Fusion welding
1-Arc welding
Shielded Metal Arc welding (SMAW)
(Stick welding)
Consumable electrode
Gas-Metal Arc welding (MIG)(GMAW) Flux-Core Arc welding (FCAW) Submerged Arc welding (SAW) Electro Slag welding (ESW ) Gas-Tungsten Arc welding (TIG) (GTAW) Non consumable Plasma Arc welding (PAW)
electrode
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Fusion welding
2-Gas welding (GW) Oxyacetylene welding (OAW) 3-Resistance welding (RW)
Spot (RSW) Seam (RSEW) Projection (RPW)
4-other fusion welding Electron beam welding (EBW) Laser beam welding (LBW)
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Fusion welding (Liquid State welding)
Fusion welding (Liquid State welding)
coalescence is accomplished by melting the two parts to be joined, in some cases adding filler metal to the joint. Examples: 1. Arc welding,
2. Resistance welding 3. Gas welding (Oxyfuel)
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1-Arc Welding (AW)
A fusion welding process in which coalescence of
the metals (joined together ) is achieved by the heat from an electric arc between an electrode and the work.
Electric energy from the arc produces temperatures ~ 10,000 F (5500 C), hot enough to melt any metal. Most AW processes add filler metal to increase volume and strength of weld joint.
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What is an Electric Arc?
An electric arc is a discharge of electric current across a gap in a circuit. It is sustained by an ionized column of gas (plasma) through which the current flows To initiate the arc in AW, electrode is brought into contact with work and then quickly separated from it by a short distance
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Arc Welding
A pool (electrode) of molten metal is formed near electrode tip, and as electrode is moved along joint, molten weld pool solidifies in its wake.
Basic configuration of an arc welding process.
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Video No.(1+2)
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..\\ ARC WELDING\fig 51.swf
..\\ ARC WELDING\fig 52.swf
..\\ ARC WELDING\1-Arcwelding .MPG
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General AW Technology
ELECTRODES
Two Basic Types of AW Electrodes
1.Consumable electrode Consumed during welding process. Source of filler metal in arc welding.
1. 2. Shielded Metal Arc Welding Gas Metal Arc Welding
2.Nonconsumable electrode
Not consumed during welding process.
Filler metal must be added separately.
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1-Consumable Electrodes
Forms of consumable electrodes Welding rods (called sticks) are 9 to 18 inches(225-450 mm) long and 9.5mm(3/8 inch) or less in diameter and must be changed frequently. Weld wire can be continuously fed from spools with long lengths of wire, avoiding frequent interruptions In both rod and wire forms, electrode is consumed by arc and added to weld joint as filler metal.
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2-Nonconsumable Electrodes
Made of Tungsten (or carbon) which resists melting by arc . Gradually depleted during welding (vaporization is principal mechanism) Any filler metal must be supplied by a separate wire fed into weld pool
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ARC SHIELDING
At high temperatures in AW, metals are chemically reactive to oxygen, nitrogen, and hydrogen in air . Mechanical properties of joint can be seriously degraded by these reactions. To protect operation, arc must be shielded from surrounding air in AW processes Arc shielding is accomplished by: Shielding gases, e.g., argon, helium, CO2
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FLUX
Definition:
Flux is substance that prevents formation of oxides and other contaminants in welding, or dissolves them and facilitates removal. Flux Functions:
1. Provides protective atmosphere for welding. 2. Stabilize the arc. 3. Reduces spattering
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Various Flux Application Methods
Pouring granular flux onto welding operation
1. Using a stick electrode coated with flux material in which the coating melts during welding to cover operation. 2. Using tubular electrodes in which flux is contained in the core and released as electrode is consumed. 3. Using tubular electrodes in which flux is contained in the core and released as the electrode is consumed.
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Power Source in Arc Welding
Direct current (DC) and Alternating current (AC) are used.
AC machines less expensive to purchase and operate, but generally restricted to ferrous metals DC equipment can be used on all metals and is generally noted for better arc control
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First: Consumable Electrode AW Processes
1. Shielded Metal Arc Welding (SMAW Or Stick)
2. Gas Metal Arc Welding (GMAW or MIG)
3. Flux-Cored Arc Welding (FCAW) 4. Electrogas Welding (EGW) 5. Submerged Arc Welding (SAW)
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1-Shielded Metal Arc Welding (SMAW)
Uses a consumable electrode consisting of a filler metal rod coated with chemicals that provide flux and shielding Sometimes SMAW is called "stick welding Applications Used for steels, stainless steels, cast irons, and certain nonferrous alloys Not used or rarely used for aluminum and its alloys, copper alloys, and titanium
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Shielded metal arc welding (SMAW). Or Stick
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Shielded Metal Arc Welding
Shielded metal arc welding (SMAW).
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Or Stick
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Shielded Metal Arc Welding Or Stick
Shielded metal arc welding (stick welding) performed by a (human) welder (photo courtesy of Hobart Brothers Co.).
Video no.3
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..\\ ARC WELDING\Weld Procedures Utube Welding Videos - 6010 stick welding.flv
..\\ ARC WELDING\3-ArcWelding (SMAW).swf
..\\ ARC WELDING\Weld Procedures Utube Welding Videos - Stick Weld from Welding Home Study Course by The Welders Lens.flv
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2-Gas Metal Arc Welding (GMAW OR MIG)
Uses a consumable bare metal wire as electrode and shielding accomplished by flooding arc with a gas. Wire is fed continuously and automatically from a spool through the welding gun. Shielding gases include inert gases such as argon and helium for aluminum welding, and active gases such as CO2 for steel welding Bare electrode wire plus shielding gases eliminate slag on weld bead - no need for manual grinding and cleaning of slag.
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Gas Metal Arc Welding
Video No.7+8+9
Gas metal arc welding (GMAW OR MIG).
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..\\ ARC WELDING\fig 9-1.swf
..\\ ARC WELDING\7- MIG Welding- Mig Welding_ Push Technique.flv ..\\ ARC WELDING\8 - MIG Welding- Mig Welding demo.flv
..\\ ARC WELDING\9- MIG welding animation.flv
..\\ ARC WELDING\msg_loop mig welding.swf
..\\ ARC WELDING\fig 9-2.swf
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GMAW Advantages over SMAW
Better arc time because of continuous wire electrode Sticks must be periodically changed in SMAW Better use of electrode filler metal than SMAW End of stick cannot be used in SMAW Higher deposition rates Eliminates problem of slag removal Can be readily automated
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Second:
Non-consumable Electrode Processes
1. 2. 3. 4. Gas Tungsten Arc Welding (TIG) Plasma Arc Welding (PAW) Carbon Arc Welding (CAW) Stud Welding (SW)
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1-Gas Tungsten Arc Welding (TIG) (GTAW)
Uses a non-consumable tungsten electrode and an inert gas for arc shielding Melting point of tungsten = 3410C (6170F) Tungsten Inert Gas (TIG) welding In Europe, called "WIG welding" Used with or without a filler metal When filler metal used, it is added to weld pool from separate rod or wire Applications: aluminum and stainless steel most common
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1-Gas Tungsten Arc Welding (TIG)
Video No.4+5+6
Gas tungsten arc welding.
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GTAW SYSTEM SETUP
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..\\ Tig\tig.swf
..\\ ARC WELDING\4- Tig Gas Tungsten Arc Welding GTAW (TIG).flv
..\\ ARC WELDING\5- Tig Welding Basics.flv
..\\ ARC WELDING\6- Tig welding.flv
..\\ Tig\Weld Procedures Utube Welding Videos - TIG Welding_2.flv
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Advantages / Disadvantages of (TIG) GTAW
Advantages: High quality welds for suitable applications No spatter because no filler metal through arc. Little or no post-weld cleaning because no flux. Disadvantages: Generally slower and more costly than consumable electrode AW processes.
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2-Plasma Arc Welding (PAW)
Special form of GTAW in which a constricted plasma arc is directed at weld area. Tungsten electrode is contained in a nozzle that focuses a high velocity stream of inert gas (argon) into arc region to form a high velocity, intensely hot plasma arc stream. Temperatures in PAW reach 28,000C (50,000F), due to constriction of arc, producing a plasma jet of small diameter and very high energy density.
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Plasma Arc Welding
Plasma arc welding (PAW).
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Advantages / Disadvantages of PAW
Advantages:
Good arc stability Better penetration control than other AW High travel speeds Excellent weld quality Can be used to weld almost any metals
Disadvantages:
High equipment cost Larger torch size than other AW Tends to restrict access in some joints
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