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A Welding Process:: Special Equipment Used With Method, For Producing Welds

1) The document discusses the equipment, setup requirements, and welding parameters needed for manual metal arc welding (MMAW) and gas tungsten arc welding (GTAW). 2) It covers the necessary safety equipment, power sources, electrodes, and considerations for each process like duty cycle, fume exposure limits, and causes of welding defects. 3) The advantages and disadvantages of MMAW and GTAW are provided, such as their portability, quality of welds, and skill requirement.

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The Engineers EDGE, Coimbatore
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48 views

A Welding Process:: Special Equipment Used With Method, For Producing Welds

1) The document discusses the equipment, setup requirements, and welding parameters needed for manual metal arc welding (MMAW) and gas tungsten arc welding (GTAW). 2) It covers the necessary safety equipment, power sources, electrodes, and considerations for each process like duty cycle, fume exposure limits, and causes of welding defects. 3) The advantages and disadvantages of MMAW and GTAW are provided, such as their portability, quality of welds, and skill requirement.

Uploaded by

The Engineers EDGE, Coimbatore
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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A welding process:*

Special equipment used with method, for producing welds

Heating Protection

Requirements:

To make a sound
weld we need to

Properties
Cleaning
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. A 100% duty cycle has no rest period
requirement. (Explained fully in the WIS 5 course notes)*
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*
Effect on Health Exposure Limit Fume or gas

Extremely toxic 0.025Mg/m3 Cadmium


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

Very low toxicity No OEL Value Argon


O2 air content to be
controlled
Constant Current/Amperage Volt Amp Characteristic*
OCV Large change in voltage
=
Volts Smaller change in amperage*
Large
arc gap*
Welding Voltage*
Small
arc gap

Amps
Power control Power source.
panel Transformer/
Rectifier
Electrode oven
(Up to 350 °C) Holding Oven
(Up to 200 °C)
Electrodes
Inverter power
Power return source
cable
Electrode holder
Safety visor Power cable
(With dark lens) *
1) A Transformer/Rectifier (Constant current type)

2) A power and power return cable

3) Electrode holder

4) Electrode (To correct specification)

5) Correct visor & glass, all safety clothing and extraction


1) Amperage 2) Arc Voltage

3) Polarity 4) Speed of Travel

5) Electrode type & Ø 6) Duty Cycles

7) Electrode condition 8) Connections

9) Insulation / extraction 10) Electrode treatments*


1) Slag inclusions

2) Arc strikes

3) Porosity

4) Undercut

Most welding imperfections in MMA are caused by a lack of


welder skill, the incorrect settings of the equipment, or the
incorrect use, and treatment of electrodes*
Advantages: Disadvantages:

1) Field or shop (Portable) 1) High skill factor

2) Range of consumables 2) Short electrode length

3) All positional 3) **Low productivity (OF)

4) *Quick electrode change 4) High level of fume

5) Simple equipment 5) Hydrogen control

* Enabling fast changes in material types to be welded


** Comparatively uneconomic with other processes*
Power control Transformer/
panel Rectifier

Power return Inverter


cable power source

Torch Power control


assemblies panel

Power cable
Tungsten
electrodes*
Flow-meter
Tungsten Tungsten
housing electrodes
Fitted ceramic
Ceramic
shielding cup
shield cup
On/Off switch
Gas lens
Split collet
Gas diffuser
Spare ceramic Torch body
shielding cup *
The tungsten must have
the correct vertex angle*

Grinding is done on a special


jig, and on a dedicated wheel*
Correctly adjusted shielding
with a gas lens will give good
cover without turbulence*

Adjustments to the flow rate


need to made according to
joint design and gas type*
Before welding

After welding*

A fusible insert is pre-formed and placed filler material


that is mainly used in the root of TIG welded pipes*

It is often termed an “EB insert” after*


The Electric Boat Company of America, who developed it*
1) A Transformer/Rectifier (Constant current type)

2) A power and power return cable


3) An Inert shielding gas. (Argon or Helium)
4) Gas hose, flow-meter, & gas regulator

5) TIG torch head with ground tungsten, collets, ceramics


6) Method of arc ignition (High frequency or lift arc)
7) Correct visor, all safety clothing and good extraction

8) Optional filler rod, to correct specification*


1) Amperage 2) Arc Voltage

3) AC or DC + Polarity 4) Speed of Travel

5) Tungsten type & Ø 6) Duty Cycles

7) Tungsten vertex angle 8) Connections

9) Gas type & flow rate 10) Insulation / extraction


11) Ceramic condition 12) Gas lens fitted*
1) Tungsten inclusions (Low skill, or wrong vertex angle)

2) Surface porosity (Loss of gas shield mainly on site)

3) Crater pipes (Bad weld finish technique i.e. Slope out)

4) Oxidation of S/S weld bead, or root by poor gas cover

Most welding imperfections with TIG are caused by a lack of


welder skill, or incorrect setting of the equipment. i.e. Current,
torch manipulation, welding speed, gas flow rate, etc*
Advantages: Disadvantages:

1) High quality 1) Very high skill factor

2) High control of weld pool 2) Range of consumable

3) All positional 3) Loss of gas shield/site

4) Lowest H2 arc process 4) Low productivity (O/F)

5) Low inter-run cleaning 5) High ozone levels*


Videos
TWI
“Welding with covered electrodes”
ESAB
“TIG Welding Steels & Stainless Steels”
Or equivalent (1 hour)*

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