Welding Processes ANB IIW
Welding Processes ANB IIW
WELDING PROCESS
GAS,SMAW,GMAW,FCAW,
SAW & RESISTANCE WELDING
Contents
Part-1 : Introduction
Part-2 : Welding & related processes
Part-3 : Brazing and soldering
Part-4 : Cutting & edge preparation
Part-5 : Plasma Cutting
Part-6 : Thermal Cutting Standards
Part-7 : Safety
Part-1
Introduction
Oxy-gas equipment
Introduction
Oxy gas processes are based on controlled
Fuel Gases
Acetylene ( C2H2 )
Propane ( C3H8 )
LPG ( Mixture of propane and butane )
Methane (CH4 ) - Natural gas
Hydrogen ( H2 )
Propylene ( C3H6 )
Butane ( C4H10 )
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CO2 + H2 O
Acetylene C2 H2 + O2
2 CO + H2
C2 H2 + 2.5O2
4 CO2 + 2H2 O
2 CO2 + H2 O
Flame
Temperature
Deg C
Heat of
combustion
MJ/m
Acetylene
2.5
3087
55
Propane
2526
104
Hydrogen
0.5
2660
12
Types of flames
Correct mixture
Neutral
Oxidising
Greenish, rounded
inner cone
Excess of O2
Blueish, sharp
inner cone
Excess of FG
Reducing
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Long white
luminous feather
9
Primary flame
(or inner cone)
Nozzle
10
OXY-ACETYLENE
HEAT CONCENTRATION
HEAT CONCENTRATION
TOTAL
Kj/m3
Primary
Secondary
Flame Temp
C
TOTAL
Primary
Secondary
Flame temp
54,772
18,890
35,882
3,160 deg
95,758 Kj/m3
10,433
85,325
2,820 deg C
11
Gas Equipment
CYLINDER VALVE
OXYGEN REGULATOR
ACETYLENE REGULATOR
FLASHBACK ARRESTOR
FLASHBACK ARRESTOR
CUTTING TORCH
WELDING TORCH
FLASHBACK
ARRESTORS
OXYGEN AND
ACETYLENE
HOSES
ACETYLENE
(CYLINDER PAINTED
MAROON)
OXYGEN
(CYLINDER PAINTED
BLACK)
T-CQ3-2
12
Cylinders
Service
Max
Pressure
(Kg)
Construction
Connection
Colour
Oxygen
150
Steel body
RH
Black
15
LH
Maroon
Dissolved
Acetylene
13
Cylinder manifolds
14
Part-2
Oxy-gas welding
and
related processes
15
Gas Welding
Torch
Tip
Filler
Flame
16
Joint recommendation
17
Welding techniques
Technique
Suitability
18
Oxidising flame
Neutral to slightly carburising (reducing)
Copper
19
Gas welding
FLAME
SETTING
FLUX
FILLER
Cast Steel
Neutral
No
Steel
Steel Plate
Neutral
No
Steel
Slightly
High Carbon Steel
Oxidising
Yes
Bronze
Yes
Cast Iron
Yes
Base
metal
METAL
Chrome steel
Neutral
Neutral
20
Special techniques
Cleaning
Preheating
21
Part-3
22
Brazing
Economical for complex assemblies
Simple way to join for large joints
Excellent stress and heat distribution
Ability to join dissimilar metals
Ability to join non metals to metals
Ability to join different thickness parts
Joints require no finishing
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23
Principle of brazing
Parts must be joined without
melting
450 deg C
physical principle
24
Brazing methods
Single/ multiple torch : suitable for low volume
automation
Induction: Suitable for continuous automated
production
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25
Braze-welding
Braze welding is a process similar to fusion
26
Problems in brazing
Problems
>>>>>>
Causes
>>>>>>
No flow
No wetting
Wrong filler
Low temp.
Dirty parts
Poor fit-up
Too little flux
Bad vacuum
Excess flow or
wetting
Erosion of
parent metal
Wrong filler
High temp.
High temp.
Excess filler Time too long
Time too long Excess filler
Wrong filler
No stop-off
27
Soldering
Parts must be joined without melting
Melting point of solder (filler) < 450 deg C
Molten solder must be able to wet surface of
28
Soldering methods
Method
Application
Air-FG torch
Soldering iron
Furnace
Wave
soldering
Vapour phase
soldering
Induction
29
Al & Al bronze
Brass
Copper
Steel/SS
Cast iron
30
Fluxes
Inorganic fluxes
Organic fluxes
Zinc chloride
Stearic acid
Ammonium chloride
Oleic acid
Tin chloride
Glutamic acid
HCl
Hydrazine hydrobromide
Phosphoric acid
Metal chloride
31
Solders
Solder
Workpiece
Sn-Sb-Pb
Sn-Zn
Sn-Ag, Sn-Cu
Cd-Ag
Zn-Al
Copper, brass
Aluminium
SS, copper,
Aluminium
Aluminium
Indium-Sn
Glass to glass,
glass to metal
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32
33
Soldering
Mech. strength
Higher
Lower
Working temp
Higher
Lower
Less
More
Versatile
34
Part-4
35
OXY
PLASMA
LASER
SS
TITANIUM
ALUMINIUM
CERAMIC
RUBBER
KEVLAR
GLASS
LAMINATES
WATER
JET
ROUTER
36
37
38
Oxy-cutting Torch
Nozzle mix system
Torch head
Cutting oxygen
Heating oxygen
Acetylene
Mixed gas
Cutting oxygen
Pre-heat flame
Cutting Nozzle
39
Oxygen cutting
NOZZLE
DIRECTION OF CUT
PRE-HEAT
FLAME
DRAG
LINES
CUTTING OXYGEN
CUTTING STREAM
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40
Drag Lines
As well as the roughness of the cut face, drag lines across the
surface of the cut can give the operator an indication if the cutting
speed is correct and the right cutting oxygen velocity is being
used.
41
CAUSES
Fluted cut
Low speed
-gouging at the bottom
Top edge melt
Heavy slag
42
43
44
Carbon
0.3
Manganese
10
Silicon
Chromium
Nickel
3
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45
17
5
15
0
12
5
10
0
75
O2 CONSUMPTION
50
2
510
0
CUTTING SPEED
99.5
99
98.5
O2 PURITY %
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9
8
46
Cutting parameters
High speed vs standard nozzle
CUTTING SPEED
m/min
1.0
0.7
5
HIGH SPEED
0.5
0.2
5
STANDAR
D
10
20
PLATE
30
40
50
T IIW-ANB
H I Crefresher
K Ncourse
E Sfor Transition
S mm
candidates
60
>>
70
47
Torch
Carriages
CONTROLS
TBA
WORKPIECE
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48
49
50
Programming Station
CUSTOMERS
ORDER
DESIGN
DXF
FILES
BOM
FINISHED
GOODS
RAW
MATERIAL
S
PROGRAMMING
STATION
PRODN
PLANNIN
G
PART
LIBRARY
NESTIN
G
GRAPHIC
EDITOR
MIS
TOOL PATH
GENERATION
CNC
CUTTIN
G
MIS
51
Part-5
52
Plasma Cutting
53
Plasma cutting of MS
54
SECONDARY
GAS
RECTIFIER
POWER
SOURCE
PLASMA
CUTTING
TORCH
HIGH
FREQUENCY
SOURCE
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Plasma cutting
CUT QUALITY
T-1>T-2>T-3>T-4
T-1
T-2
T3
WORKPIECE
T-4
TAPER CUT
SURFACE
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56
Air plasma
-
+
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candidates
57
58
Steam Layer
+
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59
60
61
WI
Air
Nitrogen
Argon
Argon+Hydrogen
(60% + 40%)
Nitrogen
(99.999%)
Oxygen
62
Plasma cutting
Further developments
WATER
MUFFLER
WATER TABLE
UNDERWATER
CUTTING
O2 PLASMA
WITH WATER
INJECTION
FINE PLASMA
NARROW KERF
63
OPEN PLASMA
WI-PLASMA
Low
>200
0.9-3
0.6
MS
Contained
30-50
--MS, SS
Cut Squareness
Good
Cut Surface
Good
V. High
30-50
3
0.4
MS, SS, Alu, etc.
Acceptable < 6mm
Bevelled > 6mm
Good < 6mm
Fair > 6mm
High
High
Cutting speed
Equipment cost
Low
Low
Good
Good
High
V. High
64
Water-jet cutting
65
66
APPLICATION
67
Pre-heat flame
Oxygen stream
68
Part-6
Thermal Cutting
Standards
69
Acceptance testing of
Oxygen cutting machines
testing the accuracy and
operational characteristics
DIN EN ISO
9013
WES 2801
70
Main
Perpendicularity/ Mean height
number of
angularity
of profile RZ5
standard
tolerance, u
ISO 9013
Angularity of
cut surface to
plate surface
4
Tolerance
class
Roughness of
cut surface Dimensional
along cutting accuracy
direction
71
Part-7
Safety
72
Protection
from
Recommendation
Skin
IR Radiation,
Spatter,
Hot metal, Burn
Apparel
Spatter, Fire
Wear apron
Feet
Spatter, Burn
73
74
75
Symptoms
A bang
Pressure
Wave
Hose
MIXED
GAS
Direction of Flashback
Toward Regulator
76
Safety in brazing
For manual brazing safety requirements are
77
Safety in soldering
Precautions for fire hazard, specially when
flame is used,
Use goggles for eye protection (use shade #
vapours,
Precaution from hot metal and burns.
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Protection
of
Recommendation
Eyes
IR, UV Radiation,
Spatter
Skin
IR, UV Radiation,
Wear leather gloves
Spatter, Hot metal, Burn & apron
Apparel
Spatter, Fire
Wear apron
Ear
Sound
Feet
Spatter, Burn
Body
Electric shock
Follow safety
instructions
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candidates
79
Eye protection
80
S. Ghoshal
1)
Ranajoy Banerjee
81
Thank You
82
Contents
Advantages of MMAW
Equipment used is simple,
inexpensive.
Electrode provides and
regulates its own Flux.
This process has excellent
suitability for outdoor use
lower sensitivity to wind
and even for use under
water.
All position capability
Principles of MMAW
An electric arc is maintained
OCV
Open circuit voltage ( ocv )is the voltage across
Power source
Welding and ground cables
Electrode holder
Ground clamp
Chipping hammer and steel wire brush
Hand-shield / welding helmet / head-shield
Welding electrode
Re-drying oven
MMAW Electrode
Core Wire
Electrode core wire: C 0.10 max; Mn 0.38-0.62; Si
0.03 max; S 0.03 max; P 0.03 max
Important feature: low level of C, Si, S & P
Coating
Arc characteristics Stability, Striking & Restriking, Force, Capability to work in positions, and
in AC & DC sets
Slag characteristics Good shielding, Capability
to bring impurities out of molten weld metal, Good
detachability, Flowability as well as quick freezing
nature
Coating Constituents
Arc stabilisers
Slag formers
Deoxidisers
Gas forming materials
Binders
Alloying elements
Deposition efficiency improvers
Extruding/slipping agents
Coating types
Rutile
Basic
Cellulosic
Acid
Acid-rutile
Oxidising
Coating Factor
CF = Electrode diameter / Core wire
diameter
Thin coated: CF <= 1.3
eg. Ferrospeed
DC based
High hydrogen level
Operator skill is important
Production Of Electrodes
The powdered coating materials are dry mixed and then liquid
Remarks
Not recommended
If wet 70 C for 30
min
Transfer to holding
oven at 125 150 C
Transfer to holding
oven at 125 150 C
Transfer to holding
oven at 125 150 C
250 C for 1 hr
B.
C.
D.
Selection of electrodes
Use an all position Electrode when welding job involves all
position
Use high deposition electrodes when the job is to be done in
Voltage
Try to use highest voltage setting available,
specially for basic coated low hydrogen
electrodes.
Quality of welding
highly dependent on the
skill of operator
A high level of manual
dexterity is required to
co-ordinate the
electrode to match the
burn off rate and to
maintain a constant
ARC length.
Cleaning Of Joints
To avoid porosity and attain satisfactory
welding procedure
Low deposition rate
Contents
Gas Metal Arc Welding
Flux Cored Arc Welding
MMAW / SMAW
GMAW / FCAW *
GTAW *
SAW
Developed
Countries
India
control
GMAW process
GMAW equipment
Shielding Gases
Shielding gases provide a
protection to the weld metal
from the atmosphere and
have a pronounced effect on:
Arc characteristics
Mode of metal transfer
Penetration and weld bead profile
Speed of welding
Undercutting tendency
Cleaning action
Weld metal mechanical properties
Types of shielding
gases used in GMAW
Carbon Dioxide (CO2)
Argon
Helium
Oxygen
Nitrogen
Mixtures of the above
gases
factors:
Magnitude, type and polarity of welding current
Electrode diameter
Electrode composition
Electrode extension and
Shielding gas composition
CO2 /
Ar Mix
GLOBULAR
CO2
SPRAY
Argon Mix
4 steps in
Short
circuiting
transfer
Globular Transfer
Spray Transfer
Spray transfer GMAW occurs when the molten
Contd.
GLOBULAR TRANSFER
Globular transfer
Globular transfer is normally encountered with CO2 as shielding
Pulse Transfer
Combines the control on heat input of short arc with the higher
deposition rate of open arc.
Gives extremely precise control on metal transfer and penetration
to give superior weld quality
In synergic pulsed systems wire feed rate synchronised with
pulsed current to control individual droplet detachment.
Spatter generated
1 metre of weld at 260 amps
using 1.2mm dia. A18 solid wire
Carbon dioxide
17.1 g
Argon - 20 CO2
8.6 g
Argon-12 CO2
5.5 g
T-GK 3 (10)
input
Comparatively high bead profile
Carbon di-oxide
20%
10%
Argon
CO2
Argon mixture
weld length
1.15 m
Ar-CO2-O2
weld length
1m
Ar-CO2
CO2
CASE STUDY - 2
Heavy Fabrication
Torch angle.
15 - 25
Direction of travel
This rake angle should be utilised for the welding of all joint types in the
flat and overhead position.
Backhand Vertical
Forehand
Process Variations
Gas metal arc spot welding is a technique in
MIG Brazing
MIG brazing is a variation of the MIG
Wire Technologies
came to the GMAW process
in early Nineties .
2 electrically isolated wires,
one behind the other (lead &
trail
electrodes),
closely
spaced, deposit metal in
single weld pool
Lead wire generates most of
base metal penetration, trail
wire controls bead contour
and edge wetting-also adds
to Depo. Rate.
Managed
by
specialized
Power control software
FCAW PROCESS
inside
Gas shielded (FCAW-G) or self
shielded (FCAW-S)
The flux produces a protective
slag and/or gas cover
Combination of benefits of
MMAW and GMAW
High productivity process with
low spatter. Smooth arc with
CO2. Argon mixtures give
superior performance
Problem of high fumes which
need to be extracted in
enclosed areas
Application of FCAW
For fabrication of
Down-hand
Vertical-up
Overhead
0.9 mm
26V 200A
23V 150A
26V 200A
1.2 mm
27V 240A
25V 200A
27V 210A
1.4 mm
28V 260A
25V 210A
28V 220A
1.6 mm
28V 275A
25V 220A
28V 240A
Acknowledgements
We gratefully acknowledge the contributions of
the following faculty members for developing
this module
Mr.R.Banerjee
Mr.R.Srinivasan
THANK YOU
Submerged Arc
Welding
Process and Practice
SAW Features
High Productivity, high
amperages may be used
Easy de-slagging
High Quality
Deep penetration
Excellent mechanical
properties
Environment friendly
Very little fume
No radiation
Easy operation
SAW Equipment
WIRE FEEDER
WELDING POWER SOURCE
FLUX HOLDER AND FEEDER
MEANS FOR TRAVERSING THE WELD
JOINT
REDRYING ARRANGEMENT FOR
FLUX
FLUX RECOVERY UNIT .
OTHER ACCESORIES
Consumables
Wire : solid / fluxcored
Soilid wires for mild and low alloy steel applications are
Consumables contd.
B. Agglomerated flux ;
SAW Fluxes
Fused
Heavier, higher bulk
Agglomerated
Lighter, lower bulk
Neutral fluxes :
These fluxes do not produce any significant change in the weld
metal chemical composition due to a large change in arc
voltage or arc length / stick out.
Active fluxes :
These contain manganese and / or silicon bearing ingredients
as de-oxidiser and changes the weld metal chemical
composition with change in arc voltage / stick out.
Alloy fluxes :
contain alloying ingredients in the flux and when used with non
alloyed carbon steel electrode give alloy weld metal.
0,4
0,3
0,2
0,1
0
40
60
80
100
120
140
160
Welding Parameters
1.
2.
3.
4.
5.
6.
WELDING CURRENT
ARC VOLTAGE
SPEED OF ARC TRAVEL
SIZE OF ELECTRODE
ELECTRODE STICK OUT
HEAT INPUT RATE
mm MS plate
Plate thickness
Pass
19 mm
1
5 mm
5mm
Current ( amps )
800
900
Voltage ( volts )
36
37
56
56
Wire size
B.
C.
D.
E.
F.
Inclusion
Contaminants of flux, Usage of cold flux.
Improper joint geometry
Viscosity of the slag
Inadequate interpass cleaning
Influence of stick-out
Longer stick-out gives higher deposition rate, but
also more shallow penetration.
Deposition rate
Recommended current range and deposition rate (kg/h)
for different wire diameters
Deposition rate
As a function of wire diameter and amperage
Kg/
h
Wire
diameter
a = 1,6 mm
b = 2,0 mm
c = 2,4 mm
d = 3,2 mm
e = 4,0 mm
f = 5,0 mm
g = 6,0 mm
16
14
12
a
10
c
b
8
6
4
2
200
400
600
800
1000 Amp
Acknowledgements
We gratefully acknowledge the contributions of
the following faculty members for developing
this module
Mr.R.Senguta
Mr.R.Banerjee
Mr.R.Ravi
Mr.N.K.Mukherjee
THANK YOU
Resistance Welding
212
Resistance welding
213
Spot welding
Butt welding
Spot Welding
Seam welding
Flash butt
216
217
218
219
220
PORTABLE
X-GUN
C-GUN
221
G A NTRY
,AIR
,
SPRING
BALANCE
T/R
SELECT S/W
3
GUN S/W
A IR
Cylin
- der
KICKNESS
CABLE
2
1
SHUNT
T /C
POINT HO LDER
Guide Rod
CAP T IP
G A NT RY
SHANK
SCR
BOX
ADAPT O R
HOLDER
GUN BODY
MOTO R
222
223
224
228
231
No nugget
Pressure
Splash
Good
weld
Explosion
Welding current
140
120
100
80
60
6
Welding current, kA
234
Electrode
force, F [kN]
Weld
current, I
[A]
Weld time
[cycles]
Hold time
[cycles]
Electrode
diameter, d [mm]
0.63 + 0.63
2.00
8 500
0.71 + 0.71
2.12
8 750
0.80 + 0.80
2.24
9 000
0.90 + 0.90
2.36
9 250
1.00 + 1.00
2.50
9 500
10
1.12 + 1.12
2.80
9 750
11
1.25 + 1.25
3.15
10 000
13
1.40 + 1.40
3.55
10 300
14
1.50 + 1.50
3.65
10 450
15
1.60 + 1.60
4.00
10 600
16
1.80 + 1.80
4.50
10 900
18
2.00 + 2.00
5.00
11 200
3x7+2
2.24 + 2.24
5.30
11 500
3x8+2
2.50 + 2.50
5.60
11 800
3x9+3
2.80 + 2.80
6.00
12 200
4x8+2
3.00 + 3.00
6.15
12 350
4x9+2
3.15 + 3.15
6.30
12 500
4x9+2
235
8
IIW-ANB refresher
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Transition candidates
Joule heating
H=I2Rt
H=Heat
I=Current
R=Resistance
t=time
Transition candidates
Temperature profile
241
242
Weld checker
Welding defects
Cap tips
Electrodes
246
247
248
249
Specific testing
Shear-tension
Cross-tension
Cross-tension test
Steel: IF-GA
254
255
256
Electrodes
258
CARRIAGE
COPPER
RAILS
MAGNETIC
TABLE
FOIL
SPOOLS
GUIDE
ELECTRODE ROLLER
SERVO DRIVE
259
FEEDERS
TELESCOPIC
COVER
260
261
262
263
264
265
266
267
268
269
270
271
Applications Of FSW
274
Acknowledgements
We gratefully acknowledge the contributions of
the following faculty members for developing
this module
Dr.A.K.Das
Dr.M.Shome
Mr.R.Ravichandran
Mr.Swapan Ghoshal
275
Thank you
276