Shielded Metal Arc Welding Gas Metal Arc Welding (GMAW) Flux Cored Arc Welding (FCAW) Gas

Cored Arc Welding (FCAW) Gas Tungsten Arc Welding (GTAW) Submerged Arc Welding (SAW) Plasma Arc Welding (PAW)
(SMAW)
Type Manual Semiautomatic (also used in Semiautomatic (also used in Manual Semiautomatic (also used in mechanized and A plasma is defind as an ionized gas
mechanized and automatic) mechanized and automatic) automatic)
We more often hear it referred to as We more often hear it referred to as The electrode used is not intended to be consumed With any process using an arc, a plasma is created.
"Stick Welding" “MIG” during welding.
This process operates by heating the An arc is created between the wire and An arc is created between the wire and An arc is created between the tungsten electrode SAW is characterized by the use of a PAW could be easily mistaken for GTAW because the
metal with an electric arc between a the workpiece to heat and melt the base the workpiece to heat and melt the base and the workpiece to heat and melt the base and continuously-fed solid wire electrode which equipment required is quite similar.
coverd metal electrode and the metals and filler material. and filler material. filler material. provides an arc that is totally covered by layer
to be joined. of granular flux.
Concept
Electrode

From electrode coating The shielding for welding is provided 1-Some electrodes are designed to The shielding for welding is provided by a Both PAW & GTAW torches use a tungsten electrode for
by a protective gas atmosphere which provide all of the necessary shielding protective gas atmosphere which is also emitted the creation of the arc. However, with the PAW torch, there
is also emitted from the welding gun from the internal flux (self-shielding). from the welding gun from external source. is a copper orifice within the ceramic nozzle. There is a
from external source. They are designated by suffixes 3, 4, 6, * Inert gases (argon and helium). plasma gas which is forced through this orifice and past the
* Inert gases (argon and helium). 7, 8, 10, 11, 13, and 14. welding arc resulting in the constriction of the arc.
AC alternately heats the electrode and base metal.
* Reactive gas (CO2) *self-shielded type are better suited foe There is tow categories of plasma arc operation:-
Used for welding aluminum
Transferred arc , the arc is created between the tungsten
Shielding

field DCEN well tend to heat the base metal more. Used With SAW a granular flux is distributed is
2-Other electrodes require additional distributed ahead of or around the wire electrode electrode and the workpiece. It is use for both welding and
for welding of steels.
shielding from an auxiliary shielding to facilitate the protection of the molten metal. cutting of conductive materials.
DCEP well tend the to heat the electrode more.
gas. They are designated by suffixes 1, Nontransferred arc, occurs between the tungsten electrode
2, 5, 9, and 12. and the copper orifice. It is preferred for cutting of
#gas type used are CO2 or (75% nonconductive materials and for welding of materials when
Argon-25% CO2) the amount of heating of the workpiece must be minimized.
*the suffixes G and GS refer to
multiple-pass and single-pass.

AC – DCEP – DCEN AC – DCEP - DCEN

DCEP DCEP (1,2,3,4,6,9,12) * 5

DCEN (7,8,10,11,13,14) * 5

A constant current power source A constant voltage, or constant A constant voltage, or constant A constant current power source A constant voltage, or constant potential power A constant current power source
source

potential power source. potential power source. source.

1- The equipment is relatively simple 1- Use in many industrial application. 1-Rapidly gaining acceptance as the It is capable of welding virtually all material, High rate of weld metal deposition. As indicated, tow separate gases are required.
and inexpensive. Portable. 2- Gas shielding reduce the possibility welding process of choice in some because the electrode is not melted during the SAW can typically deposit weld metal more Argon is most commonly employed for both types of gas.
2- Used in most industries for of introduction hydrogen into the industries. welding. efficiently than any of the more common PAW is used extensively for full penetration weld in
numerous application. weld zone 2-Good performance on contamination It is suitable for use on thinnest (down to 0.005 in.) processes. material up to ½ in. thick by employing a technique referred
3- The resulting weld quality can be 3- This is little or no cleaning surface, and increased deposition rates. of metal. Saw has high operator appeal because of the to as “keyhole” welding.
consistently high. required. (High production 3-Use with satisfactory results for both Clean and controllable (aerospace, food and drug lack of a visible arc which allows the operator to This creates a high quality weld, with no elaborate joint
situation.) shop and field applications. processing) control the welding without the need for filter preparation and fast travel speeds compared to GTAW.
Advantage

4- Less smoke is generated. 4-Electrodes produced are ferrous (for It can product welds of high quality and excellent lens and other heavy protective clothing. PAW is a very localized heat source. This allows for faster
Note: (As a welder increases arc 5- More portable. C.S & S.S). Some od Stainless types visual appearance. There is less smoke generated. welding speeds and therefore less distortion. The welder has
length, the resistance in the welding 6- Welder can more easily observe the actually employ a carbon steel sheath It is suitable for welding most material, many of Ability to penetrate deeply better visibility of the weld being made.
circuit increases due to the larger gap action of the arc and molten puddle surrounding the internal flux which which are not as easily welded using other welding
the current must cross. This increase in to improve control. contains the granular alloying elements processes.
resistance causes a slight decrease Spray Transfer - Pulsed Arc such as chromium and nickel. If there is no commercially available wire for
(10%) in the current flow across the arc Globular - Short Circuiting 5-Electrode comes on continuous reels particular metal alloy, it is possible to produce a
gap. This decrease in current results in * Spray transfer can be achieved only which increase the arc time suitable filler metal by simply shearing a piece of
a significant increase in voltage (32%) when there is at least 80% argon 6-An aggressive - deeply penetration identical base metal to produce a narrow piece
supplied by the power source, which present in the gas mixture. w2hich can be hand-fed into the weld zone as if it
limits the drop in current. were a wire.
Speed (replace the electrode). GMAW is sensitive to drafts or wind. 1-Layer of solidified slag which must Slowest of the available welding processes. Can only be done in position where the flux can PAW is limited to the effective joining of material 1 in. or
Short arc time Not suited for field weld be removed. Have a low tolerance for contamination be supported in the weld joint. less in thickness. The initial cost of the equipment is
Limitation

There is a layer of solidified slag which Equipment required is more complex 2-There is a significant amount of Required a high skill level welder. Layer of solidified slag which must be removed. slightly greater than that for GTAW.
must be removed smoke generated during welding. PAW may require greater operator skill than GTAW.
3- Equipment required is more
complex
Porosity (long arcing – arc blow) Porosity due to contamination or less of Slag inclusion Porosity (Contamination) If the arc is not properly directed, incomplete Tungsten inclusion result from too high current
Slag inclusion – cracking – undercut – shielding. Wire feeding problems Tungsten inclusion fusion can result. Also copper inclusion.
overlap – incomplete joint penetration Incomplete fusion due to the use of Incomplete joint penetration and If the flux become wet, porosity and underbead Another problem that may be encountered when keyhole
Problem

short circuiting transfer on heavy Porosity. cracking may be result wilding is being done is referred to as tunneling. This
section. Solidification cracking results when the welding occurs when the keyhole is not completely filled at the end
Equipment should be well maintained condition provide a weld bead having an of the weld.
to alleviate the problems. extreme width to depth ratio. Incomplete fusion
 Electroslag Welding (ESW) Oxyacetylene Welding (OAW) Stud Welding (SW) Resistance Welding (RW) Brazing Processes Cutting Ptocesses
It typically exhibits the highest deposition Term “oxyfuel welding” is also This method is used to weld studs RW is a group of welding Brazing differs from welding in that brazing is accomplished without any 1-Oxyfuel Gas Cutting (OFC)
rate of any of the welding processes. ESW used. or attachments to some metal processed that produces melting of the base metal. The heat applied is only for melt the filler metal. We use an oxyfuel flame to heat the material to a
is characterized by the joining of members Acetylene is the only fuel gas surface. coalescence of the joining *Soldering is also required melting filler metal temperature below 840 F temperature at which it will readily oxidize, or
which are placed edge to edge so that the capable of producing high The process is controlled by a surfaces with heat obtained (450C). burn. The temperature needed is referred to as the
joint is vertical. The welding is done in a enough temperatures foe mechanical gun which is attached from resistance of the * Brazing required melting filler metal temperature above 840 F (450C). kindling temperature, and for steels, it is about
single pass such that the progression is effective welding. With OAW to a power supply through a workpieces to the flow of The braze joint is designed to have a large surface area. The clearance, or 1700F (925C). once that temperature has been
from the bottom to the top of the joint the energy for welding is created control panel. SW equipment welding current in a circuit of gap, between the tow pieces to be joined is kept to a minimum. Capillary achieved, a high pressure stream of cutting oxygen
without interruption. (the position of by a flame. The equipment for consists of DC power source, a which the workpiece are a action is that phenomenon which causes a liquid to be pulled into a tight is directed on the heated surface to produce an
welding is considered flat due to the OAW is relatively simple. It control unit, and a stud welding part, and by the application of space between tow surfaces. oxidation reaction. This stream of oxygen also
location of the electrode with respect to consists of several parts: gun. pressure. It is used for sheet So, if the surfaces are not properly cleaned, the ability of the capillary action tends to remove the slag and oxide residue which is
the puddle. During welding the molten Oxygen cylinder (tank) (2200 Variations can include automatic metal application up to about to occur will be reduced to the point that the braze material will not be drawn produced by this oxidation. The equipment used
metal is supported on tow sides by water psi) stud feeding apparatus as well as 1/8 in. (3mm) thick. No filler sufficiently into the joint. for OFC is essentially the same as that foe OAW
cooled shoes. Acetylene cylinder (tank) (15 gas shielding for use in the metal or fluxes are used. The braze filler material configuration include wire, strip, foil, paste and except that, instead of the welding tip, there is now
psi) welding of aluminum studs. There is three major resistance preforms. a cutting attachment which includes an additional
Pressure regulators, torch, and welding processes:- Braze alloy designations are preceded by a “B” followed by abbreviations of lever or valve to turn on the cutting oxygen.
connecting hoses. 1-Resistance Spot Welding the most prominent chemical elements included. The brazing filler metals OFC using several different types of fuel gases
*A higher amount of oxygen will (RSW) the most common. having an “R” in front of such as acetylene, methane (natural gas), Propane,
create an oxidizing flam and a The electrodes are typically the “B” in their designations denotes their chemistry is identical with Copper gasoline, and methylacetylene-propadiene (MPS).
higher amount of acetylene will cylindrical in shape, but can and Copper-Alloy Gas Welding Rods. Karf is the width of the cut produced. Drag is the
produce a carburizing flam. have various configurations. To maintain the cleanliness of the joint during the application of heat, brazing amount of offset between the cut edge.
ESW is not considered to be an arc OAW is considered to be SW is considered to be an arc The tow electrodes apply a fluxes are often used. There are numerous methods of brazing:- OFC is used extensively by most industries, it is
welding process. chemical welding method. welding process. pressure and a force to hold 1-Torch Brazing (TB) heating is accomplished using an oxyfuel flam. It can usually limited to the cutting of carbon and low
ESW is used when very heavy section are Filler material are (RG-45 & RG- the tow pieces of sheet metal be done manually, mechanically or automatically. alloy steels. In order for OFC to be effectively
being joined. 60) in intimate contact, current is 2-Furnace Brazing (FB) is performed in a furnace, often with a controlled accomplished the material must comply with the
R (rod), G (Gas), 45 & 60 then passed through the atmosphere. The braze filler material and flux are preplaced at or near the following criteria: (1) it must have the capability of
(tensile strength) electrodes and the workpieces. joint. burning in a stream of oxygen. (2) its ignition
Resistance to the flow od 3-Induction Brazing (IB) relies on the heat produced in a metal when placed temperature for burning must be lower than its
current produces heat at the within an induction coil. melting temperature. (3) its heat conductivity
faying surfaces, forming a 4-Resistance Brazing (RB) is accomplished by heating the base metal using should be relatively low. (4) the metal oxide
weld nugget. One spot weld is its own inherent electrical resistance. produced must melt at some temperature below the
made at a time. 5-Dip Brazing (DB) differs from the other types in that the parts to be joint melting point of the metal. (5) the formed slag
2-Projection Welding (PW) are immersed in some type of molten bath (braze filler metal) to provide the must be of low viscosity.
one sheet has projections or necessary heating. Advantage (inexpensive and portable equipment –
dimples formed in it. The 6-Infrared Brazing (IRB) relies on heating provided by radiant energy (using use in shop and field – can mad on thin or thick
current is concentrated to pass a high intensity infrared light source) section)
through the projections at the Limitation (finish cut may require additional
faying surfaces. Large, flat cleaning or grinding – there may be a HAZ
electrodes are used on produced having a very high hardness – the flame
opposite sides of the sheets. and hot slag produced result in safety hazards.)
Advantage The major advantage of ESW is its high The equipment relatively First, since the process is This allows several welds to *The biggest advantage of brazing is that it can be used to joint dissimilar 2- Air Carbon Arc Cutting (CAC-A)
deposition rate. (can use multiple inexpensive and can be made controlled essentially by the be made during a single metals. This process uses a carbon electrode to create an
electrodes or metal strip) very portable. electrical control unit and welding cycle. *it is suited for the joining of metals which does not welding of any type. arc for heating, along with a high pressure stream
There is no special joint preparation Its primary tasks include the attached gun, little operator skill Resistance Seam Welding *The equipment can be relatively inexpensive. of compressed air to mechanically remove the
required. (a rough, flame cut surface is welding of thin steel sheet and is required once the control unit (RSEW) a continuous seam molten metal. The equipment used for CAC-A
satisfactory for this method) small steel piping. settings are made. SW is a weld is made that is actually a consists of a special electrode holder which is
There is no tendency for any angular tremendously economical and series of the overlapping spot attached to a constant current power source and a
distortion to occur. effective method for welding welds. The electrodes are compressed air supply.
various attachments to a surface. typically rotating wheels CAC-A has applications in most industries,
Limitation The primary limitation of ESW is the The flame does not provide as An electrical or mechanical between which the tow sheets The part must be extremely clean prior to brazing. especially since it can be used to cut any material
extensive time required to set up and get concentrated a heat source as can malfunction could produce poor pass. The joint design must provide sufficient surface area to develop the required and alloys. It is important to realize that it can be
ready to weld. be achieved by an arc. weld quality. Stud shape is Robotic resistance spot strength. used as a weld joint preparation tool.
Requires a substantial skill level limited to some configuration welding is utilized extensively Advantage (has ability to cut removal) any metal –
for best results. which can be held in the gun’s in the automotive industry. use the same power source as those used for some
chuck. types of welding. )
Problems Gross porosity can occur due to wet flux Improper manipulation or Lack of 360 flash and incomplete The formatting of voids or unbounded areas within the joint. when too much Limitation (very noisy and dirty process – a fire
or the presence of leak in one of the water adjustment of the flame. If the fusion at the interface. localized heat ia applied to the base metal resulting in melting and erosion of watch may required to make sure the gouged metal
cooled shoes. flame is adjusted such that an the base metal. droplets do not create a fire hazard – the finished
There is a possibility of getting centerline oxidizing flame or carburizing The corrosion of the base metal by some of the extremely reactive fluxes. cut may require some cleanup prior to additional
cracks due to weld metal shrinkage. flame is produced weld metal welding).
Also due to the tremendous amount of properties could be degraded.
heating there is a tendency for grain
growth in the weld metal.
3-Plasma Arc Cutting (PAC)
This process is similar in most respects to PAW
except that now the purpose is to remove metal
rather than joint pieces together. The power
required may be much higher than the used for
welding. For mechanized PAC cutting, not only is
the torch water-cooled internally, but the actual
cutting may take place under water or oil to reduce
noise and particulate levels.
*It is for cutting of non-ferrous metals. PAC is also
useful for the cutting C.S.
Advantages include ability to cut metals which
cannot be cut with OFC. The result high quality
cut, and increased cutting speeds for carbon steel.
Limitation – the kerf is generally quit large and the
cut edges may not be square. Special techniques,
such as water injection, can be used to improve this
edge configuration if desired. Higher cost of
equipment as compared to OFC.
 Laser Beam Welding (LBW) & Electron Beam Welding (EBW) Reed from the book.