.
 Manual Metal Arc Process (MMA)
Arc length is another important consideration in weld quality. If
the arc length is too short the arc will be come unstable and my
short circuit. If the arc length is too long this causes high
spatter and incorrect shielding form the atmosphere.
 Welding Power Sources
Drooping or Constant Current Characteristic
100
O.C.V. Striking voltage (typical) for arc
90
initiation
80

70
Required for: MMA, TIG, Plasma
arc and SAW > 1000 AMPS
60
Voltage

50

40 Large voltage variation, e.g. +

Normal Operating 10v (due to changes in arc
30 Voltage Range length)
Small amperage change
20
resulting in virtually constant
current e.g. + 5A.
10

20 40 60 80 100 120 130 140 160 180 200

Amperage
 MMA Welding Basic Equipment

Control panel Power source

(amps, volts)

Electrode Holding oven

oven
Electrodes Inverter power
source
Return lead
Electrode holder
Welding
visor/filter Power cables
glass
Manual Metal Arc Process (MMA)

Welder controls

Arc length

Angle of electrode

Speed of travel
 Welding Plant
Transformer:
Changes mains supply voltage to a voltage suitable for
welding. Has no moving parts and is often termed static
plant.
Rectifier:
Changes a.c. to d.c., can be mechanically or statically
achieved.
Generator:
Produces welding current. The generator consists of an
armature rotating in a magnetic field, the armature must be
rotated at a constant speed either by a motor unit or, in the
absence of electrical power, by an internal combustion
engine.
Inverter:
An inverter changes d.c. to a.c. at a higher frequency.
 Variable Parameters
Voltage
The arc voltage in the MMA process is measured as close to
the arc as possible. It is variable with a change in arc length
O.C.V.
The open circuit voltage is the voltage required to initiate, or
re-ignite the electrical arc and will change with the type of
electrode being used e.g 70-90 volts
Current
The current used will be determined by the choice of
electrode, electrode diameter and material type and
thickness. Current has the most effect on penetration.
Polarity
Polarity is generally determined by operation and electrode
type e.g DC +ve or DC -ve
 Manual Metal Arc (MMA)
The three main electrode covering types
used in MMA welding

Rutile - general purpose

Basic - low hydrogen

Cellulose - deep penetration/fusion

 Checks when MMA Welding
The welding equipment
A visual check should be made on the equipment to ensure it
is in good working order
The electrodes
Checks should be made to ensure that the correct
specification of electrode is being used, the electrode is the
correct diameter and in good condition. In the case of basic
fluxed electrodes ensure the correct heat treatment is being
carried out before use
e.g Baked at 350oC, holding 150oC, quiver temps 70oC
Cellulose and rutile electrodes do not require pre-baking but
should be stored in a dry condition.
 Checks when MMA Welding
OCV open circuit volts
A check should be made to ensure that the equipment can
produce the OCV required by the consumable and that any
voltage selector has been moved to the correct position
Current & polarity
A check should be made to ensure the current type and
range is as detailed on the WPS
Other variables
Checks should be made for correct electrode angle, arc gap
and travel speed
Safety
 Advantages & Disadvantages
Advantages Disadvantages

Field or shop use High welder skill required

Range of consumables Low operating factor*
All positions High levels of fume
Portable Hydrogen control (flux)
Simple equipment Stop/start problems

* Comparatively uneconomic when compared with

some other processes i.e MAG, SAW and FCAW
Arc Blow / Wander

Electrode

Magnetic
flux

Welding
arc
 Arc Blow / Wander
Arc blow is the deviation of
the arc due to magnetic
influences.
Electrode
Arc blow occurs using DC
current only Magnetic
flux
The occurrence of arc blow
may cause the following
problems
Poor penetration/fusion
Poor cap profiles
High spatter
Welding
General manipulation arc
problems
 Precautions Against Arc Blow
If the procedure allows Change the electrodes
change welding current angle, opposite to the arc
from d.c. to a.c. blows direction.
Hold as short an arc as If possible weld towards
possible. heavy tack welds or
Reduce welding current previously deposited
(within the procedures welds.
range) Wrap ground cables
Reduce welding voltage (return leads) around the
within the procedures work piece or the welder.
range De-magnetise component
being welded
Any Questions

Copyright © 2003 TWI Ltd M.S.Rogers

 Questions
QU 1. State the main welding parameters of the MMA welding
process

QU 2. What type of power source characteristic is considered

essential for a MMA welding plant?

QU 3. Give the main advantages of the MMA welding process

when compared to the MAG welding process

QU 4. State the four criteria that will govern the number of weld
passes in a MMA welded joint

QU 5. State two types of electrical supply and give the advantages

of each
 Tungsten Inert Gas (TIG)

USA: GTAW

Cap
Switch
power
Switch cable
Handle

Filler wire Electrode

Shielding gas
Deposited
weld metal Gas
inlet
 TIG Welding Basic Equipment

Power source
Power control
panel Inverter power
source

Return lead Source control

panel
Torch
assembly Power cable hose
Tungsten Flow-meter
electrodes
 TIG Torch Assembly

Tungsten Tungsten
housing electrode

Fitted ceramic Ceramic

shielding cup shield cup

On/Off switch Gas lens

Split collet

Gas diffuser
Torch body
Spare ceramic
shielding cup
 Variable Parameters
Voltage
The voltage of the TIG welding process is variable only by
the type of gas being used, and changes in the arc length
Current
The current is adjusted proportionally to the tungsten
electrodes diameter being used. The higher the current the
deeper the penetration and fusion
Polarity
The polarity used for steels is always DC –ve as most of the
heat is concentrated at the +ve pole, this is required to keep
the tungsten electrode at the cool end of the arc. When
welding aluminium and its alloys AC current is used
 Variable Parameters
Tungsten electrodes
The electrode diameter, type and vertex angle are all critical
factors considered as essential variables. The vertex angle is
as shown

DC -ve AC

Vetex angle

Note: too fine an angle will promote Note: when welding aluminium with
melting of the electrodes tip AC current, the tungsten end is
chamfered and forms a ball end
when welding
 Tungsten Electrodes
Old types
Thoriated: DC -ve electrode - steels and most
metals
1% thoriated + tungsten for higher current values
2% thoriated for lower current values
Zirconiated: AC - aluminum alloys and magnesium

New types
Cerium: DC -ve elctrode - steels and most metals
Lanthanum: AC - Aluminum alloys and magnesium
 Tungsten Electrodes
Metal Tungsten Filler Rod Shielding Flow Rate
Thickness Joint Type Diameter Diameter Amperage
Gas L/mm
mm mm mm
Butt 60-70
Lap 70-90
1.5 1.6 1.5 Argon 8
Corner 60-70
Fillet 70-90
Butt 80-100
Lap 90-115 Argon
3.0 1.6-2.4 2.4 8
Corner 80-100
Fillet 90-115
Butt 115-135
Lap 140-165
5.0 2.4 3.2 Argon 10
Corner 115-135
Fillet 140-170
Butt 160-175
Lap 170-200
6.0 3.2 4.0 160-175 Argon 10
Corner
Fillet 175-210
 Variable Parameters
Gas type and flow rate
Generally two types of gases are used in TIG welding, argon and helium,
though nitrogen may be considered for welding copper and hydrogen
may be added for the welding of austenitic stainless steels. The gas flow
rate is also an important
Argon (Ar) Inert Helium Argon mixes
Suitable for welding carbon Suitable for welding carbon
steel,stainless steel, aluminium steel, stainless steel,
and magnesium copper, aluminium and
magnesium
Lower cost, lower flow rates
High cost, high flow rates
More suitable for thinner
More suitable for thicker
materials and positional
materials and materials of
welding high thermal conductivity.
 Tungsten Inert Gas Welding

1. 2. 3. 4. 5.
1. Pre-flow timer control 4. Down-Slope control (Slope-out)
Adjusts the time the gas and Crater fill and controls crater
water valves are open pipe and the possibility of
2. Up-Slope control (Slope-In) crater cracks
Prevents burn throughs and the 5. Post-flow timer control
possibility of tungsten inclusions Adjusts the time the gas flows
3. Output control after welding
Welding current control
 Checks when TIG Welding
The welding equipment
A visual check should be made to ensure the welding
equipment is in good condition
The torch head assembly
Check the diameter and specification of the tungsten
electrode, the required vertex angle and that a gas lens is
fitted correctly. Check the electrode stick-out length and that
the ceramic is the correct type and in good condition
Gas type and flow rate
Check the shielding gas is the correct type, or gas mixture
and the flow rate is correct for the given joint design, welding
position as stated in the WPS
 Checks when TIG Welding
Current and polarity
Checks should be made to ensure that the type of current
and polarity are correctly set, and the range is within that
given on the procedure.
Other welding parameters
Checks should be made to other parameters such as torch
angle, arc gap distance and travel speed.
Safety
Check should be made on the current carrying capacity, or
duty cycle of the equipment and all electrical insulation is
sound and in place. Correct extraction systems should be in
use to avoid exposure to toxic fume.
 Advantages & Disadvantages
Advantages Disadvantages
High quality High skill factor required
Good control Small consumable range
All positions High protection required
Low hydrogen Low productivity
Minimal cleaning High ozone levels
Any Questions

Copyright © 2003 TWI Ltd M.S.Rogers

 Questions
QU 1. Give three reasons for the occurrence of tungsten
inclusions
QU 2. State the main welding parameters with the TIG welding
process

QU 3. Which electrode polarity is considered essential for the

welding of carbon steel? And give a brief description why

QU 4. Which electrode polarity is considered essential for the

welding of aluminium? And give a brief description why

QU 5. State the tungsten electrode activators required to weld

carbon steel and the light alloys

QU 5. State the main advantages and disadvantage of the TIG

welding process
Metal Active/Inert Gas (MAG/MIG)

USA: GMAW
Wire electrode

Shielding gas in
Contact tip and
electrode wire guild
Electric Arc
Gas shield
Molten weld pool Build up of weld metal
Penetration

Parent material
 Flat or constant voltage characteristic

Flat or Constant Voltage Characteristic Used With MIG/MAG, ESW &

SAW < 1000 amps

O.C.V. Arc Voltage

Virtually no Change.
33

32

31
Small Voltage
Voltage Change.
Large Current Change

100 200 300

Amperage
 MAG Welding Basic Equipment

External wire External wire

feed unit feed motor
control panel

Transformer/
Power Rectifier
control panel
Power cable &
15kg wire spool hose assembly
Power return Spare contact
cable tips
Welding gun Liner for wire
assembly
 MAG/MIG Torch Head Assembly
Torch body
On/Off switch
Torch head assembly
(Less nozzle)

Hose port

Nozzles or Spot welding

shrouds spacer
Gas diffuser
Contact tips
MAG/MIG Internal Wire Drive

Plain top roller

Half grooved Wire guide

bottom roller
 Metal Transfer Modes for MAG/MIG
Dip Transfer: Voltage < 22 Amperage < 200
Thin materials positional welding
 Metal Transfer Modes for MAG/MIG
Spray Transfer: Voltage > 27 Amperage > 220
Thicker materials, limited to flat welding positions,
high deposition.
 Metal Transfer Modes for MAG/MIG
Globular Transfer: Between Dip & Spray Transfer
Limited commercial, Used only in some mechanised
MAG process using CO2 shielding gas
 Metal Transfer Modes for MAG/MIG
Dip Transfer: Voltage < 22 Amperage < 200
Thin materials positional welding
Globular Transfer: Between Dip & Spray Transfer
Limited commercial, Used only in some mechanised MAG
process using CO2 shielding gas
Spray Transfer: Voltage > 27 Amperage > 220
Thicker materials, limited to flat welding positions, high
deposition
Pulse Transfer: Both spray and dip transfer in
one mode of operation, frequency range 50-300
pulses/second
Positional welding and root runs
 Variable Parameters
Wire feed speed
Increasing the wire feed speed automatically increases the
current in the wire
Voltage
The voltage is the most important setting in the spray
transfer mode, as it controls the arc length. In dip transfer it
controls the rise in current
Current
The current is automatically increased as the wire feed is
increased. Current mainly affects penetration
 Variable Parameters
Gasses
The gasses used in MIG/MAG welding can be either 100%
CO2 or Argon + CO2 mixes.
100% CO2: Can not sustain true spray transfer, but gives
very good penetration. The arc is unstable which produces
a lot of spatter and a coarse weld profile.
Argon + CO2 mixes: Argon can sustain spray transfer
above 24 volts, and gives a very stable arc with a reduction
in spatter. Argon being a cooler gas produces less
penetration than CO2. Argon in normally mixed with CO2 at
a mixture of between 5-20%
 Variable Parameters
Inductance
Applicable to MIG/MAG process in dip transfer mode.
The electrode is fed slowly through the arc until it
touches the weld pool, at this point the output from the
power supply is short circuited and a very high current
flows through the electrode. If this was allowed to
continue, the wire would melt and eject excessive
amounts of spatter.
The inclusion of the choke in the welding circuit controls
the rate at which the current rises so that the electrode
tip is melted uniformly without excessive spatter
 Checks when MIG/MAG Welding
The welding equipment
A visual check should be made on the equipment to ensure it
is in good working order
The electrodes
The diameter, specification and the quality of the wire are
essential for inspection. The level of deoxidisation in the
wire, single, double or triple de-oxidised. The quality of the
wire winding and the copper coating should also be
inspected to minimize wire feed problems.
 Checks when MIG/MAG Welding
Wire liner
Check that the liner is the correct type and size for the wire
being used. Steel liners for steel and Teflon liners for
aluminium.
Contact tips
Check the tip is the correct size for the wire being used and
check the amount of wear. Excessive wear will affect wire
speed and electrical current pick-up
Gas and gas flow-rates
Type of gas and the flow rate need to be checked to ensure
they comply with the WPS
Other welding variables
Check WFS, amps, volts and travel speed
 Flux Cored Arc Welding
Flux core
Insulated extension nozzle

Current carrying guild tube

Wire joint

Flux cored hollow wire

Flux powder
Arc shield composed of
vaporized and slag forming
Flux core compounds
wires

Molten
weld Metal droplets covered
Solidified weld pool
with thin slag coating
metal and slag
 Advantages & Disadvantages
Advantages Disadvantages

High productivity Lack of fusion (dip)

Easily automated Small range of
All positional (dip &
consumables
pulse)
Material thickness Protection on site
range Complex equipment
Continuous electrode Not so portable
Any Questions

Copyright © 2003 TWI Ltd M.S.Rogers

 Questions
QU 1. State the possible problems when using the dip transfer
mode in the MAG welding process

QU 2. State the application areas for the spray transfer mode

when using the MAG welding process.

QU 3. What power source characteristic is required and electrode

polarity/current type for the MAG welding process

QU 4. State the main variables for the MAG welding process

QU 5. State the advantages and disadvantages of the MAG

welding process when compared to MMA

Section Ref 12
Sub-arc Welding
(SAW)
Filler wire spool
Flux hopper
Power
supply

- +

Slide rail
Wire electrode

Flux
Sub-arc Welding
(SAW)
Filler wire spool
Flux hopper
Power
supply

- +

Slide rail
Wire electrode

Flux
 Sub-arc Welding basic equipment

Transformer/
Rectifier
Power return
cable Welding carriage
Power control control unit
panel
Welding carriage

Granulated Electrode wire

flux reel

Granulated
flux
Sub-arc Welding (SAW) Fluxes

Fused SAW Agglomerated SAW

Fluxes Fluxes
 Sub-arc Welding (SAW) Fluxes
Fused Flux Agglomerated Flux
Flaky appearance Granulated appearance
Lower weld quality High weld quality
Low moisture intake Addition of alloys
Low dust tendency Lower consumption
Good re-cycling Easy slag removal
Very smooth weld Smooth weld profile
profile
 Advantages & Disadvantages
Advantages Disadvantages

Low weld-metal cost Restricted welding

Easily automated positions
Low levels of ozone Arc blow on DC current
High productivity Shrinkage defects
No visible arc light Difficult penetration
Minimum cleaning control
Limited joints
Any Questions

Copyright © 2003 TWI Ltd M.S.Rogers

 Questions
QU 1. State the possible problems when using damp and
contaminated fluxes when using the sub-arc process

QU 2. State the two flux types used in the sub-arc welding

process.

QU 3. Generally what power source characteristic is required

for the SAW welding process

QU 4. State three main items of sub-arc fluxes, which require

inspection

QU 5. State the advantages and disadvantages of the sub-arc

welding process
 Electro-slag Welding (ESW)
Consumable-Guide Non Consumable-Guide

Electrode
Feed Rolls Electrode Wire
Electrode Wire
Electrode
Guide Tube Feed Rolls
Drive Unit
Molten Slag
Bath Electrode
Guide
Copper
Shoe Copper Shoe
Solid Weld Solid Weld
Metal Metal

More suitable for short weld lengths and More suitable for longer weld lengths
mechanically simpler. Can also be used and mechanically more complicated.
in portable models.
 Electro-slag Welding (ESW)
Electro-slag welds are relatively defect free
More suited to the joining of thick materials
No costly joint edge preparations required, square butt
Minimal distortion
Minimal pre-heat required
Low flux consumption
High deposition
Vertical up welding position only
Low toughness values, may require PWHT.
Timely Set-ups
 Process Comparisons

Process Electrical characteristic Electrode current type

MMA Drooping / constant current DC+ve, DC-ve, AC

TIG Drooping / constant current DC-ve, AC

MIG/MAG Flat / constant voltage DC+ve,

MAG FCAW Flat / constant voltage DC+ve, DC-ve,

Drooping / constant current >500amp

Sub-arc DC+ve, DC-ve, AC
Flat / constant voltage <500amp

Electro-slag Flat / constant voltage DC+ve,

Any Questions

Copyright © 2003 TWI Ltd M.S.Rogers