Welding Technology

NASB B. Tech 2nd year

Lecture 4 : Welding power Sources

 Identify current types

Classify welding power sources

Contents Comparison between power

sources
 Welding power sources
There are various types of welding machines available to accommodate the wide range of welding
processes:

Welding power sources

Generated power Static power

AC generator DC generator Transformer Rectifier Inverter

AC AC/DC DC AC DC
 Welding power sources
• Current you use during the welding can be either alternating (AC) or direct (DC) current
• The arc in welding is formed once you close the electrical circuit between the positive and
negative sides of the cycle. (electrode or welding torch, ground).
• Once the electrode touches the base metal, the circuit is closed, and the arc is formed

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 DC current in welding
• DC current that flows consistently in a single direction.
• It is characterized by a constant voltage polarity (positive and negative terminals remain
fixed)
• Due to the continuous flow, the DC welding process produces a stable arc and consistent
welding
• In welding, the direct current flows consistently between positive and negative polarity.
• There is a polarity in DC welding, which will affect the direction of electron flow.
Electrons flow from the negative to the positive polarity, so depending on the terminal of
your torch and ground
• Direct Current Electrode Negative (DCEN) or Direct Current Electrode Positive
(DCEP) polarity.

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 Direct Current Electrode Negative (DCEN)
• In the DC negative, DCEN, or straight polarity: torch is connected to the negative side of
the terminal and the ground or earth clamp is connected to the positive terminal of the
welding machine.
• electrons flow from the negative to the positive side
• 2/3 of the heat is focused on the plate, while 1/3 of the heat is focused onto the electrode.
• It produces good penetration, stable arc, and consistent results with less spatter or electrode
consumption

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 Direct Current Electrode Positive (DCEP) polarity
• In the DC positive, DCEP, or reverse polarity: the electrode (torch) is positive polarity, and
ground is negative side of the terminal.
• Due to electron flow, 2/3 of the heat is concentrated into the electrode, while 1/3 of the heat
is focused on the base metal.

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 Direct Current Electrode Positive (DCEP) polarity
• As more heat is focused onto the electrode, the penetration is lower, but the electrode
consumption is higher
• This is desired when you need higher welding speed, higher deposition rates, and less heat
in the base plate.
• higher consumption can shorten the electrode life and create more spatter and lack of
penetration
• The biggest advantage of DCEP is the cleaning action. As the electrons flow from the base
plate into the electrode, they remove the oxide layer that forms on the material surface as it
is exposed to atmospheric contamination. Additionally, it can help with dirt, rust, or other
contaminants on the surface 8
 Welding power sources
There are various types of welding machines available to accommodate the wide range of welding
processes:

Welding power sources

Generated power Static power

AC generator DC generator Transformer Rectifier Inverter

AC AC/DC DC AC DC
 Transformer
• Welding Transformers are used in AC machines to change alternating
current from the power line into a low-voltage, high amperage current in
the secondary winding
Advantages:
• Reliable and durable due to their simple design.
• Relatively inexpensive compared to newer inverter
welding machines.

Disadvantages:
• Can be heavy and bulky due to the large
transformer
• Less efficient than inverter welding machines
• May have limited control over welding
parameters
 Rectifier
• Rectifier converts AC to DC
• provides a stable, reliable, and continuous supply of DC power to the welding electrodes
• allow better control of the arc, produce higher-quality welds, and reduce the risk of
welding defects

Transformer Rectifiers:
• The transformer is used to step down the voltage, while the rectifier circuit converts AC
power to DC power
• used in heavy-duty welding applications : shipbuilding, pipeline construction, and
structural steel fabrication

Inverter Welding Rectifiers:

• convert the AC power to DC power using an electronic circuit
• used in light-duty welding applications :automotive repair, home repairs, and hobby
welding
• more efficient than transformer rectifiers
 Inverter
• It takes the incoming AC power, increases its frequency significantly,
then converts it into a stable DC voltage suitable for welding.
Advantages:
• Smaller size: Inverter technology allows for smaller and lighter welding machines due to
efficient power conversion.
• Precise control: Enables fine adjustments to welding parameters like voltage and current,
leading to better weld quality.
• Energy efficiency: Minimizes power loss during conversion, resulting in lower energy
consumption.

Disadvantages:
• Expensive repair costs
• Less durable
• Low duty cycle
 Generator
• It produces the electrical power needed for welding, typically powered by
a diesel or gasoline engine, which converts mechanical energy into
electricity that can be used to create the welding arc.

• It is self-contained power source that allows welding to be done in

locations without access to a standard electrical outlet.

• High cost and poor efficiency