Constant Voltage Volt/Amp Characteristic*

Small change in voltage

OCV =
Changes in large change in amperage*
arc length*
The self
adjusting arc.
Volts

Amps
External wire Transformer/
feed unit Rectifier

Internal wire
feed system Power cable &
hose assembly
Power control
panel
Liner for wire
15kg wire spool
Power return Welding gun
cable* assembly
Internal wire drive system* Plain top roller

Half grooved Wire guide*

bottom roller
 Torch body
On/Off switch
Torch head assembly
(Less nozzle)*

Hose port

Nozzles or Spot welding

shrouds spacer
Gas diffuser Contact tips
Types of metal transfer:
Dip transfer: < 24 Welding volts. Low amps. & C02 Gas.
All positional. Low heat
input. Low deposition rate
Spray transfer: > 24 Welding volts High amps Ar/C02 Mix
Down-hand only. (steels) High heat input. High deposition rate
Pulse transfer: Variable pulses of high current
All positional. Controlled heat input. High deposition rate*
Globular transfer occurs between dip & spray, but is unstable*
1) A Transformer/Rectifier (Constant voltage type)

2) A power and power return cable

3) An Inert, active, or mixed shielding gas (Argon or CO²)

4) Gas hose, flow-meter, & gas regulator

5) MIG torch with hose, liner, diffuser, contact tip & nozzle

6) Wire feed unit with correct drive rolls (Push or Pull)

7) Electrode wire to correct specification and diameter

8) Correct visor & glass, all safety clothing and good extraction*
1) WFS/Amperage 2) OCV & Arc Voltage

3) Wire type & Ø 4) Gas type & flow rate

5) Tip size/condition 6) Roller size & pressure

7) Liner size 8) Inductance settings

9) Insulation/extraction 10) Connections

11) Duty cycle 12) Angles & travel speed*

1) Silica inclusions (Poor inter-run cleaning)

2) Lack of side wall fusion (Primarily with dip transfer)

3) Porosity (From loss of gas shield on site etc)*

Most welding imperfections in MIG/MAG are caused by lack

of welder skill, or incorrect settings of the equipment
The use of low quality wires will cause wire feed problems
Worn contact tips will cause poor power pick up, or transfer
Bad power connections will cause a loss of voltage in the arc*
 Advantages: Disadvantages:

1) Lower skill required 1) Lack of sidewall fusion

2) Easily automated 2) Range of consumables

3) All positional (Dip/Pulse) 3) Loss of gas shield/site

4) Thick/thin materials 4) Complex equipment

5) High productivity (O/F) 5) High ozone levels*

Power return Welding carriage
cable control unit

Power control Carriage assembly

panel with flux hopper
Transformer/
Rectifier

Granulated Reel of wire

flux*
 1. Wire 2. Flux 3. Dilution
SAW with low arc voltage
1
Typical SAW Short arc length 3 2
preparation*

Possible weld metal % composition*

Effect of increased arc voltage 1. Wire 2. Flux 3. Dilution

Long arc length
1
3 2

Change in weld metal composition*

1) A Transformer/Rectifier (Constant voltage type)

2) A power and power return cable

3) A torch head assembly
4) A granulated flux

5) A flux delivery system

6) A flux recovery system
7) Electrode wire to correct specification and diameter

8) Correct safety clothing and good extraction*

1) WFS/Amperage 2) OCV & Arc Voltage

3) Flux type & mesh size 4) Flux condition

5) Wire Ø & condition 6) Wire Specification

7) Flux delivery/recovery 8) Electrode stick-out

9) Insulation/duty cycle 10) Connections

11) Tip size & condition 12) Speed of travel*

1) Lack of fusion (Caused by high levels of arc blow)
2) Solidification cracks (From S pick up from high dilution)
3) Shrinkage cavities (From high depth:width ratio)
4) Porosity (Using damp fluxes, or un-cleaned plates)*
Most welding imperfections in SAW are caused by incorrect
setting of the equipment, using incorrect or wrongly dried
consumables, or welding plates that have not been properly
cleaned. Minor changes in the welding parameters of SAW can
have a major effect on weld composition and weld quality.
Bad cable connections can have a serious effect on changes in
arc length, and thus effect alloying to the weld via the flux*
 Advantages: Disadvantages:

1) Low weld metal costs 1) Restricted in position

2) Easily mechanized 2) Arc blow with DC

3) Low Ozone production 3) Shrinkage cavities (d:w)

4) High productivity (O/F) 4) Penetration control

5) No visible arc light (U/V) 5) Variable compositions*

 Videos
ESAB
“MIG/MAG Welding Steels”
Or equivalent (30 minutes)*
 Videos
Millar
“Submerged Arc Welding”
Or equivalent (20 minutes)*
All those things used up in the production of a weld
Though generally, we refer to those elements that are used in
a specific welding process i.e:

Electrodes, Wires, Fluxes and Gases*

 In MMA/SMAW the only consumables used are short
electrodes, which are covered in a flux coating
This flux coating has many functions and there are
many different types
These functions are not limited too, but include:
1) To aid arc striking 5) To add alloying elements
2) To stabilize the arc 6) To form a protective slag
3) Form a shielding gas 7) To refine solidifying metal
4) To add de-oxidants 8) To control hydrogen content *
 :Classification Main Shieldin General
Constituent :g gas :Uses
:
Rutile: E6013 Titania CO2 General
Purpose
TiO2
Basic: E7018 Calcium CO2 High quality
compounds work
Cellulosic: Cellulose Hydroge Pipe root
E6010 Ground cocoanut shells
n *runs
The core wire for most MMA electrodes is of a low quality steel, as this is a cheap
method of manufacture and the steel will be refined during the process of welding
by the refining agents and elements contained in the flux coating*
 Electrical parameters
Electrode efficiency
Toughness 28 & 47 Joules
Electrode
E 5133B
Tensile & yield strength
Flux coating type
Positional capabilities
Low hydrogen potential
(After baking)
Strength Toughness Coating Shown on all electrodes*
Positional capabilities
Flux coating type
Toughness 47 Joules
Electrode

E 46 3 1Ni B
Tensile & yield strength
Any light alloying composition
Electrical parameters & efficiency
Low hydrogen content achievable*
Strength Toughness Coating Shown on all electrodes*
Positional capabilities
Electrode

E 80 18

Tensile strength
(PSI x
1000)
Flux coating &
electrical characteristics*
1: Electrode size Diameter & length*

2: Electrode condition Cracks, chips & concentricity*

3: Electrode specification Correct specification/code*

E 51 33 B
Gases used for TIG:
Argon or Helium or a mixture of these gases*

Helium gas has higher ionization potential than argon and gives
deeper penetration, whilst argon is denser than air and gives good
coverage of the weld area in the down hand position. We would
need 2-3 times the flow rate of helium to get the same coverage
as helium is less dense than air. In the overhead position the
reverse is true. We often mix these gases to get both benefits*

We sometimes use additions of nitrogen when welding some

stainless steels, or copper*
Gases used for MIG: Argon or Helium
Gases used for MAG: CO2 or mixtures of CO2 and Argon*

CO2 : Very good penetration, cannot support spray transfer

produces an unstable arc, with lots of spatter
Argon: Shallow penetration. Very stable arc, with low spatter
We mix both gases in mixture of between 5 – 20% CO2 in
argon to get the benefits of both gases*

For  stainless steels we use argon with a 2% oxygen, this

gives more fluidity to the weld and an improved toe blend*
Wires must be drawn as deposited and are therefore of very high
quality. Electrode wires for MIG are the same as rods for TIG*
The quality of temper and copper coating is also very important.
The copper coating on MIG wires maximises the current pick
up*
Specifications for wires are as per their chemical compositions*
Grades:
Composition + Single, double, and triple de-oxidised wires*
Quality of winding:
Random wound. Layer wound. & Precision layer wound
Wires diameters:
0.6 - >2.4 mm Ø supplied on 1 kg (fine wire) & 15 kg spools*
Consumables for Submerged Arc Welding consist of a wire
and a flux*

The wire is similar to that of solid wire MIG/MAG and is

chosen from a table of chemical compositions*

Fluxes are varied and are classified by their method of

manufacture and composition*
The 2 methods of flux manufacture are:
1) Fused
2) Agglomerated*

Fused fluxes are baked at a high temperature after mixing

and all components are fused together like glass. The slab
is then smashed into very small particles and sifted into
grain sizes*

Agglomerated fluxes are not baked as high as the fused

fluxes and are held together as particles by binding agents.
These fluxes are also sifted into grain sizes*
Fused fluxes: cannot contain certain alloying elements
such as Ferro Manganese, and tend to be used for lower
quality work. These fluxes are non moisture absorbant*

Agglomerated fluxes: contain many alloying elements,

but are prone to moisture absorption. They are used for
higher quality work*

All Submerged Arc Fluxes should be separately and

carefully stored in a dry area*
Fused SAW Fluxes
*
Agglomerated Fluxes
*
Fused:

Baked at high temperature, glossy,hard and black in colour,

cannot add ferro-manganese, non moisture absorbent and
tends to be of the acidic type*

Agglomerated:
Baked at a lower temperature, dull, irregularly shaped,
friable, (easily crushed) can easily add alloying elements,
moisture absorbent and tend to be of the basic type*
 Pipe Visual Inspection Form
Page 1 of 3 CSWIP VISUAL INSPECTION PIPE REPORT

Name [Block capitals]____________ Signature_________Pipe Ident#________

Code/Specification used_________Welding Process_______ Joint type______

Welding position__________ Outside  & Thickness_____ Date ________

A B C

C D A

Complete as per plate report form *

Practice observing & reporting using the pipes and forms
provided.
Use your nominated pipe code for all your visual inspections
as this will help you become conversant with the specification.
Practice this up and till the end of the day, or as directed by
your course lecturer*