2 Physics of Welding

Physics of Welding
Physics of Welding
Learning Activities
Lesson Objectives 1. Read Handbook
When you finish this lesson you will pp 32-62
understand: 2. Look up
Heat input and heat transfer from arc to Keywords
3. View Slides;
weld
4. Read Notes,
Metal melting and regions of weld. 5. Listen to lecture
Arc physics and plasma properties of arc 6. Do on-line
workbook
7. Do homework
Keywords:
Heat Input, Heat Transfer Efficiency, Heat Affected Zone, Enthalpy
of Melting, Latent Heat, Melting efficiency, Plasma, Polarity,
Thermionic Work Function, Ionization, Cathode Spot, Anode Spot,
Arc I-V Characteristics
Physics of Welding
Heat Input Concepts

Energy Sources
Arc Characteristics
Wire Melting
Heat Loss
Heat input
Heat Input
H = energy input, energy/unit length, joules /mm
H = Power/Travel Speed, = P/v

P = total input power, Watts
v = travel speed of heat source, mm/sec
Describes energy per unit length delivered,

not rate of delivery
Used in codes & specifications
This energy does not all go entirely to the work

Heat Input for Arcs
H = P/v = EI/v
E = Arc Voltage (Volts)
I = Arc Current (Amps)
EI = Process power, converted to Heat
v = Welding Travel Speed
Not all the arc energy goes into the work
Hnet = f1H = f1P/v = f1EI/v
f1 = Heat Transfer Efficiency
f1 = Heat Transfer Efficiency
short
Arc Length
long
Melted Base Metal Reinforcement
Heat
Affected
Zone
Aw = Cross Section of Weld = Am + Ar
For Autogenous Weld (no filler metal)

Aw = Am
Heat Required to melt Heat Required to + Latent Heat
Q= =
a Given Volume of Weld elevate solid to MP of Fusion
Enthalpy of Melting
Heat Required to melt Heat Required to + Latent Heat
Q= =
a Given Volume of Weld elevate solid to MP of Fusion
Q C p Tm To L
Density(mass / volume)
C p HeatCapacity (thermalenergy / mass o C
Tm MeltingTem perature
To InitialTem perature, usuallyroomtemperature
L LatentHeatofFusion
Not all the net heat transferred goes into melting

Melting Efficiency
f2 = Melting efficiency, the fraction of the process heat

energy per unit length delivered to the metal which
is required to melt the metal
f2 = QAw/Hnet From previous slide:

Hnet = f1H = f1P/v = f1EI/v
f2 = QAwv/f1EI
Melting Efficiency Depends On:
Higher Thermal Conductivity - Lower Efficiency
High Energy Density Heat Source - Higher Efficiency
Turn to the person sitting next to you and discuss (1 min.):
We can select a range of processes for arc welding from a
tiny GTAW run at 15 volts and 100 amps and 30 ipm to twin
arc submerged arc welds run at 25 volts and total curretn of
over 1000 amps run at 8 ipm. What is the heat input in each
of these welds? What do you think might happen to the
cooling rate in the part being welded when the weld is
stopped in each of these weld?
Other Energy Sources
H = Heat generated, joules

Arc H = EI/v E = Voltage, volts
Resistance: H = I2Rt v = Travel Speed, mm/sec
I = Current, amps
Electroslag: H = EIt R = Resistance, ohms
t = Time, sec
4 P1 PD = Power Density
Laser: PD
f
2 P1 = Input power
f Focal lenght of lens

EI angle of beam divergence
EB: PD

A wavelength
laser constant
A = Area of focused beam

OXYFUEL GAS WELDING
THERMIT WELDING
Do Homework Assignment 4 Physics of Welding
From the Assignment page of the WE300 Website.
Often engineering calculations require conversion

of units. In the Slide Show Mode, clicking on
this icon will open a free program to help you with
Convert.exe conversions. You might want to bookmark this
program for later use as well. On your first use,
please click on help and register this free program.
Polarity and Current Flow
Welding Electrode or "Electrode"
Anode Cathode
I I
DCEP DCEN
Cathode Anode
Work Electrode or "Work"
Reverse Straight
RPEP SPEN
Plasma State
Gas is hot enough so that high energy collisions

produce free electrons

A A e -
Plasma may only be a few % electrons

Conduction of Current in the Arc
Cathode
Electrons Emitted
Thermal
Ionization Free
Electron
Ion
Plasma
T>10,000K Recombination
Anode Neutral
Gas Atom
Electrons Absorbed
Argon
Arc
Thermionic Work Function
Energy Required for electron to escape a solid surface
I I/e electrons/second
Cathode
Energy into
emitted electrons = I x WF
V (from arc)
I/e electrons/second
Anode
Energy deposited by
impinging electrons = I x WF
(into anode)
Work Function of pure Tungsten = 4.4 eV
Work Function of Thoriated W = 4.1 eV
Ionization
"Neutral" Free
I
Atom Electron
Ionization
Collision
Free
Ion
Free Electron with

Energy > Ionization Potential
Ionization Potentials: He 24.6 eV
Ar 15.8
N 15.6
Fe 7.9
Na 5.1
}
}
}
Will total voltage change if we change the amount of current (say from 200 amps to
300 amps)?
Arc V-I Characteristic
V
A 40
Welding Welding Unstable
Power Arc
30 h3
Source V V
h2
h 20
h1
10 h=0
0 I
0 50 100 150 200 250 300
We see that current and arc length have an effect, what happens if we change from Ar
to some other ionizing gas?
Ionization Potential
He 24.6 ev
Ar 15.8
N 15.6
Fe 7.9
Na 5.1
P 4.3
Turn to the person sitting next to you and discuss (1 min.):
The arc characteristics that we looked at were for a Gas
Tungsten Arc where the electrode is not melted so the metal
ions in the arc do not come from molten electrode. What
happens in GMAW where the wire (electrode) melts? Would
you expect anything different to happen?

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Physics of Welding

Heat Input Concepts

H = Power/Travel Speed, = P/v

Describes energy per unit length delivered,

This energy does not all go entirely to the work

Aw = Cross Section of Weld = Am + Ar

For Autogenous Weld (no filler metal)

Not all the net heat transferred goes into melting

f2 = Melting efficiency, the fraction of the process heat

f2 = QAw/Hnet From previous slide:

H = Heat generated, joules

A = Area of focused beam

Often engineering calculations require conversion

Work Electrode or "Work"

Gas is hot enough so that high energy collisions

Plasma may only be a few % electrons

Free Electron with

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