COMIMSA Module 3

1. Introduction

In addition to weldability, the factors that influence the selection of a

welding process are:

1) Dimensions of the material being welded, especially its thickness,

shape, and form

2) Position in which welding must be done

3) Requirements for the weld root

4) Back side accessibility

5) Joint preparation

6) Availability of welding equipment, power sources, and fixtures.

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The processes discussed here can be divided in three basic groups:

Welding
Brazing
And cutting

The Welding Inspector should have some Knowledge of:

Important features
Processes advantages
Limitations
Equipment requirements
Electrodes/filler metals
Techniques
Applications, and possible process problems
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1. Introduction

Welding is a coalescence of metals or nonmetals produced either by

heating the materials to the welding temperture, with or without

application of pressure, or by the application of pressure alone and with

or without addition of filler metal.

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1. Introduction

WI must be know for the AWS CWI examination the following processes:

SMAW Shielded Metal Arc Welding

GMAW Gas Metal Arc Welding

FCAW Flux Cored Arc Welding

GTAW Gas Tungsten Arc Welding

PAW Plasma Arc Welding

SAW Submerged Arc Welding

ESW Electroslag Welding
Oxyacetylene Welding Figure 3.1
OAW
SW Stud Welding
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2. Shielded Metal Arc Welding (SMAW)

SMAW uses the heat of an electric arc between a covered metal

electrode and the work. Shielding comes from the decomposition of the

electrode flux coating. Filler metal is supplied by the electrode core wire

and covering.
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2. Shielded Metal Arc Welding (SMAW)

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2. Shielded Metal Arc Welding (SMAW)

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2. Shielded Metal Arc Welding (SMAW)

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2. Shielded Metal Arc Welding (SMAW)

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2. Shielded Metal Arc Welding (SMAW)

The electrode coating provides the following:

1) Arc stabilization from ionizing elements (witch dictate the usability of

the electrode on ac, dcep, or dcen)

2) Gas shielding for the weld puddle

3) Slagging agents contained in the coating that remove impurities

4) Deoxidizers contained in the coating that reduce the tendency for

porosity in the weld

5) An insulating blanket

6) Alloy elements

7) Increased weld metal depositation, when iron powder is

incorporated in the coating
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2. Shielded Metal Arc Welding (SMAW)

Advantages:

1) Equipment is relatively simple and inexpensive

2) Is portable

3) Availability o numerous electrodes makes the process quite versatile.

Disadvantages:

1) The process is relatively slow

2) The slag must be removed

3) Low hydrogen electrodes require special storage.

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2. Shielded Metal Arc Welding (SMAW)

Discontinuities

Almost any discontinuity can be produced by the SMAW process, if

not applied properly.

1) Porosity

2) Slag inclusions

3) Incomplete fusion

4) Incomplete joint penetration

5) Undercut
Improper manipulation of electrode
6) Overlap

7) Incorrect weld size

8) Improper weld profile.

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3. Gas Metal Arc Welding (GMAW)

GMAW uses the heat of an

electric arc between a
continuous bare wire filler
metal electrode and the work.
Shielding is obtained entirely
from externally supplied inert
gas such as argon or helium,
an active gas such as CO2 or
O2 or some combination
thereof.
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3. Gas Metal Arc Welding (GMAW)

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3. Gas Metal Arc Welding (GMAW)

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3. Gas Metal Arc Welding (GMAW)

The GMAW deposits the weld metal in the joint by one of the following

modes:

Transfer Current and Voltage Gas de proteccin Observations

Spray Low Least 75-80 % Ar Flat and Horizontal

Globular Low CO2

Spatter

Short Circuiting Current continuous CO2 The wire contacts the

work piece
Pulsed Low Ar-CO2 Pulse adjusted high
current and voltage
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3. Gas Metal Arc Welding (GMAW)

Figure 3.11 GMAW Electrode Identification System

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3. Gas Metal Arc Welding (GMAW)

Advantages:
1) Used to join or overlay many types ferrous and nonferrous metals
2) Gas shielding instead of a flux
3) Reduce the possibility of hydrogen induced
4) No slag are moved after welding
5) Automatic and robotic using or high production
6) High productivity

Disadvantages:

1) Excessive contamination of the base metal may cause porosity

2) Drafts or wind may disperse shielding gases
3) Complex equipment
4) Short-circuiting transfer can lead to lack of fusion
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3. Gas Metal Arc Welding (GMAW)

Discontinuities:

1) Any of the common weld discontinuities, except slag inclusion.

2) Porosity

3) Incomplete fusion

4) Overlap

5) Undercut
Poor technique by welder
6) Underfill
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4. Flux Cored Arc Welding (FCAW)

FCAW uses the heat of an electric arc between a continuous filler metal

electrode and the work, which is similar to GMAW, except that in FCAW

the electrode is tubular and contains a granular flux instead of the solid

wire of GMAW.
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4. Flux Cored Arc Welding (FCAW)

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4. Flux Cored Arc Welding (FCAW)

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4. Flux Cored Arc Welding (FCAW)

The FCAW electrode contains flux, deoxidizers, and alloy elements.

Self-shielded electrodes require no external gas protection.

If external shielding is provided the choice is usually, CO2 or a mix 75%

Ar- 25% CO2.

Electrical stickout is an important variable when using self-shielded cored.

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4. Flux Cored Arc Welding (FCAW)

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4. Flux Cored Arc Welding (FCAW)

Advantages:
1) Due to increased depositation rates and high tolerance for
contamination, FCAW has replaced SMAW and GMAW in many
applications.
2) Can be use in shop or field
3) High productivity
4) Aggressive deeply penetrating arc.
5) Can be used in all position

Disadvantages:
1) Remove slag
2) Generates a significant amount of fumes, which reduce a welder
visibility
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4. Flux Cored Arc Welding (FCAW)

Discontinuities:

1) Slag entrapment
Poor technique by welder

2) Porosity
Inadequate shielding
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5. Gas Tungsten Arc Welding (GTAW)

GTAW uses an electric arc between a nonconsumable electrode and the

work. Shielding is obtained from an inert gas or inert gas mixture. Filler

metal can be added as needed. The torch is usually water cooled, but

can be air cooled for low-current applications. Fig. 10.15.

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5. Gas Tungsten Arc Welding (GTAW)

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5. Gas Tungsten Arc Welding (GTAW)

Can be, manual, mechanized, or automatic methods.

When filler metal is added, the process calls for a two handed
technique.

Slow heating and low temperatures combined with the slow cooling rates,

that are characteristic of GTAW result in improved weld metal and HAZ

mechanical properties

With exception of aluminum, which is normally welded using ac, most of

the GTAW is done using DCEN.

The classification for filler wire for GTAW operations is the same as that
for the GMAW process.
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5. Gas Tungsten Arc Welding (GTAW)

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5. Gas Tungsten Arc Welding (GTAW)

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5. Gas Tungsten Arc Welding (GTAW)

Advantages:

1) The GTAW is capable of welding virtually all metals, even extremely

thin materials.

2) High quality welds excellent visual appearance

3) Process clean, no slag removed

Disadvantages:

1) The skill level necessary

2) Low tolerance for contamination,

3) Is the slowest of available welding process.

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5. Gas Tungsten Arc Welding (GTAW)

Discontinuities:

1) Any of the common weld discontinuities, except slag inclusions.

2) Tungsten inclusions
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Sumerged Arc Welding (SAW)

SAW uses the heat of an electric arc or arcs between the electrode or

electrodes and the work, all shielded by a blanket of granular flux.

Semiautomatic,

Mechanized

Automatic
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Sumerged Arc Welding (SAW)

Electrode feed and arc length are controlled by the wire feeder and

power supply.

The arc is hidden in submerged arc welding.

For machine or automatic welding , the path is prealigned.

Shop dirt, grease or moisture can contaminate the flux.

Some fluxes require heated storage containers and hoppers

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Sumerged Arc Welding (SAW)

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Sumerged Arc Welding (SAW)

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Sumerged Arc Welding (SAW)

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Sumerged Arc Welding (SAW)

Advantages:

1) Can be performed on numerous metals.

2) High rate of weld metal depositation

3) Operator has no need for a filter lens

4) Less smoke generated

5) Has very deep penetrating capabilities

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7. Sumerged Arc Welding (SAW)

Disadvantages:

1) Cleaning the work surfaces and aligning the machine travel are very
important

2) The flux low hydrogen require storage in heated oven.

3) Extreme width to deep ratio, that can lead to centerline cracking

Improper alignment will result:

4) In offset beads with incomplete joint penetration

5) High restraint joint, cracks.

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Sumerged Arc Welding (SAW)

Discontinuities:

Welds may exhibit all of the common discontinuities

1) Undercut

2) Cracks

3) Incomplete fusion
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Sumerged Arc Welding (SAW)

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Plasma Arc Welding (PAW)

PAW is a process which utilizes a constricted arc between the electrode

and workpiece (transferred arc) or the electrode and the constricting

nozzle (nontransferred arc). In many respects, this process is quite

similar to GTAW; however, the constricted arc provides a much more

localized heat source.

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Plasma Arc Welding (PAW)

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6. Plasma Arc Welding (PAW)

Shielding for this process is obtained from the hot, ionized gas issuing

from the torch, which may be supplemented by an auxiliary source of

shielding gas. This shielding gas may be inert gas or a mixture of gases.

There is no pressure utilized and filler metal may or may not be required
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6. Plasma Arc Welding (PAW)

Like the GTAW, PAW uses a tungsten electrode, but the electrode is

recessed into the torch. The constricted arc produces a more localized

heat source that results in the ability to weld materials at higher travel

speeds than those obtainable with GTAW. This tends to reduce the heat

input, resulting in faster HAZ cooling rates.

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6. Plasma Arc Welding (PAW)

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Plasma Arc Welding (PAW)

Fig. 3.30 Plasma Arc Welding Equipment, Including Control Console

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6. Plasma Arc Welding (PAW)

Advantages:

1) Process easier to control manually

2) Faster process, tend to the amount of distortion

3) High quality weld

Disadvantages:

1) Is limited to materials 1 in. thick or less.

2) The use of PAW may require greater operator skill due to more
complex equipment.

3) Low tolerance for contamination,

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6. Plasma Arc Welding (PAW)

Discontinuities:

1) Same that GTAW

2) Cooper inclusion

3) Incomplete Fusion

4) Tunneling
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8. Electroslag Welding (ESW)

ESW uses an electrically melted metallurgical flux that melts the filler

metal and the surfaces of the work. The heat is created by the electrical

resistance of the flux. There is not arc, except at the start of the weld

before the granular flux melts and becomes conductive. The slag is then

kept molten by its resistance to the flow of electric current passing

between the electrode and the work.

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8. Electroslag Welding (ESW)

Mechanized

Automatic

Welding is done in the flat position

Water-cooled, backing shoes in contact with the joint sides contain

the molten weld metal and the molten flux

The slag refines the fused base metal and the filler metal
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8. Electroslag Welding (ESW)

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8. Electroslag Welding (ESW)

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8. Electroslag Welding (ESW)

Advantages:

1) High depositation rate.

2) Use multiple electrodes

3) No require special preparation

4) There is no tendency for angular distortion

Disadvantages:

1) Extensive time to set up

2) Only thicker sections can be economically joined

3) Faces of the joint must be aligned

4) The plate edge must be smooth

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9. Oxyacetylene Welding (OAW)

OAW is a chemical welding process which relies on the chemical reaction

between the oxyacetylene flame and the base metal to produce the

necessary heat for melting the base and filler metal

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Stud weld (SW)

Stud welding is a two-step process used to join attachments to metal

surfaces. A stud gun holds the tip of the stud against the workpiece. Fig

10.27. a timer in the control circuit then cut off the current, and the stud-

holding mechanism in the gun plunges the stud into the molten pool to

make a weld.
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Stud weld (SW)

Advantages:

Is an economical and effective method for welding attachment to a

surface

Disadvantages:

The welding operator must correctly adjust the stud arc equipment.

Defective gun action, improper current levels and arc blow may result in

incomplete fusion or undercut

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Laser beam Welding (LBW)

Is a fusion joining process that produces coalescence of materials with the

heat obtained from a concentrated beam of coherent, monochromatic light

impinging on the joint to be welded

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Laser beam Welding (LBW)

Major advantages of laser beam welding include the following:

Less grain growth in HAZ and less workpiece distortion
High depth-to-width rations
Single pass laser welds have been made in materiales up to 1-1/4
thick
Can be focused on a small area
A wide variety of materials can be welded, including disimilars
The laser beam is not influenced by the prescence of magnetic
fields
No vaccum or X-ray shielding is required, as in EBW
The beam can be transmitted to more than one work station using
beam switching optics
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Laser beam Welding (LBW)

Major advantages of laser beam welding include the following:

Joints must be accurately positioned under the beam

Square groove butt joints are required

Workpieces must often be forcer together

The high reflectivity and thermal conductivity of some materials (aluminum,

cooper) can affect

The fast cooling rates can produce cracking and embrittlement in the HAZ and

can trap porosity in the weld metal.

With higher power lasers, aplume of vavor is often produced above the weld

joint, wich interferes with ability of the laser to reach the joint

Equipment is expensive
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Electron Beam Welding (EBW)

EBW is a fusion joining process that produces coalescence of

materials with heat obtained by impinging a beam of high energy

electrons onto the joint to be welded.

electrons are generated by heating a negatively charged emmitung

cathode or filament to its thermionic emmision temperature range, thus

causing electrons to boil off and be attracted to the positively charged

anode.
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Electron Beam Welding (EBW)

EBW produces even higher power densities than laser beam

An electron beam can be readly moved by electromagnetic deflection. In

most instances, is used to adjust the beam-to-joint alignment.

This deflection modifies the average power density into joint, and results

in a change in the weld bead shape.

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The following are advantages of Electron beam welding:

Less grain growth in HAZ and less workpiece distortion

High depth-to-width rations
Single pass laser welds have been made in materiales up to 4 in thick
Can be focused on a small area
A wide variety of materials can be welded, including disimilars
The laser beam is not influenced by the prescence of magnetic fields
No vaccum or X-ray shielding is required, as in EBW
The beam can be transmitted to more than one work station using
beam switching optics
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Brazing (B)

Is a group of joining process that produce coalescence of materials by

heating, a filler metal having a melting point above 840F and below the

melting point of the base metal.

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Brazing (B)
A major diference between the various brazing methods is the manner n
which the heat is applied:

Torch brazing (TB)

Furnace brazing (FB)

Induction brazing (IB)

Resistance brazing (RB)

Dip brazing (DB)

Infrared brazing (IRB)

Difusion brazing (DFB)

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Cutting Processes

Thermal and mechanical

Thermal cutting is standard method for:

Preparing base metal joints, repair, and backgouging

Kerf Is defined as the area cut a width

Metal is removed by combustion (oxidation) in oxifuel gas cutting, by

simple melting in the plasma jet, or by arc melting in a blast of air.

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Cutting Processes

Oxifuel cutting (OFC)

Air Carbon Arc Cutting (CAC-A)

Plasma Arc Cutting (PAC)

Mechanical cutting
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