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Parameter 1

Welding Parameter Development


Many welding equipment suppliers offer a series of pre-calculated weld programs for a
variety of tube diameters, wall thicknesses and materials. Welders should always follow
an equipment supplier's suggested procedures first, because they have usually performed
a significant amount of qualifying and troubleshooting work to optimize electrode
preparation for their equipment.

However, it is impossible for the equipment suppliers to have welding procedures for
every welding application and there will always exist a trade off in maximum weld speed
possible versus weld quality and repeatability. Where weld parameter specifications do
not exist or the welder or engineer would like to change those settings to possibly
improve or optimize their welding, the guidelines noted below give information on how
to modify the welding parameters for a desired result.

Following are the important welding parameter for pulse tig welding of thin low alloy
tubes:

1. Electrode Material Selection


2. Tungsten Diameter Selection
3. Electrode Tip Geometry
4. Arc Length
5. Welding Current
6. Welding Current Level
7. Arc Pulsing Parameter

These Parameter are the thumb rules for starting welding and is organized by
NED University Student of Final year material(BATCH 2006-07) ….During
their project .And this is Uploaded by one of the student of that batch ….
NAME: HUZAIFA
ROLL#: MM-047
Parameter 2

Electrode Material Selection


For quite some time, tungsten manufacturers have added an oxide to pure tungsten to
improve the arc starting characteristics and the longevity of pure tungsten electrodes.
Below is a chart that lists the major commercially sold tungsten types, their American
Welding Society (AWS) and International Standards Organization (ISO) classifications,
and the amount and type of oxide contained in the electrode.

Material AWS Class ISO Class Oxide Content


2% Thoriated EWTh-2 WT20 1.7-2.2% ThO2
2% Ceriated EWTh-2 WC20 1.8-2.2% CeO2
1½% Lanthanated EWLa-1.5 N/A 1.3-1.7% La2O3
1% Lanthanated EWLa-1 WL10 0.8-1.2% La2O3
Zirconiated EWZr-1 WZ3 0.15-0.40% ZrO2
Pure Tungsten EWP W None

Below is a description of each of these types and their uses:

2% Thoriated Tungsten

This is the most commonly used tungsten material because it was the first to display a
significant improvement over pure tungsten. This is a good general use tungsten for DC
applications, because it has a low work function and operates well even when overloaded
with extra amperage. While many companies still use this material because it is specified
as part of a qualified weld program.The thoria contained in 2% Thoriated tungsten is
slightly radioactive and many welders and safety officers are leading the move away
from this material. The American Welding Society, in their A5.12 "Specification for
Tungsten and Tungsten-Alloy Electrodes for Arc Welding and Cutting" state the
following on this issue:

Thoria is a low-level radioactive material. However, if welding is to be performed in


confined spaces for prolonged periods of time or if electrode grinding dust might be
ingested, special precautions relative to ventilation should be considered. The user should
consult appropriate safety personnel.

These Parameter are the thumb rules for starting welding and is organized by
NED University Student of Final year material(BATCH 2006-07) ….During
their project .And this is Uploaded by one of the student of that batch ….
NAME: HUZAIFA
ROLL#: MM-047
Parameter 3

The primary concern in using this material is in ingesting the dust produced while
grinding points on them.

2% Ceriated Tungsten

This non-radioactive alternative to 2% Thoriated Tungsten is best when used primarily in


DC welding at low currents. It has excellent arc starting capabilities at low currents and
therefore it has become the standard for many orbital tube and pipe welding equipment
manufacturers. In addition, it is often used in other low amperage applications where
small or delicate parts are being welded. It would not be good for higher amperage
applications, because the oxides migrate very quickly to the heat at the tip under these
conditions and the oxide content and benefits are then removed.

1½% Lanthanated Tungsten

This has been a very popular new material internationally and has recently been
introduced in the United States. The 1½% content (as opposed to 2%) was chosen by two
of the largest manufacturers as the optimum content amount based on scientific studies
which showed that this content amount most closely mirrors the conductivity
characteristics of 2% Thoriated Tungsten. Therefore, welders can usually easily replace
their radioactive 2% Thoriated material with this tungsten and not have to make any
welding program changes. It makes the switch quick and easy.

In addition, one major manufacturer had an independent study performed on this material
and it was presented at the 1998 American Welding Society Exhibition in Detroit,
Michigan. In summary, 2% Thoriated, 2% Ceriated and two manufacturer's 1½%
Lanthanated were compared by observing tip erosion after 300 DC arc strikes at both 70
amps and 150 amps. In both cases, the 1½% Lanthanated tungsten showed the least
amount of tip erosion.

This material is also suitable for AC welding. Therefore, if you are considering
optimizing your welding, this is an excellent material to consider.

Zirconiated

This material is used primarily for AC welding. The AWS states, "This electrode
performs well when used with alternating current as it retains a balled end during welding
and has a high resistance to contamination." This electrode has reduced in importance as
other alternatives have become available.

These Parameter are the thumb rules for starting welding and is organized by
NED University Student of Final year material(BATCH 2006-07) ….During
their project .And this is Uploaded by one of the student of that batch ….
NAME: HUZAIFA
ROLL#: MM-047
Parameter 4

Pure Tungsten

Like Zirconiated Tungsten, this tungsten is also only used for AC welding and there are
better alternatives available. Try 1½% Lanthanated instead of this material.

Tungsten Diameter Selection

The welding equipment supplier's recommendations and the American Welding Society
recommendations are the best place to start with this variable. Equipment suppliers
normally have specifications handy that they can provide you with. If they are not
available or you would like to experiment with altering their guidelines, the chart that is
published by the American Welding Society can be of help to you.

Keep in mind that as you increase the diameter of the electrode you are able to handle
more amperage. For a given amperage, larger diameter electrodes are more difficult to
start than smaller ones, but they will probably erode less rapidly. If you use too large an
electrode for your amperage level, you are likely to experience arc instability.

Direct Current Alternating Current


(Amps) (Amps)
Electrode Straight Reverse Unbalanced Balanced
Diameter Polarity Polarity Wave Wave
in. mm DCEN DCEP
0.010 0.3 0.1 to 15 Not 0.1 to 15 0.1 to 15
Applicable
0.020 0.5 5-20 Not 5-20 5-20
Applicable
0.040 1.0 15-80 Not 10-80 20-60
Applicable
0.060 1.6 70-150 10-20 70-150 60-120
0.093 2.4 150-250 15-30 140-235 100-180
0.125 3.2 250-400 25-40 225-325 160-250
0.156 4.0 400-500 40-55 300-400 200-320
0.187 4.8 500-750 55-80 400-500 290-390
0.250 6.4 750-1000 80-125 500-630 340-525

All values are based on the use of Thoriated, Ceriated, or Lanthanated Tungsten
electrodes with argon gas.

These Parameter are the thumb rules for starting welding and is organized by
NED University Student of Final year material(BATCH 2006-07) ….During
their project .And this is Uploaded by one of the student of that batch ….
NAME: HUZAIFA
ROLL#: MM-047
Parameter 5

General Diameter x 1,500 = Average amperage for acceptable electrode life


Formula: (20-30 degree angle)
Example: .040" diameter x 1,500 = 60 amps maximum
Rule of Thumb: For a given amperage, larger diameters offer longer electrode life
but may be more difficult to arc start at low amperages.

1. Electrode Tip Geometry Selection

In AC welding, the electrode is typically balled up and used so there is no tip geometry to
prepare. Therefore, this section is dedicated to DC welding.

Welding should follow an equipment supplier's suggested procedures and dimensions


first, because they have usually performed a lot of qualifying and troubleshooting work to
optimize electrode preparation for their equipment. However, where these specifications
do not exist or the welder or engineer would like to change those settings to possibly
improve and optimize their welding, Pro-Fusion offers the following guidelines:

A. Electrode Taper - This is usually called out in degrees of included angle (usually
anywhere between 14 degrees and 60 degrees). Below is a summary chart that
illustrates how different tapers offer different arc shapes and features:

Sharper Electrodes Blunter Electrodes


Easy arc starting Usually harder to start the arc
Handle less amperage Handle more amperage
Wider arc shape Narrower arc shape
Good arc stability Potential for more arc wander
Less weld penetration Better weld penetration
Shorter electrode life Longer electrode life

In addition, to demonstrate graphically how the taper selection will effect the size
of the weld bead and the amount of penetration, below is a drawing that shows
typical representations of the arc shape and resultant weld profile for different
tapers.

These Parameter are the thumb rules for starting welding and is organized by
NED University Student of Final year material(BATCH 2006-07) ….During
their project .And this is Uploaded by one of the student of that batch ….
NAME: HUZAIFA
ROLL#: MM-047
Parameter 6

Rule of Thumb: Use 20-30 angles for up to 90 amps, average. Higher currents
can use larger included angles

The fusion zone profile will also depend on:

1. Electrode tip diameter (flat)


2. Arc Gap
3. Material to be welded
4. Shield gas used

B. Electrode Tip Diameter - Grinding an electrode to a point is sometimes desirable


for certain applications, especially where arc starting is difficult or short duration
welds on small parts are performed. However in most cases it is best for a welder
to leave a flat spot or tip diameter at the end of electrode. This reduces erosion at
the thin part of a point and reduces the concern that the tip may fall into the weld.
Larger and smaller tip diameters offer the following trade-offs:

Smaller Tip Larger Tip


Easier arc starting Usually harder to start the arc
Potential for more arc wander Good arc stability
Less weld penetration More weld penetration
Shorter electrode life More electrode life

General Amperage/4,000 = "Rule of Thumb" Flat Diameter


Formula:
These Parameter are the thumb rules for starting welding and is organized by
NED University Student of Final year material(BATCH 2006-07) ….During
their project .And this is Uploaded by one of the student of that batch ….
NAME: HUZAIFA
ROLL#: MM-047
Parameter 7

Example: 120 amps/4,000 = .030" "Rule of Thumb" Flat Diameter


Rule of Thumb: Use above calculation as a starting point for tip flat dimensions. As
with electrode angle/taper, smaller tip diameter (sharper electrode)
offers better arc starting an a more stable arc at low amperages.
Larger tip diameters offer longer electrode life.

Arc Length

The arc length (sometimes called the arc gap) is the distance from the electrode tip to the
part to be welded.This setting is dependent on weldcurrent, arc stability, and part
concentricity/ovality. The welding engineer'sobjective is to keep the electrode at a
constant distance from the part surface with a sufficient gap to avoid stubbing out.

As a "rule of thumb" use a base arc gap of 0.010" and add to this half the
penetration required (usually the tube wall thickness) expressed in thousandths of
an inch.

Example: Thus if the tube wall is .030" then a good starting arc gap would be 0.010" +
0.015" = .025". For a wall thickness/penetration requirement of .154" the arc gap would
be 0.010" + .070" = 0.080"

2. Welding Current

The welding current corresponds to the amount of heat applied to the part to effect the
weld, and it depends on the material to be welded, material thickness, welding speed, and
shield gas.The objective is the achieve defect-free welds with the required penetration.

As a starting point use 1 average current per 0.001" wall thickness if the material is
stainless steel. Thus for a 0.030" wall tubing the average weld current will be 30 amps in
the first level.

To compensate for heat buildup in circular parts during welding, a downslope at the end
of the weld or multiple levels of weld current can be used. If the weld current used to
initially penetrate
the parts were held at the same level for the complete weld, the weld penetration would
increase as the weld progressed around the part potentially producing too much
penetration.

These Parameter are the thumb rules for starting welding and is organized by
NED University Student of Final year material(BATCH 2006-07) ….During
their project .And this is Uploaded by one of the student of that batch ….
NAME: HUZAIFA
ROLL#: MM-047
Parameter 8

The number of levels of welding current needed depend greatly on the welding
application and the associated welding speed.

Weld Current Levels

Orbital welding normally uses multiple levels of weld current to compensate for heat
building up in the tube during the welding process. If the weld current used to initially
penetrate the tubing was held at the same level for the complete weld, the weld
penetration would increase as the weld progressed around the tube, producing too much
penetration.

Normally orbital welding uses a minimum of 4 levels of weld time with each level
decreasing in weld amperage

Starting parameters: Set weld level 4 to be at 80% of weld level 1 amperages. Set weld
level 2 and weld level 3 to gradually decrease the current from level 1 to level 4.

3. Arc Pulsing

Arc pulsing involves using the welding power supply to alternate the weld current rapidly
from a high (peak current) to a low (background current)value. This creates a seam of
overlapping spot welds. This technique reduces the overall heat input to the base material
and also can allow for increases in weld speed.

Arc pulsing brings many benefits to the welding procedure, often improving weld quality
and repeatability.In some cases, materials and weld joints with poor fit-up that are
difficult to weld successfully with a nonpulsed arc can be welded easily with a pulsed arc
technique. The results are improved weld quality and increased output.

Arc pulsing involves four welding parameters: peak current, background current, pulse
width (duty cycle), and pulse frequency. Many welders arrive at the same welding result
using somewhat different welding parameters. The primary objective is to use the
benefits of weld pulsation to improve weld quality and output.

o Peak/Background Current Ratios: The peak to background current ratios


basically provide a means for the welding current to pulse from one level to
another. Industry usage generally varies from 2:1 ratios to 5:1 ratios. A good
starting point is to use 3:1 ratios, make the required weld and test other
parameters to see if any benefit can be gained.
These Parameter are the thumb rules for starting welding and is organized by
NED University Student of Final year material(BATCH 2006-07) ….During
their project .And this is Uploaded by one of the student of that batch ….
NAME: HUZAIFA
ROLL#: MM-047
Parameter 9

o Pulse Frequency: The pulse frequency is dependent on spot overlap required.


Good starting parameters are to attempt for a 75% spot overlap. Pulse rate for thin
wall tube is often equal to the weld speed in ipm (5 ipm = 5 pps)

o Pulse Width: The pulse width (the percentage of time spent on the peak current)
is dependent on heat sensitivity of material and available current from power
supply. Higher heat sensitivity requires lower pulse width % on peak current.
Standard pulse widths are often 20% to 50%. A good starting parameters would
be to set a pulse width of 35%.

These Parameter are the thumb rules for starting welding and is organized by
NED University Student of Final year material(BATCH 2006-07) ….During
their project .And this is Uploaded by one of the student of that batch ….
NAME: HUZAIFA
ROLL#: MM-047
Parameter 10

Welding Parameter of 15CDV6 Tubes


Tube dia = 4.56" = 116.000 mm
Tube Wall Thickness = .062" = 1.600 mm

Arc Length/Gap

Arc Length/Gap = .010" + (0.5 x penetration req)


Starting Parameter: .010" + (0.5 x .062") = .041"

Welding Current

o Peak Current

As a starting point use 1 average current per 0.001" wall thickness

Starting Parameters:
Level 1 Peak Current = .062" wall thickness = 62 amps
Level 4 Peak Current = 62 amps x 80% = 50 amps
Level 2 Peak Current = 58 amps
Level 3 Peak Current = 54 amps

o Background Current

Background Current will be 1/3rd of peak current.


Back Ground Current = 1/3(62) = 20 amps

Note:Peak to Background Current ratio: 3:1 (Standard Pulse)

o Average Current

Average current = (Peak Current x Peak Pulse width) + (Background Current x Back
round Pulse Width)

Avg current = (62 x 0.35) + (20.68 x 0.65)


These Parameter are the thumb rules for starting welding and is organized by
NED University Student of Final year material(BATCH 2006-07) ….During
their project .And this is Uploaded by one of the student of that batch ….
NAME: HUZAIFA
ROLL#: MM-047
Parameter 11

= 35.15 amps
Pulse width

Pulse width/duty cycle is 35%

ie if
Frequency = 2 pulses / sec
Peak current = 0.175 sec
Base Current = 0.325 sec

Frequency = 4 pulses / sec


Peak current = 0.0875 sec
Base Current = 0.1625 sec

Weld Speed

Weld Speed = 5 ipm surface speed


RPM = ipm/(3.1415 x dia.)
Start Para: 5/(3.1415 x 4.56") = 0.349 RPM

These Parameter are the thumb rules for starting welding and is organized by
NED University Student of Final year material(BATCH 2006-07) ….During
their project .And this is Uploaded by one of the student of that batch ….
NAME: HUZAIFA
ROLL#: MM-047

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