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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:
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
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:
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 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.
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.
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
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.
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:
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
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.
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 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
Arc Length/Gap
Welding Current
o Peak Current
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
o Average Current
Average current = (Peak Current x Peak Pulse width) + (Background Current x Back
round Pulse Width)
= 35.15 amps
Pulse width
ie if
Frequency = 2 pulses / sec
Peak current = 0.175 sec
Base Current = 0.325 sec
Weld Speed
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