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Tig Mig

Electroslag welding uses an electric current to generate heat by passing through a molten slag covering the weld surface. Prior to welding, a gap between workpieces is filled with flux powder. An initial arc melts the flux to form the slag, which reaches 1930°C and is maintained in liquid state by current heat. Metal droplets from a consumable electrode fall through the slag to join the workpieces. Electroslag welding deposits metal at rates up to 20 kg/h and produces low distortion welds of unlimited thickness, but results in coarse grains and low toughness when used on steels.

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484 views15 pages

Tig Mig

Electroslag welding uses an electric current to generate heat by passing through a molten slag covering the weld surface. Prior to welding, a gap between workpieces is filled with flux powder. An initial arc melts the flux to form the slag, which reaches 1930°C and is maintained in liquid state by current heat. Metal droplets from a consumable electrode fall through the slag to join the workpieces. Electroslag welding deposits metal at rates up to 20 kg/h and produces low distortion welds of unlimited thickness, but results in coarse grains and low toughness when used on steels.

Uploaded by

satish448
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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INERT GAS WELDING

In conventional arc welding, the fluxes are used to shield atmosphere around the molten metal and arc. In inert gas welding, separate inert gas such as argon, helium, carbon dioxide are used for surrounding the electric arc and molten metal from the metal . Thus inert gas serves as a shielding gas which displaces the oxygen and nitrogen from the air surrounding the arc and molten metal. Thus it provides protective shield around arc and molten metal. Thus it eliminates formation of metal oxides and nitrides which lower weld metal ductility and toughness. Inert gas welding is of following types 1. Gas tungsten arc welding (GTAW) or Tungsten inert gas ( TIG ) 2. Gas metal arc welding ( GMAW ) or Metal inert gas ( MIG )

INERT GAS WELDING


Similarities between TIG and MIG 1. No fluxes are used to shield the atmosphere around molten metal 2. Instead of that , both are using separate inert gas ( Argon, helium, Carbon dioxide ) for shielding purpose Differences between TIG and MIG

TIG
1. Arc is stuck between a non consumable tungsten electrode and work piece to be welded.
1.

MIG
Arc is struck between consumable electrode( which serves as a filler material ) and work piece to be welded.

2. Filler material is added from a hand held filler rod or wire of the same composition as the work piece

2. The electrode / filler is a wire fed from a reel continuously to the welding zone. Consumable electrode is having the same composition as work piece material

Metal Inert Gas (MIG)


Uses a consumable electrode (filler wire made of the base metal) Inert gas is typically Argon

CONSUMABLE ELECTRODE

DRIVE WHEELS

POWER SOURCE

SHIELDING GAS

ARC COLUMN

BASE METAL

WELD POOL

GMAW ( MIG ) :- Main equipment


- torch - electric power source - shielding gas source - wire spool with wire drive control
Equipment required for the GMAW

The GMAW ( MIG ) process


The heat is produced by an electric arc between the continuously fed metal electrode and the base metal. Both the base metal and the filler are melt. The weld area is protected by inert shield gases. Weldable metals: -steel carbon

- steel low-allow
- steel stainless - aluminum - copper and its allows - nickel and its allows - magnesium - reactive metal (titanium, zirconium, tantalum)
Characteristics of the weld joint by GMAW

Metal Inert Gas Welding (MIG, GMAW) Metal Inert Gas Welding (Gas Metal Arc Welding) is the arc welding process, in which the weld is shielded by an external gas (argon, helium, CO2, argon + oxygene or other gas mixtures). Consumable electrode wire, having chemical composition simiilar to that of the parent material, is continuously fed from a spool to the arc zone. The arc heats and melts both the work pieces edges and the electrode wire. The fused electrode material is supplied to the surfaces of the work pieces, fills the weld pool and forms joint. Due to automatic feeding of the filling wire (electrode) the process is referred to as a semi-automatic. The operator controls only the torch positioning and speed.

Advantages of Metal Inert Gas Welding (MIG, GMAW): Continuous weld may be produced (no interruptions); High level of operators skill is not required; Slag removal is not required (no slag); High welding speed and can be easily automated Disadvantages of Metal Inert Gas Welding (MIG, GMAW): Expensive and non-portable equipment is required; Outdoor application are limited because of effect of wind, dispersing the shielding gas.

Gas Tungsten Arc Welding

Tungsten Inert Gas Arc Welding (TIG, GTAW) Tungsten Inert Gas Arc Welding (Gas Tungsten Arc Welding) is the welding process, in which heat is generated by an electric arc struck between a tungsten non-consumable electrode and the work piece. The weld pool is shielded by an inert gas (argon, helium, nitrogen) protecting the molten metal from atmospheric contamination. The heat produced by the arc melts the work pieces edges and joins them. Filler rod may be used, if required. Tungsten Inert Gas Arc Welding produces a high quality weld of most of metals. Flux is not used in the process.

Advantages of Tungsten Inert Gas Arc Welding (TIG, GTAW):


Weld composition is close to that of the parent metal; High quality weld structure Slag removal is not required (no slag); Thermal distortions of work pieces are minimal due to concentration of heat in small zone. Flux is not used; therefore, finished welds do not require cleaning of corrosive residue.

Disadvantages of Tungsten Inert Gas Arc Welding (TIG, GTAW):


Low welding rate; Relatively expensive; Requres high level of operators skill

Electroslag Welding (ESW) Electroslag Welding is the welding process in which the heat is generated by an electric current passing between the consumable electrode (filler metal) and the work piece through a molten slag, which covers the weld surface. Prior to welding the gap between the two work pieces is filled with a welding flux. Electroslag Welding is initiated by an arc between the electrode and the work piece (or starting plate). Heat, generated by the arc, melts the fluxing powder and forms molten slag. The slag, having low electric conductivity, is maintained in liquid state due to heat produced by the electric current. The slag reaches a temperature of about 3500F (1930C). This temperature is sufficient for melting the consumable electrode and work piece edges. Metal droplets fall to the weld pool and join the work pieces. Electroslag Welding is used mainly for steels.

Advantages of Electroslag Welding: High deposition rate - up to 45 lbs/h (20 kg/h); Low slag consumption (about 5% of the deposited metal weight); Low distortion; Unlimited thickness of work piece.

Disadvantages of Electroslag welding:


Coarse grain structure of the weld; Low toughness of the weld; Only vertical position is possible.

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