Weld Bead Exp Mig

TO STUDY THE EFFECT OF
RATE OF HEAT INPUT ON

WELD BEAD GEOMETRY
PRODUCED BY METAL INERT
GAS (MIG) WELDING
WELDING
Welding is a fabrication process whereby two or more parts are fused together by
means of heat, pressure or both forming a joint as the parts cool.
Types of Welding Methods
Numerous techniques and technologies have been developed to optimize the welding process for
different materials and products, including:
•Arc welding uses an electrical current to weld metals. Types of arc welding include metal inert gas (MIG)
welding and tungsten inert gas (TIG) welding, among others.
•Friction welding melts the bonding and base material through mechanical friction. This process can be
used with thermoplastics and metals.
•Electron beam welding uses a stream of electrons to melt materials into a joint. This process must be
completed in a vacuum and is typically used for thicker components.
•Laser welding is a high-speed process that employs a laser to melt and join metals and/or thermoplastics
together.
•Resistance welding uses heat generated between electrodes or rotating wheels to melt and join the base
materials. Types include spot welding and seam welding.
Introduction
MIG welding, also known as Gas Metal Arc Welding (GMAW), is a popular and widely used welding
process in the metalworking industry.
Principle of MIG Welding

MIG welding involves creating an electric arc between a consumable wire electrode and the
workpiece metal. The wire electrode is continuously fed through a welding gun, and an inert gas
(usually argon or a mixture of argon and carbon dioxide) is used to shield the weld pool from
atmospheric contamination.
The combination of the electric arc, consumable wire, and shielding gas ensures a stable and
controlled welding process.
Implications of using DCEN and DCEP in MIG welding:
1.DCEN (Electrode Negative):

1.Penetration: DCEN provides deeper penetration, which is beneficial when welding thicker metals.
2.Heat Input: The majority of the heat is concentrated in the base metal, leading to a narrower and
deeper weld bead.
3.Electrode Life: Since the electrode is cooler compared to DCEP, it may result in longer electrode
life.
4.Suitable Applications: DCEN is often used for welding metals like steel and stainless steel.
2.DCEP (Electrode Positive):

1.Penetration: DCEP provides shallower penetration compared to DCEN, making it suitable for
thinner materials.
2.Heat Input: The electrode becomes hotter, resulting in a wider and shallower weld bead.
3.Electrode Life: DCEP can lead to faster electrode consumption due to the increased heat on the
electrode.
4.Suitable Applications: DCEP is often used for welding aluminum and some non-ferrous metals.
Weld Bead
• The size, shape, and penetration of the weld

bead can affect the strength and quality of
the weld.
• Through experimentation with different

parameters such as voltage, amperage, wire
feed speed, and gas mixture, we can
determine the optimal settings for achieving
the desired weld bead.
Welding Defects
Porosity
• Porosity specifically refers to the formation of gas pockets or bubbles
within the weld metal. These gas pockets are typically trapped during
the solidification process when the molten metal cools and hardens.
Undercut
• Undercut is a welding defect characterized by a groove or depression
formed along the weld toe or root. It typically occurs on the base
metal adjacent to the weld and is often caused by excessive heat or
improper manipulation of the welding electrode.
• Slag inclusion is a welding defect that occurs when non-metallic
materials, known as slag, become trapped in the weld metal during the
welding process.
• Slag is a byproduct of the welding flux or the protective coating on the
electrode. It consists of impurities, oxides, and other substances that are
not part of the desired weld composition.
• Spatter in welding refers to the small droplets of molten metal that are
expelled from the welding arc during the welding process accumulate on the
base metal throughout the weld bead along its length.
• These droplets can land on surrounding surfaces, equipment, or even the
weld itself. This is particularly common happens in gas-metal arc welding.
Incomplete penetration in welding refers to a welding defect where the
weld metal does not fully penetrate the joint or reach the root of the weld.
• It occurs when the depth of fusion is insufficient, resulting in an

incomplete connection between the base metal pieces.
Incomplete fusion, also known as lack of fusion, refers to a welding defect

where there is inadequate bonding or fusion between the weld metal and
the base metal or between different layers of the weld.
• In an ideal weld, the molten filler metal should fuse completely with the
base metal, creating a sound and continuous joint.
Safety Precautions
• MIG welding can pose various

safety hazards, including arc
ﬂash, fumes, a n d electric shock.
• It is essential to follow proper

safety procedures, such as
wearing personal protective
equipment a n d ensuring proper
ventilation in the work area.
• Failure to follow safety protocols

can result in severe injury or
death.
PROBABLE Q&A
What is ARC welding?
ARC welding is a welding process that uses a welding power supply to create an electric arc between a metal electrode
and the workpiece. The heat generated by the arc melts the metal and the electrode forms a pool of molten metal that
solidifies to form a strong joint.
What is the principle behind ARC welding?

The principle behind ARC welding is that heat is generated by an electric arc between the electrode and the workpiece.
The heat generated by the arc melts the metal, and the electrode forms a pool of molten metal that solidifies to form a
strong joint.
What are the different types of ARC welding?

There are several types of ARC welding including Shielded Metal ARC Welding (SMAW), Gas Tungsten ARC Welding
(GTAW), Gas Metal ARC Welding (GMAW), Flux-Cored ARC Welding (FCAW), and Submerged ARC Welding (SAW).
What are the advantages of ARC welding?

ARC welding has several advantages including high deposition rates, the ability to weld in all positions, and the ability to
join a wide range of metals including steel, aluminum, and stainless steel.
What is the difference between a coated electrode and a bare electrode in ARC welding?
A coated electrode in ARC welding is covered in a flux that protects the weld from atmospheric contamination and
provides a shielding gas. A bare electrode does not have a flux coating and is typically used for welding in a controlled
environment where atmospheric contamination is not a concern.
What is the purpose of the shielding gas in ARC welding?
The purpose of the shielding gas in ARC welding is to protect the weld from atmospheric contamination, which can
cause porosity, cracking, and other defects in the weld. The shielding gas also affects the transfer of metal from the
electrode to the workpiece, and can influence the penetration, bead shape, and overall quality of the weld.
What are the factors that influence the penetration of an ARC weld?
The factors that influence the penetration of an ARC weld include the welding current, electrode size, electrode
composition, shielding gas, and welding speed. Increasing the welding current or using a larger electrode can increase
penetration, while reducing the welding speed or using a smaller electrode can reduce penetration.
How does welding speed affect the quality of an ARC weld?

Welding speed affects the quality of an ARC weld because it affects the penetration, bead shape, and overall
appearance of the weld. Too slow of a welding speed can result in shallow penetration and a wider bead, while too fast
of a welding speed can result in excessive penetration and a narrower bead.
What is the difference between DC and AC welding current?

DC (Direct Current) welding current flows in one direction, while AC (Alternating Current) welding current changes
direction. DC welding current is typically used for welding steels and stainless steels, while AC welding current is used
for aluminum and magnesium.
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Weld Bead Exp Mig

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TO STUDY THE EFFECT OF

RATE OF HEAT INPUT ON

Principle of MIG Welding

1.DCEN (Electrode Negative):

2.DCEP (Electrode Positive):

• The size, shape, and penetration of the weld

• Through experimentation with different

• It occurs when the depth of fusion is insufficient, resulting in an

Incomplete fusion, also known as lack of fusion, refers to a welding defect

• MIG welding can pose various

• It is essential to follow proper

• Failure to follow safety protocols

What is the principle behind ARC welding?

What are the different types of ARC welding?

What are the advantages of ARC welding?

How does welding speed affect the quality of an ARC weld?

What is the difference between DC and AC welding current?

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