Basics Of Welding

EWAC Alloys Ltd

 Welding
• Welding is a process of
joining metals
* With the application
of heat,
*With or without the
application of pressure,
* With or without the
application of filler
metal to form a
metallurgical joint.
 Types of Welding
Fusion Non-Fusion
• SMAW • Forge Welding
• Gas / Brazing • Resistance Welding
• TIG • Thermal Spraying
• GMAW(MIG/MAG) • Electron beam welding.
• FCAW • Laser beam welding.
• SAW • Soldering
 Types of Joints
• There are 5 types of
joints …
 Fillet and Groove Welds
• Groove and fillet welds can be made on many
types of joints
 Parts of a Weld

Heat Affected Zone

Joint and Weld
 What are Welding Positions?
• There are various positions that a weld can be
made in:
 Why is Welding Important?
• Many things around us are welded …
– Pipelines that bring fresh water
– Towers that carry electricity to houses
– Cars and buses that take people where they need
to go
 Can All Metals Be Welded?
• Most metals can be welded, but not all
• The three most common weldable metals include:
– Mild Steel - inexpensive and strong
– Stainless Steel – does not rust
– Aluminum – does not rust and is light weight

Mild steel Stainless Steel Aluminum

Arc Welding
 What is Arc Welding?
• Arc welding is most commonly used to join two
pieces of metal
– The welder creates an electric arc that melts the base
metals and filler metal (consumable) together so that they
all fuse into one solid piece of metal

Steel Pipe – Tack Root Pass or Final weld after

Welded “Stringer Bead” several beads are
made
 Basic Steps of Arc Welding
• Prepare the base materials: remove paint and rust
• Choose the right welding process
• Choose the right filler material
• Assess and comply with safety requirements
• Use proper welding techniques and be sure to protect
the molten puddle from contaminants in the air
• Inspect the weld
 The Arc Welding Circuit
• The electricity flows
from the power source,
through the electrode
and across the arc,
through the base
material to the work
lead and back to the
power source
 Basic Electricity
• Voltage – The electrical DC -
potential or pressure that
causes current to flow
– Measured in Volts

• Current – The movement DC+

of charged particles in a
specific direction
– Measured in Amps
AC
• Polarity
– DC- (Direct Current
Electrode Negative)
– DC+ (Direct Current
Electrode Positive)
– AC (Alternating Current)
SMAW welding
 SMAW Principles
• The American Welding
Society defines SMAW as
Shielded Metal Arc
Welding
• SMAW:
– Is commonly known as
‘Stick’ welding or manual
arc welding
– Is the most widely used
arc welding process in the
world
– Can be used to weld most
common metals and alloys
 SMAW Welding Circuit
• Current flows through the electrode cable, to the
electrode holder, through the electrode, and across
the arc.
• On the work side of the arc, the current flows
through the base material to the work clamp and
back to the welding machine.
 SMAW Process
Let’s take a little closer look at the SMAW
process… Electrode
1
Travel direction

Shielding Gas
4

Slag
6 Slag
6
Weld Puddle 3
3 Weld Puddle
2 Arc
2 Arc

5 Solidified Weld Metal

5 Solidified Weld Metal
 1- The Electrode
• Is a consumable - it gets
melted during the welding
process
• Is composed of two parts
– Core Rod (Metal Filler)
 Carries welding current
 Becomes part of the weld
– Flux Coating
 Produces a shielding gas
 Can provide additional filler
 Forms a slag
 2- The Arc
• An arc occurs when the
electrode comes in
contact with the work-
piece and completes the
circuit … like turning on a
light!
• The electric arc is
established in the space
between the end of the
electrode and the work
• The arc reaches
temperatures of
10,000°F which melts
the electrode and base
Can you identify the weld joint material
and position being used?
 3- Weld Puddle
• As the core rod, flux
coating, and work
pieces heat up and
melt, they form a
pool of molten
material called a
weld puddle
• The weld puddle is
what a welder
watches and
manipulates while 1/8” E6013 at
welding 125 Amps AC
 4- Shielding Gas
• A shielding gas is
Shielding Gas
4 formed when the flux
coating melts.
3 • This protects the weld
2
puddle from the
atmosphere
preventing
The shielding gas protects the molten contamination during
puddle from the atmosphere while
stabilizing the arc the molten state
 5- Solidified Weld Metal
• As the molten weld
puddle solidifies, it
forms a joint or
connection between
two pieces of base
material
• When done properly
on steel, it results in a
weld stronger than the
surrounding base
metal
 6- Slag
• Slag is a combination of the flux
coating and impurities from the
base metal that float to the
surface of the weld.
• Slag quickly solidifies to form a
solid coating
• The slag also slows the cooling
rate of the weld
• The slag can be chipped away and
cleaned with a wire brush when
hard
This welder chips the slag off of a
weld during the repair of railroad
tracks
 Application Activity
Let’s review the SMW process …
• 1= The electrode
• 2= The arc
1
• 3= Weld puddle

4 • 4= Shielding gas

Solidified weld
6 • 5= metal
3
2
• 6= Slag
5
 SMAW Equipment Set Up
1. Turn power supply on 4. Adjust output
2. Connect work clamp a. Polarity
3. Select electrode b. Amperage
a. Type 6. Insert electrode into electrode
b. Diameter holder
 SMAW Process Variables
• Settings on the
machine
– Polarity : AC, DC+, DC-
– Amperage Output
• Operator Controlled
Variables
– Work Angle
– Travel Angle
– Arc Length
A straight AC machine will not
– Travel Speed have a polarity switch like this
AC/DC machine
 Striking an Arc
• To begin the SMAW Process, you must first
strike an arc. This can be done using one of the
following techniques:
– Scratch start – scratch the electrode on the base
metal like a match
– Tap Start – tap the rod against the base metal
 Work Angle
• The work angle is the
angle between the
electrode and the work
as depicted on the left
90° • Work angles can vary
depending on the
position the weld is
being made in
 Travel Angle
• Also commonly called
Lead Angle
• The travel (lead) angle
20-30° is the angle between
the electrode and the
plane perpendicular to
the weld axis
 Arc Length
• After striking the arc, maintain a 1/8” distance
between the electrode and the workpiece
– If the arc length becomes too short, the electrode will get
stuck to the workpiece or ‘short out’
– If the arc length becomes too long; spatter, undercut, and
porosity can occur

Arc Length = 1/8”

 Travel Speed
• The travel speed is the
speed at which the End of Weld

electrode moves along the

base material while
welding
– Too fast of a travel speed
results in a ropey or convex
weld The travel speed impacts the
– Too slow of a travel speed shape of the bead.
results in a wide weld with
an excessive metal deposit
 Restarting a Bead

• Here is the proper technique for restarting a

weld:
1. Strike Arc Here

2. Move Electrode to
Crown of Crater

3. Resume Forward
Travel
 Advantages of SMAW
• Low initial cost
• Portable
• Easy to use outdoors
• All position capabilities
• Easy to change
between many base
materials
What safety precautions should be
taken by these welders?
 Limitations of SMAW
• Lower consumable
efficiency
• Difficult to weld very thin
materials
• Frequent restarts
• Lower operating factor
• Higher operator skill
required for SMAW than
some other processes
Building a barge in a large shipyard
 AWS Classification
of SMAW Electrodes

E70XX
Electrode
Tensile in Psi
Welding Position:
1 = All Position, 2 = Flat & Horizontal
Type of Current and Coating
 WEAR
“LOSS OF MATERIAL” CAUSED IN AN
ENGINEERING SYSYEM.
 TYPES OF WEAR
PRIMARY SECONDARY
• FRICTION • CAVITAION
• ABRASION • CORROSION
• IMPACT • HEAT
• EROSION
 FRICTION
• FRICTIONAL WEAR IS CAUSED BY MOVEMENT
OF ONE METALLIC SURFACE OVER THE OTHER
CAUSING LOCALISED MATERIAL LOSS.

• NO ABRASIVE MATERILA IS INVOLVED.

• EXAMPLES : SHAFT JOURNALS, BEARINGS

 ABRASION
• LOSS OF MATERIAL FROM A
PART CAUSED BY THE ACTION
OF HARD FOREIGN MATERIAL
IN MOTION OR UNDER LOAD.

Ex :Raw Mill roller, Chutes etc

 TYPES OF ABRASION
• GOUGING : Large coarse abrasives strike the surface and
remove large amount of material.
Ex: Chutes.
• HIGH STRESS : Wear caused by crushing of abrasive
material between metal parts. High stress abrasion.
Ex: Grinding rollers..
• LOW STRESS: Small abrasive parfticles move rapidly over
the part. Low stress abrasion.
Ex : I D Fans.
 IMPACT
• WEAR DUE TO IMPACT IS THE RESULT OF
SUCCESSIVE SHOCK LOADS CAUSED BY AN
OBJECT STRIKING AGAINST AN OTHER AND
CAUSING LOCALISED COMPRESSION,
DEFORMATION, CRACKING, FLAKING OR
FATIGUE.
• Ex: Impactor arms, hammer crusher.
 EROSION
• WEAR CAUSED BY FINE ABRASIVES CARRIED
IN A HIGH VELOCITY FLUID STREAM

• Ex: Pumps, ID Fans

 HEAT
DEGRADATION MODES
• WARPAGE/DISTORTION
• MATERIAL SOFTENING
• MATERIAL EMBRITTLEMENT
• OXIDATION/SCALING
• THERMAL CRACKING
• THERMAL SHOCK
• THERMAL FATIGUE
Ex: Cooler plates in Cement Kiln.
 CORROSION
• RESULT OF CHEMICAL OR ELECTROCHEMICAL
ACTION OF ENVIRONMENT ON THE BASE
METAL.

Ex: Pumps, Valves, Screw Conveyors

 Selection of Polarity

ELECTRODE
- +

WORK PIECE
+ -
PENETRATION

CONCENTRATION OF HEAT MORE HEAT GENERATED

MORE AT ELECTRODE AT WORK PIECE
SHALLOW PENETRATION DEEPER PENETRATION
LESS DISTORTION CLEANSING ACTION ON
WORK PIECE
 IDENTIFICATION FOR CI
• SHAPE
• CHIP TEST
• SPARK TEST
• SOUND TEST
• TAB TEST – TESTING WELDABILITY OF JOB
BRASS Vs BRONZE

BRASS BRONZE
ALLOY ZINC & COPPER ALLOY TIN & COPPER
MALLEABLE HARD & BRITTLE
USED UNDER STRESS CORROSION
RESISTANT
GOLDEN COPPER
Thank You