•

Welder Training
Welding Process

WeIer

I
•

" -;,;"4''''''',..<,-,, "'!'_<i '''::ai;'~~t<,_,*,,: <, ' •

" ",'.li:~~ , - ~~-; .--.,..,-,"
BS 499 prt 1 Welding terms
A union between pieces of metal at faces
rend ered plastic or liquid by heat,pressure or
both .

.....,'>'< -..,
- ., - '

OXY FUEL LASER

WELDING WELDING

2
2 . The weli:Jfh~g~p~r~;c;;'e;i's""lsmust be capable of
remov;ngC~riy oxide anacon t amination from
the joint
3. Atmosphere contamination must be avoided
4. The welded joint must possess the
mechanica l properties req uired by the
specification being adapted

3
•

-e.~~;;:;,
. _
SHEILDED METAL ARC WELDING (SMAW)

core w i r'~e-­
...."......
,)

-
~.o;-.tp.",,~

I-~ E,""

" " " Clamp

Return Cable

4
•

-'" - .,
PE OF POLARITY

• ALTERNATING
CURRENT

5
•

W':lding P~wer~S~o:u':':~r c::e~s~~~;;;;~~

Drooping or Constant Current Characteristic

As the welder increases the arc As the welder reduces th e arc

gap, more volts are req uired for gap, less volts are required for the :-
the arc to bridge t he increased arc to bridge the reduced arc gap. -'
a rc gap_

•,

---I-----------.'r-
., , ~~-
Large voltage Yarlation, e.g.!.
-
___ Nanna l O perating
~~g.: ~n!e ~
10V (due to thanges in a rc
leng th) -
Small a mperage change
~.J_:~"'---..

. tf lOt .. la ue
_I
.t--t-t--t-t-~I--t-I--t-t-L.j.1..-reurrenl e.g. :t 5A.
I' 1M . tt 1.. I" I"
resulting In virtually cons tant A;O

Amperage

6
~T h e three main electrode covering
. types used in..MMA welding
- '--- _-
--. ~ ~

• Rutile - general purpose (E6013)

--
• Basic - low hydrogen (E701817016)

• Cellulose - deep penetration/fusion (E6010/601 1)

• ALLOYING ELEMENT - Ferro

Manganese and Ferro Silicon
• ARC IONISER
• DEOXIDISER - Ferro Silicon, Ferro
Manganese

7
" ..... '

CONDITION: Moderate Preparations on -;-_ oJ<_

Welding Area I Joint from •

Contaminations

E7018 , E7016,
E6010,E6013

2. STAINLESS STEEL

3. ALUMINIUM E1188, E4043,E5356

8
 AW AS.S Alloyed Electrodes
E 70 IBM G
c;::::.c=-- I

Welding Position . """'-":-_ ----' ---J

Flux Covering ---.J

Moisture Control - - - - - - - -- - ---'

Alloy Content ---J

~0 2003 TW1Ud

_. . .

CONDITION: Basic - Bake 350·C

- Hold 150·C
- Store I Quiver 75-
90·C.
Rutile - Dry
Cellulose - Dry

9
•

DISADVANTAGES

• Required Proper
Inter - run cleaning
. • Slow weld process
.. Requ ired proper
consumable storage
.. Required moderate
welder skill
.. Low in maintenance

10
 ..........

au 4. State the four criteria that will govern the number of weld
passes in a MMA welded joint

au 5. State two types of electrical supply and give the

advantages of each

11
 . .

Switch
POWe\cable ,

Gas inlet
& power -
cable

Tung sten .':. ,~,,>

housing.
,

Fitte,d cer~rrl1c Ceramic %

shielding cup Shiel;;;

d@ci;u ~~..

O n/Off switch ' ''' Gas lens

Split collet "

Gas diffuser
Spare ceramic Torch body
shie lding cup

12
 Basic Tm.Equipment Diagram

Welding To rch

Work Piece
/'

Earth

Gas Hose
Return Cable
Work Cab le

• New types
o Cerium: DC -ve elctrode - steels and most metals
o Lanthanum : AC - Aluminum alloys and magnesium

13
 !.t~:"=;;;:;::::~~~~;;;;; 9,,C.V.· Striking voltage (typical) for arc
o. initiation

---I-----------
Normal Operating
r - - r u rge vo/Uge ViltiaUOn, e.9- !.
10... (due to changes in arc
___ ~~g; ~~e ~ , length)
SmaU amperage ehange
-' "",ublng In virtually constant

",+--;--t--t-t--+-+-+--;--t-'-1r>-1"'
,. ...so 1\& 101
,urnnte. g• .!.
12t1 UO 1-10 . 641 I" !M
SA.

Amperage

"
1. 2. , 3. -....."

1. Pre-flow timer control 4. Crater fill control

.
Adjusts the time the gas and water Current down slope (slope o ut)
valves are open 5. Post-flow timer control
2. Start current control Adjusts the time the gas flows
Curre nt up slope (slo pe-in) after welding
. -- . , ~

3, Output control
Welding current control

14
 '''" h ~ .. . _ , . .< ~· " , .H H ' , ~ : JJ .
~ ',... ' " ':~''' '' ". '" " - . ,~". " - ,., .
• , 23% heavier-than alr " 0 ,i'"

• FOPms a tight aFCcolumn, high current density,

small arc concentration, 10weFaFC voltage,
moderate penetration and moderate thermal
conductivity <," •

• Mope suitable fOFthinner materials and

positional welding

i,; ~ A ,.
"
..

• SUitable fOLwelding caFDon steel, stainless steel"

. copper, alumiAium and magnesium due to
better puddle fluidity and bead wettin g "., :
• Second lightest gas - 1/7 as heavy as air
• FOPm a wider aFC, 10weFCUFFent density, higher
aFC voltage, deeper penetration and high
therma l conductivity
• RequiFes hiqher flow Fates

15
- - - -- - - - - - - - - - - - - - - -- - - --

• High cost, high flow rates

• More suitable for thicker materials and
materials of high thermal conductivity.

•
•

16
 MATERIAL WELDABILITY.

~1 . 0 mm MIN through 6.0 mm

TYPE: .
Ferrous
.
" .
Metal" and Non-
Ferrous Metal .
.:.-;,,; .~c;~:'-o:.~~';: .v-
-_.-" _ _~~--t';z"i~
.~ - - .. 'm • . . ,.

CONDITION: Strictly Clean Preparations

on Welding Area I Joint from
Contaminations

,- ,~4'i'·, ~_",.~~;..::'

., ... "'-J,:t. TYPE: As per parent metal

-."'>-~_
,< ". _ .".' ';;; 4<:t;iO;. ;,;;i;
_ .~- ~ ", . .:.",

CONDITION:

17
•

SELECTION FILLER METAL:

" , __ • _ ." _ '. C,' ,

3. ALUMINIUM ER1188, ER4043,

ER5356

• • ~
"-
~
.~~
~
~ ... -

* . . HEAiPISTRIBU]IOf'J:~\ND
CURRENT POLARITY~BbE

PE"f:TRATIO'

'>I.·HER! .\!. CARBON STEEl, c..\ RllO~S1T.El.., ALU M I"'IUM.

STA INLESS STEE L, STAI:"' LESS STEEL. '\tAGi'li ESIUM
i\ U; ~f1 :" l l.i M , .\ I I'M I:-; I V '\t . ,·\ 1.1.0 '"
\IA"<;'\ 'I::S': .\ IA.\ 'G." " ESE

18
•

DISADVANTAGES

• Virtually no · · • Expensive equipment

spatters produced • Required high skill

•• weld technique.
• High quality welds · . .
• Capable to weld thin • Very slow weld ~ ~-,-)7:;_----~~_~

material process.
•
• Capable to weld any • High in maintenance. ~~....

type of material.
• Capable to be used
in all weld position.

• LACK OF ROOT PENETRATION

19
•

-
,au 1. Give three reasons for the occurrence of tungsten
•• l _ _ __ ' _ c-,_ _" -,-- -

.. InclUSlonsv ;; _
au 2:What type of power.source characteristic is considered
essential fOI MMAwelding
' , ' .-,,"".-. "'=-..
--~ -
~ Ia nt? · . a ~
-r '
" ".

_~~
' i

..
, • _ .~,~"'~<l" _~"
_ ,- r. ,
au 3. Give three advantages of the MMA welding process when
compared to the MAG welding process

au 4. State the four criteria that will govern the number of weld
passes in a MMA we lded joint

au 5. State two types of electrical supply and give the

adva ntages of each

20
•

.,'"
<:,-,:"",!;."". .~." ,:';,

,
,
-.,.,-"" ...
, -
I
Filler ~''-:'::::_
_f _
Extension
Nozzle to work Contact Tube to
dlstance W o/1( Distance

r'--f"r -----,------"-
"

21
Nozzles or Spot welding
shrouds space r
Gas diffuser

,
Drive I

Half grooved Wire guide

bottom roller

22
 MAG/MIG Wire Spool

.'
•
, _' -;;-:!;"'~ ..n..
Uses larger wire diameter, high deposition rates , t >2.4mm,
restricted to flat & horizontal position.

Voltage - > 27 Amperage - > 250

• Globular Transfer: Deposits at high rates & capable
producing high quality welds and for flat & horizontal position.
Between Dip & Spray Transfer Modes.

23
 3 mm
._~- ----

Arc gap to small, Correct arc gap Arc gap to large,

requires the current to
requires the cu rrent to
be reduced to slow '
be increased to allow
down the burn off rate
the wire to burn back
to the correct arc gap to allow the correct
arc gap to be
main ta i ned

• •
-
I
I
I
Vol tage
Large CUl'n.!nt Change I
,I
I I
I I
I I

'00 Amperage ' 00

24
 > Filler
Extension

Shorter filler Longer filler extension

extension produces lack of
produce s burn- fusion (cold lap),
through at welding spatter.
area The w ire tends to melt
before reaching the
weld pudd le.

• Suitable for ferrous metal welding

25
 Shielding gases
Example gases a'nd applications for MIG/MAG welding
Aluminium, copper, 9%
nickel stee!~*,, ;, .~ .
Sta i niess'steei!fi.,''

,'" 'carbona'ndlow alloy

steelS:<~C\"
Argon + 15%njtrogen Copper and its:aIlOys,
75% helium + 25% argon Aluminium and copper
75% helium + 25% argo n + Austenitic stainless steel
CO trace
High purity argon Titanium, Zirconium alloys
Note: A H2 trace may be added to most gases to
increase arc voltage and therefore overall deposition
rates.

•nv'.4l},,,' ,., '

C02

•
•

Helium has a high Ionisation poten tial and produce

a high arc energy in plasma column.
• Very high thermal cond uctivity and produces
very low arc density
• Deep penetration
• Stable arc
Copyrighl C 2003 rn LId 0.14 (Specific gravity of g as with respect to air) n SooI06

26
 Shielding gases

"" Argon as. mU~h lowe r Ionisation potentia and can -

se sustar n sJ?ray transfer ab ove 24 wQlding volt s. Argon gives :

• Very s ta ble arC',,-

~ .. ~ Little s patter-- '"
• Low thermal conductivity and produces hi
• '"' l owe r p e n etra-tio n~ th a n C0 2: ' . ~; :: " " --=- ,
• 1.4 (Specific gravity of gas with respect to air)
• We m ix both argon and C02 gas in m ixtures of between 5 "":' _
20% C02 in argon to get th e benefit of both gases Le. good-' ":-
penetration wit h a stable arc and very little spatter (sm oother
profile). C02 gas is m uch cheaper t han argon or its
mixtures.

Copy<ogttI C 2003 TWI Ll<! 53 Sc<>/ 06

.,
_'M-i;':f~' F.'\I":A.l loy Composit ion

' - - - - - -- - Rod
1---- - - - - - Elect rode

27
•

.-" ~, ~ .

VA ;
•
ER308E,E'R316L, Joi\,'t
' } ij' .1

ER347L

<
3. ALUMINIUM ER1188, ER4043,
ER5356

'- ~ "- - ,

. Inductance or Choke
. ~ Applicabl~ to M" ' •. ~(:tprocess':~~p transfer
" mode.'" ""11'1 · '. ,~

•", "'he electrode is fed slowly

~,. '# '"
throug~mearc
' -. . ' ",' , -
until it
., touches the weld pool;
_. ".,. -
at tfiis pointtbe, ,. -"
output from
the power supply is short circuited and • '0' ,' -
a very high
current flows through the electrode. If this was ..
allowed to continue, the wire would melt and eject
excessive amounts of spatter.
• The inclusion of the choke in the welding circuit
controls the rate at which the current rises so that
the electrode tip is melted uniformly without
excessive spatter

28
 r - - Flux powd~er

Arc shield c omposed of

" -,,.... vapo rized and sla g fonning
Flux core c om ppunds
w i res ~," .ii>:.<>

"",-_Molten
weld L _ _ Metal droplets covered
L-_Solidified weld pool
with thi n sl ag coating
metal and slag

SELECTION OF FILLER WIRES

3. ALUMINIUM ER1188T, .'

ER4043T,
ER5356T

29
•

flqxhopper *'
..-
'" l'

30
•

Fused SAW Agg lomerated SAW

Fluxes Fluxes

31
•

>c-

• Low dust tendency

• Good re-cycling •
.
• Very smooth weld •
profile

-. - -, -

au 3. What power source characteristic is required 'fo~:r'!ia"l!5iioo

amp out-put sub-arc welding plant

au 4. State three main items of sub-arc fluxes, which require

inspection

au 5. State the advantages and disadvantages of the sub-arc

welding process

32
•

... MAG - Non inert G as s h ie ld

... Flux-cored m etal arc welding ,
... G a s Shielded w elding with non-consu ma ble
electrode
141 ~
TIG Weld ing
~ ... Pla sma Arc

CCPi' ogrt 0 2CI03 TWIl1d

33
 SHIELDING GAS RELATED TO
WELD PROFILE
FOR DCEP

ARGON ARGON co, ARGON HEUUM ARGON

• • •
OXYGEN co, HEUUM

Cop,.igtIt 02000 TWI lid

USAGE OF SHIELDING & MIXED GASES

Shielding Gas Gao GMAW GTAW
Reactio n &FCAW & PAW

'" Argon IAr) Inert

Inert
Non F errus All Metals

'd
'" Helium (He)
Carbondioxide (CO2
Non r errus Al,Mg ,Cu

'"
) Oxidizing Mild & Low Not u s ed
A lloy suel
Inert
'" AI ... 2 0-50 % He Al,Mg.Cu A{.Mg,Cu

~ AI ... 2()..30 % CO:l OxidWng MlId&Low

A lloy steel

~ CO2+ up to20 % 02 Oxidldng Mlld &Low Not u sed

Alloy s teel
Q) A r'" 5 % Hydrogen Oxidizing - Mckel,.s/mel/AJ -

1
•

Metallic Arc Showing Polarity and Heat

I + + •
M:udmum Hn t
•
ld.i..ftimum H e at

Maximum Heat

Shallow Penetration Deep Pene tration

C<lpjilQl'll 0 2003TWI Ltd , SooIOQ

2
 DUTY CYCLE
'-' The'dtIty'~cle of a-power supply is
ba§e? .9?J -p.e 9;;,'TI
"",tps,uiiMt",c;;u;;I;.;.;;
Te,;;n;.:t_ _

Formula for estimating the duty cycles a nd rated output

A . T. = (lfl. l'xT B.I, = I X (TfT.I'"

Where T = rated duty cycle in percent

T, = the required duty cycle in percen t
I = rated current at ra ted duty cycle
I, = the maximum current a t required duty cycle

DUTY CYCLE
Example 1 :

At what duty cycle can a 200 A power s upply rated at 6 0 %

duty c ycle be operated at 2 5 0 A o utput.

From formula A :
T2 ={2001250P x 60% ::: {.8)2 = 38%

Exam ple 2 :

From formula B :

The same power s up ply is to be operated continuously ( 100%

duty c ycle ). Wh at ou t pu t c urrent m ust n ot be exceeded?

'a =200x (60/100)'P = 200x .775 = 155 amps

1
•

' ,' ,
300A 60%
,
Duty Cycle
• 200 ••
150 200A60 %
Duty Cycle

1001-+-+-+-+ + + + + -+-+-+-+
9G.':.1-+++++++++++-1
80 f-+-+-+-+ + + ++-+-+-4-+
70 '--;i~~--'-"""'--;~~~~~100
'.