Basics of Welding PP
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Types Of Welding
Welding
Gas Welding Arc Welding
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Normal practiced process
Manual Metal Arc Welding MMAWGas Tungsten Arc Welding GTAW
Flux Cored Arc Welding FCAW
Sub Merged Arc Welding SAW
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WELDING PROCESS
The present process of welding used tomanufacture various components generally are as
follows
MMAW- Manual Metal Arc Welding Process GMAW- Gas Metal Arc Welding process
GTAW - Gas Tungsten Arc Welding
FCAW- Flux Cored Arc Welding
SAW- Submerged Arc Welding
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SMAW/MMAW
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GTAW
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GMAW(MIG/MAG)
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FCAW
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SAW
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Advanced process
Narrow Gap Welding Laser Beam Welding
Electron Beam Welding
Plasma Welding
Plasma Transfer Arc Technique (PTA)
Robotic Welding
Orbital Welding
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Selection of Welding process
Type of Base Material The Joint Design
The lace of weldin
Welding Position
Type of consumables availability
The skill availability of personnel
The types of equipment availability
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&
WELDING EQUIPMENTS.
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RECOMMEDATIONS
The selection of the correct welding consumablesdepends on the following parameters
Base materials composition
e we a y o e s ee Selection of the welding consumables as per
ASME section-II- C
Acceptance of AWS or any other standardsdepends on the clients requirements.
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WELDING CONSUMABLES
The Welding consumables like the welding electrodes andfiller wires that are required and are recommended are asfollows
E-6013 Welding Electrodes for Welding in MMAWprocess for Carbon steel, Mild steel, For the generalpurpose welding applications up to thickness 18 mm or3/4th inch.
For thickness over the above mentioned must be weldedwith Low Hydrogen electrodes as per AWS E 7018 orE7018-1 Type of welding consumables.
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Welding consumables for various
steels.
General Mild steel Up to 18mmAWS 6013 class welding electrodes,
ER 70 S-6 in case of GMAW process.
General Mild steel Above 18mm
AWS 7018class ER 70 S2 & ER 70 S-6
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Selection contd.
For Radiography jointsThe following grades consumables are
.
AWS E6013 & E7018 classified Electrodes
ER 70 S2 TIG welding filler wires
ER 70 S-6 MIG Welding continuous filler
wires.
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Consumables- gases
ER 70 S-6 Solid wire for welding theGMAW (MAG) welding process
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carbon steel welding .
The use of 100 % CO2 gas for MAG
welding and 100 % pure Argon gas for TIGwelding applications are the main criteria.
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Alloy steels
AWS class of low alloy electrodes & wires
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Consumables- LAS
In the case of use of Low alloy steels where
, ,
creep properties are important and hence the
matching composition of the weld metals
are mandatory
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Consumables S.S.
Welding of Stainless steels like commonlyused steels such as 304, 304L, 308L, 309,
316. and other cate ories such as 310 321
347, Duplex, Super Duplex Steels, therespective grade of Electrodes and the Filler
wires to be used with proper shielding
gases.
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Stainless steel
301,304,308 ClassAWS E 308 & 308 L grades Electrodes
.
316 and 316 L
-AWS E- 316 & 316 L
-ER 316 L TIG and MIG fillers
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SS Contd.
For 309 Grade steelsAWS E 309 Electrodes
Dissimilar metals of SS and SS-MS
AWS 309L and 309 MoL
ER 309L & ER 309 MoL
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SS Contd.
Stabilized steels of 321, 347Namely Niobium/Columbium, Ti and Ta stabilizedsteels the use of
- e ectro es an w res oER 347 grade is recommended.
For other grades like 310,312, 317 the respectivegrades of consumables be used.
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Other metals
Cast Iron
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Aluminium, Copper, Nickel, Magnesium
etc.
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Welding Position
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Proper Arc Length
Long arc results in:
Large globules melting
Wavering arc
Wide spatter and irregular bead
Short arc results in: Electrode sticks Poor penetration
Convex bead
Slag inclusions Irregular bead
Use short length for vertical welds
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Speed of Travel
Travel speed influences: Bead width
Penetration
Use a uniform speed
Both hands on the electrode holder
Operator comfort
Bead should be about twice the diameter of theelectrode wire
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Read the Bead
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TYPES OF EQUIPMENTS
Standard Type of welding Equipments Arc Welding Transformers
D.C. Rectifiers
Thyristor controlled Welding Rectifiers
Welding Invertors
TIG Welding Equipments
MIG/MAG Welding machines
Sub Merged Arc Welding machines
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MMA Power sources
Transformer RectifierWelding generator
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category of MIG Welding
Pulsed MIG Welding Machines, Inverter based MIG Welding Machines
Surface Tension Transfer Machines (STT)
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Cont
Under TIG Welding category we can have DC Pulsed welding machines
AC Square wave pulsing machines
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Advanced Welding Machines:
Electron Beam Welding machines
Laser cutting and welding
Plasma Welding
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Selection of the correct equipment
Selection of the right type of equipment isimportant to get the desired welding properties.
The selection decides the feasibility of the use of
the process. The selection should be based on the availability
of the equipment,
The acceptance of the process The convenience of the operation.
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Welding Defects
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TYPE OF DEFECTS
Lack of fusion Lack of Penetration
Crack
Porosity
Slag inclusion
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Lack of Penetration
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Lac of Fusion
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Undercut
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Porosity
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Crack
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ITS CAUSES AND REMIDIES
Re-drying of Consumables/ Proper Storage Base metal Cleaning.
Welding Parameter.
Use of correct welding consumables.
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!
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