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Welding terms
MAGS
Metal Arc Gas Shielded (covers all shielding gases MIG & MAG)
MIG
Metal Inert Gas (covers totally inert gases e.g. Argon and/ or Helium)
MAG
Metal Active Gas (covers gas mixtures that are not totally inert e.g.
Argon + CO2, or Argon + Hydrogen or Argon + Oxygen etc)
Tungsten Arc Gas Shielded (covers all shielding gases TIG & TAG)
TIG
TAG
Tungsten Active Gas (covers gas mixtures that are not totally inert e.g.
Argon + Hydrogen or Nitrogen or Nitrogen + Argon etc)
GTAW
MAGS Welding
The MAGS welding process was first developed in 1948 for the purpose of welding
aluminium plates. This type of welding is a refinement of the TAGS process and uses a
consumable wire electrode, which replaces the fixed Tungsten electrode of the TAGS
process.
In 1953, the introduction of the constant potential type-welding machine opened up
brand new welding applications for the MAGS process.
The advent of the constant potential type welding machines was a significant
advancement for the MAGS process. For the first time the amperage could be
changed over wide ranges with very little change in the arc voltage. This led to the
development of wire feed equipment with constant speed drive motors. Instead of the
wire feed speed varying, as it had to do with the conventional type welding machines.
The constant potential welding machines make the amperage correction to maintain
the pre-set voltage. The power supply unit must be the constant potential type.
Units normally comprise of a D.C. generator or A.C. rectified transformer. The rectified
transformer is a device that permits current flow in one direction only. Its main function
is to change A.C. to D.C. It is usual with units to provide a voltmeter and ammeter for
voltage and amperage adjustment purposes, and voltage and wire feed controllers.
The volt and ammeters purpose is primarily to assist the operator in setting up the
correct welding conditions for the welding applications.
The voltmeter is read in different ways depending on the conditions. For example, the
voltmeter will read 'O' when the welder is energised but not being used. It will read
open circuit voltage (OCV) when the trigger is actuated but no arc struck. It will read
the 'load voltage' when the arc is initiated. The 'arc' voltage is only measured at the
arc.
This type of welding is a refinement of the TAGS process and uses a consumable wire
electrode, which replaces the fixed Tungsten electrode of the TAGS process. In the
MAGS process, the heat generated by an arc formed between the end of a
consumable filler wire and the workpiece is used to fuse the joint area. The filler wire is
fed continuously through a contact tube or tip. The arc is formed in an inert gas, which
prevents oxidation of the weld, assists in cleaning, and determines the heating
characteristics of the arc and the mode of transfer.
Wire Feeder
This may either be a push or a pull type or combined.
Push Type
In the push type, the mechanism consists of two or more feed rolls where the grip or
pressure can be adjusted. This method of feeding is used for base soft wire or a
diameter not less than 1.2mm and of not less than 0.6mm in the case of hard wires.
Pull Type
The pull type consists of a drive usually built into the handle of the welding gun. Feed
rolls pull wire off a small reel attached to the gun. In the combined method, push and
pull feed units are used. One is mounted near the electrode wire reel assembly, and
the other in the welding gun.
Spool On Gun
Welding Torch
For dip transfer and pulse transfer welding, the electrode holder normally has a curved
neck. It is known as a welding gun since it resembles the shape of an oxy-acetylene
welding nozzle and incorporates a button or lever-operated switch. Where a watercooled gun or gun is required, there is usually a mechanism that cuts off electrical
power should the water flow cease.
For free flight transfer welding (spray transfer) with flux-cored wires 1.2mm diameter or
larger, or where a pull feed unit is incorporated, the equipment is generally pistol
shaped, has a trigger type switch and is referred to as a welding gun. It can be water
cooled when required for use with currents in excess of 300/400 amps.
Contactor Control
All constant potential welding machines have built in primary contactors as standard
equipment. The function of the primary contractor is that of a switch. It blocks the flow
of current to the primary coil of the main welding transformer when in the 'open'
position. When the contactor coil is energised it 'closes' and completes the circuit in
the primary section of the welding machine. Something must trigger the primary
contactor so that its coil will energise and cause the contactor to close. This function is
performed when the trigger switch is actuated on the gun.
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11
12
13
Correct
Stubbing
Argon
Argon is a chemically inert gas that will not combine with the products of the weld zone.
Argon has a low thermal conductivity. The arc plasma is constricted with the result that
high arc densities are present. The high arc density permits more of the available
energy to go into the work as heat. The result is a relatively narrow bead width with
deep papillary penetration at the weld centre. Argon causes a more concentrated arc
than any of the other commonly used gases employed with the MAGS process. It is
this reason that argon has a reputation for cleaning the work area. Actually, it is the
concentration of the arc plasma, and therefore heat energy, that causes the refractory
oxides to be loosened. This phenomenon is particularly noticeable when welding
aluminium.
Argon is in abundant supply since it comprises almost 1% of the earth's atmosphere.
The gas is obtained as a by-product in the manufacture of oxygen.
Argon is used as the shielding gas when welding many types of metal. Its primary use
is in the welding of non-ferrous metals and alloys such as aluminium, magnesium,
alloys of the two, and copper. In some metals applications, argon does not provide the
penetration characteristics required for heavier weldments.
In these cases, argon-helium mixtures are sometimes used. This gas mixture will be
discussed under a separate heading.
14
Helium
Helium is also an inert gas and may be compared to argon in that respect. There the
similarity ends. It is lighter than air and has high thermal conductivity. The Helium arc
plasma will expand under heat (thermal ionization) reducing the arc density. With
Helium there is simultaneous change in arc voltage where the gradient of the arc length
is increased by the discharge of heat from the arc stream or core. This means that
more arc energy is lost in the arc itself, and is not transmitted to the work. The result is
that, with Helium there will be a broader weld bead with relatively shallower penetration
than with argon. This also accounts for the higher arc voltage, for the same arc length
that is obtained with helium as opposed to argon.
Helium is derived from natural gas. The process by which it is obtained is similar to
that of argon. First the natural gas is compressed and cooled. The hydrocarbons are
drawn off, then nitrogen, and finally the helium. This is a process of liquidifying the
various gases until at 253 0C the helium is produced.
Helium has sometimes been found in short supply due to governmental restrictions,
and therefore has not been used as much as it might have been for welding purposes.
Helium is used primarily for the non-ferrous metals such as aluminium, magnesium and
copper. It is also used in combination with other shielding gases.
15
Argon-Oxygen
Argon is an excellent shielding gas for the MAGS process because it allows the use of
spray type metal transfer. When depositing flat or horizontal fillet welds however, the
typical deep central penetration does not allow the weld metal to 'wet out' at the toes of
the weld. This is particularly noticeable when welding steel or stainless steel. These
phenomena will invariably cause undercut at the edges of the weld bead. The
tendency to undercut may be prevented by the addition of 1-5% oxygen to the argon.
The oxygen permits a controlled oxidation to take place, as well as increasing the
temperature of the molten metal transferred across the arc. The additional time at
16
liquidus allows the hot molten metal to 'wet out' at the toes of the weld. This action
produces a featheredge at the junction of the weld and parent metal.
Argon-oxygen mixtures are very common for welding stainless steels. They may be
used for low carbon and low alloy steels, but the cost is usually prohibitive. Argonoxygen shielding gases are usually purchased as pre-mixed gases.
Argon- CO2
For some applications of low carbon steel welding, welding grade CO 2 does not provide
the arc characteristics needed for the job. This will usually manifest itself where
surface appearance is a factor, in the form of intolerable spatter in the weld area. In
such cases a mixture of argon- CO2 has usually eliminated the problem. Some welding
authorities believe that the mixture should not exceed 25% CO2.
The reason for wanting to use as much CO2 as possible in mixture is primarily the cost.
By using a cylinder of each type of gas, argon and CO 2, the mixture percentages may
be varied by the use of flow meters. This method precludes the possibility of gas
separation such as may occur in pre-mixed cylinders. The price of CO 2 is 15% cheaper
that that of argon in most areas.
Argon CO2 shielding gas mixture are employed for welding low carbon steel, low alloy
steel and in some cases for stainless steel.
Argon-Helium- CO2
This mixture of shielding gases is used primarily for welding austenitic stainless steels.
The combination of gases provides a unique characteristic to the weld. It is possible to
make a weld with very little build up of the top bead profile. The result is excellent for
those applications where a high crowned weld is detrimental rather than help. This gas
mixture has found considerable use in the welding of stainless steel pipes.
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The shielding gas will also have a pronounced effect upon the following aspects of the
welding operation and the resultant weld:
Arc characteristics
Mode of metal transfer
Penetration and weld bead profile
Speed of welding
Undercutting tendency
Cleaning action
Industrial Gases
A new standard governing the colour coding of transportable gas cylinders is coming
into force across Europe. As a result many UK industrial gas cylinders will be repainted.
The aim of the new standard (EN 1089-3), which replaces the old colour scheme
(BS349), is to help improve safety standards within the gases industry.
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RED
Inert
BRIGHT GREEN
Oxygen
WHITE
Argon
DARK GREEN
Nitrogen
BLACK
Carbon Dioxide
GREY
Helium
BROWN
Acetylene
MAROON
In an emergency and when cylinder label is not clearly visible this will quickly help you
identify the main chemical hazard of the gas.
19
20
Pure Argon
Pure Helium
Argon + Helium
Argon + Oxygen
21
Spray Transfer
Flat position (butt)
Because of the high heat input and high welding speeds possible when using spray
arc, it is important to maintain adequate gas coverage to the solidifying weld area
trailing the gun. Forehand welding (most right handed welders move left to right with
the gun inclined towards the body is preferable and weaving is permitted allowing an
even further spread of shielding gas.
Horizontal/vertical fillet
Forehand welding is desirable for good gas cover and optimum weld shape.
Techniques
22
Dip Transfer
Vertical Down
Adequate gas cover is important - stick out length should be kept constant for an even
weld contour. By controlling stick out, poor 'fit up' can be tolerated by depositing a
much cooler weld. Vertical down is not recommended for heavier sections because of
the risk of cold lapping and lack of fusion particularly in the root run.
Vertical Up
Generally gives a convex weld contour and it is suggested that a slight weaving
technique be used, even on smaller passes. This weaving produces a weld of good
appearance.
Larger fillets require a triangular movement, with slight pauses at either side to
eliminate under cutting and to deposit enough metal at the edges to avoid a convex
bead shape. Illustrated are various joint configurations using dip transfer.
Overhead (thicker sections)
A circular movement can be used to flatten the weld face and lessen the risk of a
convex weld.
Horizontal butt joint Use forehand technique for good gas cover and use weaving as
shown.
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Techniques Applications
Low Carbon Steel
It has been estimated that approximately 80% of all welding performed today is on
some type of steel material. Probably 90% of the steel that is welded is classed as low
carbon or 'mild' steel. In the past few years, the MAGS process has successfully
competed for the right to be used in place of other processes for a good share of this
work. The reason is that it is faster, cleaner and does a better job. The MAGS process
has found applications in practically every type of industry where welding is done.
Spray Transfer
For spray transfer on steel, the shielding gas usually used is argon-oxygen mixtures
with a 5% oxygen content being the most popular. Spray transfer of steel, using solid
wire and argon-oxygen gas is not widely used due to the high cost of the shielding gas.
Argon- CO2 with up to 20% CO2 is now mainly used.
In any type of welding there are always failures. A weld failure can cause rework of the
part, and in some cases can actually cause scraping of the part. Since rework is
always expensive (sometimes it can cost more than the original weld!), it is to be
avoided whenever possible. Some of the items that cause rework are slag inclusions,
porosity, lack of penetration and lack of fusion. Of these the most common fault is
porosity.
Porosity is one of the recurring problems faced in welding any metal. There are
several general rules that will help to minimize porosity problems. The following data
are not intended to answer all the reasons that porosity occurs, but it will certainly help
to decrease the possibility of porosity if due notice is made of the suggestions.
Welding speeds that are too fast will cause either partial or complete loss of shielding
gas pattern in the arc area and will cause porosity.
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Current densities that are too high will often cause porosity due to excessive heat of
the molten metal from the electrode. In some cases alloying and deoxidising elements
have excessive burnout across this type of arc. It is probable that the electrode wire is
too small in diameter for the application and the next larger diameter should be used. If
the smaller wire size must be used then decrease the current value by decreasing wire
speed feed.
Shielding gases used with the MAGS process must be of the right type for the metal
being welded, and must have the right flow in litres per hour (LPH), or unsatisfactory
results will occur. Shielding gas flows are usually above 10 LPH but not more than 30
LPH. It is imperative that the shielding has to be clean and dry. Argon and helium
purities are approximately 99.99+%.
It is very important that the welding electrode be kept centred in the flow of shielding
gas. If the wire is off centre it can cause an erratic arc as well as porosity.
In all steel welding there is the possibility that a silicate residue will be left on the
surface of the weld bead. This is particularly true when welding steels that have a high
silicon content, or when the electrode has a substantial silicon content. The residue
appears as a glassy substance that is extremely hard. The silicate residue should be
removed during multi-pass welding or prior to painting or plating operations. It can
usually be removed by chipping or with a power wire brush.
Welding
Principles of Semi-Automatic Welding
Description of the Process
Semi-automatic MIG/MAGS welding consists of a D.C. arc burning between a thin bare
metal wire electrode and the work piece. The arc and weld zone are enveloped in a
protective gas shield. The wire electrode is fed automatically from a spool, through a
torch, which is connected to the positive terminal and is moved by hand.
The arc is self-adjusting. This means that any variation in the arc length made by the
welder produces a change in the burn off rate of the electrode and the arc rapidly reestablishes its original length.
Applications
This process is a development of TIG (tungsten-insert-gas) welding, but the tungsten
electrode replaced by a continuously fed wire and was first used only on aluminium
with argon as the shielding gas. The price of argon restricted its application until the
use of carbon dioxide (CO2) was successfully developed as a much cheaper shielding
gas for carbon steels. Semi-automatic welding is now employed on steels of all
thicknesses, aluminium, copper and many of their alloys, also nickel and stainless
steel.
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Safety precautions
The general safety precautions concerning metal are welding which appear in previous
notes are applicable to MIG welding. Good ventilation is essential with gas shielding
processes and overhead fume extractors may be ineffective where the heavier the air
gases, especially CO2, are employed. CO2 is heavier than air and will accumulate at a
low level in confined spaces, reducing the oxygen content and raising the danger of
suffocation.
Equipment
The basic equipment consists of: Power Source
A direct current unit is essential. This may be a motor generator, but for shop
use a rectifier is the normal unit. The design and capacity varies according to
the particular application.
Wire Feed Unit
The continuous wire electrode is fed to the arc by feed rolls connected to a
variable speed motor.
Torch or gun (Water or air cooled)
Connected to the wire feed unit by a flexible hose assembly through which pass
the wire electrode and shielding gas.
Shielding Gas
CO2 (carbon dioxide) for steels argon for aluminium and argon mixtures for
stainless steel and special applications.
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Electrical Conditions
Welding Current and Wire Feed Speed
Wire feed speed and amperage are generally set by the same control i.e. higher wire
speed means higher amperage and lower wire speed means amperage. An ammeter
is normally fitted to the power source.
Voltage
Open circuit voltages may be varied by stepped or stepless control and a voltmeter is
normally provided as standard equipment. Means are generally provided for reading
the arc voltage, i.e. by press button, switch or first pressure on the torch trigger.
Metal transfer
The various MIG welding techniques known as dip, spray, pulsed arc fall into
various ranges of application and are distinguishable mainly by the method of transfer
or type of wire.
Dip Transfer
Dip transfer, known also as short arc welding is carried out using currents below 200
amperes and voltages below 25 volts with a relatively small gauge electrode wire.
Under these conditions the arc is so short that the molten globules at the electrode tip
short circuit to the work piece at rapid, regular intervals. The rise in current during
short-circuiting melts off the electrode tip and allows re-establishment of the arc. This
cycle occurs at a frequency in the range of 100 times per second.
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Spray Transfer
In the higher current range of approximately 250-500 amperes and over 25 volts the
metal is transferred across the arc in small free flight droplets in the form of a fine
spray. Positional welding is not practicable due to the highly fluid state of the molten
pool, but aluminium is successfully welded in all positions by the spray transfer
technique.
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gas Metal
Transfer
Characteristics
All positions and
thicknesses.
All positions and
thicknesses. Used also
with flux cored wire
Totally inert. Completely
prevents oxidation of the
weld pool.
Pure CO2
Argon with 5% or
20% CO2 plus
2% Oxygen
Pure Argon
Aluminium and
alloys, copper and
alloys
Stainless steels
Austenitic stainless
steels
Low carbon and low
alloy steel
Or
Pure Helium
Argon with 1%
oxygen
Argon with 5%
oxygen
Argon with 2%
oxygen and 5%
CO2
Argon-HeliumCO2 mixtures
Argon with 2%
oxygen and 2 %
CO2
30
Arc voltage
The open circuit voltage setting should be the lowest that will give the required arc
voltage. Too high an arc voltage will give a tendency for the arc to be long with a
blobby transfer and excessive spatter. Too low an arc voltage may lead to stubbing of
the electrode wire into the weld pool or excessive penetration. These faulty effects are
more noticeable with dip transfer.
Welding current
Welding current is set with the wire feed control the calibrations of which vary from one
power source to another.
31
Edge Preparations
32
33
34
35
Inductance setting
When using dip transfer technique the effect of increasing inductance at any given open
circuit voltage setting is to produce a hotter arc giving quieter welding conditions with
less spatter and a smoother finish to the weld. Decreasing inductance has the opposite
effect; the arc is cooler with a more crackling sound and the weld surface has a more
pronounced ripple. Therefore high inductance is required on thick plate and low
inductance on very thin sheet.
Dip
Spray (steel)
Spray (aluminium)
Gas purging
The gas hose should be purged of air before use if the equipment has been left unused
for any length of time. This is achieved by allowing shielding gas to flow through the
hose assembly and nozzle for approximately 15 seconds, usually by a gas purge button
on the wire feed unit or by light pressure on the torch trigger.
Gas heater
Pure carbon dioxide is supplied in steel cylinders as a liquid under pressure, the liquid
occupying about two thirds of the capacity. Heat from the atmosphere raises the
liquefied gas to its boiling point and the gas formed above the liquid prevents further
boiling when a certain pressure is reached. Vaporization recommences when gas is
drawn from the cylinder. The moisture content of the gas rises as the cylinder is
emptied. To prevent this moisture being carried to the weld area and causing porosity
syphon type cylinders should be used.
Carbon dioxide tends to cause freezing up of the regulator as a result of the refrigeration
effect of the expansion into gaseous form. To prevent this freezing and to convert the
liquid to gas an electric heater-vaporizer is fitted between the regulator and cylinder.
The heater-vaporizer must always be switched on before starting to weld when using
carbon dioxide but is not necessary with argon.
3.25 mm to 6 mm
20 mm to 30 mm
30 mm to 44 mm
Burn Back
Burn backs are the result of some obstruction of the electrode wire either in the feed
hose or on the wire reel, which in turn causes fusion of the electrode wire to the contact
tip. No attempt should be made to clear the fault by operating the torch or gun; the
obstruction should be traced and cleared.
Welding Speed
Too fast a welding speed may cause spatter and undercut. There may also be a
tendency to porosity due to gas being trapped in the solidifying weld metal. Too slow a
welding speed will cause excessive penetration. Optimum speeds for various material
thicknesses and wire diameters will come instinctively with experience and increasing
skill.
Welding conditions
The following tables are intended only as a guide-
Low carbon steel, Dip transfer, Butt welds with Argon- CO2 shielding gas
Gas Pressure 30 1b/sq in (2.0 Bar)
Plate
thickness
(m/m)
1.0
1.6
3.0
6.0
10.0
Above
10.0
Edge
Preparatio
n
Square
edge,
no
root gap
Square
edge,
no
root gap
Square
edge, 1mm
root gap
60
single
vee, 1mm
root face &
1mm
root
gap
60
single
vee, 2mm
root face &
2mm
root
gap
60 double
vee, 2mm
root face &
2mm
root
gap
3.5-4.0
Gas
flow
1tr/min
12
Wire
size
(mm)
0.8
17-18
4.7-6.0
14
0.8
1.0
120-160
17-19
3.0-4.3
15
1.0
All
140-160
17-18
3.2-4.0
15
1.0
All
140-160
17-18
3.2-4.0
15
1.0
1.2
or
All
140-160
17-18
3.2-4.0
15
1.0
1.2
or
Positio
n
Current
(amps)
Arc
Volts
All
45-65
14-15
All
130-160
All
Wire feed
(m/min)
or
Low carbon steel, Dip transfer; Fillet welds with Argon- CO2 shielding gas
Gas Pressure 30 1b/sq in (2.0 Bar)
Plate
thickness
(m/m)
1.0
Position
Current
(amps)
Flat
& 45-65
horizontal
/ vertical
1.6
Flat
& 130-160
horizontal
/ vertical
3.0
Flat
& 120-160
horizontal
/ vertical
6.0
Flat
& 250-270
horizontal
/ vertical
10.0
Flat
& 270-310
horizontal
/ vertical
Inductance adjusted as necessary
14-15
Wire
feed
(m/min)
3.5-4.0
12
17-18
4.7-6.0
14
0.8 or
1.0
17-19
3.0-4.3
15
0.8 or
1.0
26-27
6.6-7.3
16
26-28
7.0-7.8
16
1.0
or
1.2
1.0
or
1.2
Arc
Volts
Gas flow
(1tr/min)
Wire
size
(mm)
0.8
Aluminium Butt welds, flat position with Pure Argon shielding gas.
Metal
thickness
(mm)
Wire
Dia
(mm)
1.6
3.0
1.0
1.2
70-100
105-120
17-18
17-20
4.0-6.0
5.0-7.0
Gas
flow
(1ltr/
min)
14
14`
6.0
1.2
120-140
20-24
6.5-8.5
14
Overhead
&
vertical up
6.0
10.0
1.2
1.2
160-200
120-140
27-30
20-24
8.0-10.0
6.5-8.5
14
16
Flat fillet
Overhead
&
vertical up
10.0
Above
10.0
1.6
1.6
240-300
130-200
29-32
20-26
7.0-9.0
6.5-8.0
16
18
Flat fillet
Overhead
&
vertical up
Above
1.6
300-500
10.0
No inductance required
32-40
9.0-14.0
18
Flat fillet
Current
(amps)
Arc
Volts
Wire
feed
(m/min)
Welding
position
All
All
Edge
preparation
Square edge
Square edge,
root
gap
1mm, no root
face
60 single vee,
root
gap
2mm,
root
face 2mm
No gap
60 single vee,
root
gap
2mm,
root
face 2mm
No gap
60
double
vee, root gap
2mm,
root
face 2mm
No gap
Fault Finding
Weld Defect
Scattered Porosity
Cause
Torch at wrong starting
Angle.
Remedy
Correct the angle
Remove slag
Windy conditions
blowing away shielding gas
No shielding gas
Too
much
turbulence
gas
Over-penetration in
root
Increase voltage
Heavy deposition
Torch angle
Stainless Steels
Stainless Steel is a name given to a group of Steel Alloys with many differences in
properties and behaviour having one property in common resistance to corrosion.
When an Alloy of Steel contains more than approximately 10% Chromium it can be
classed as a Stainless Steel. This is due to the fact that Chromium has a high affinity for
Oxygen and forms a tenacious, stable Oxide film which is resistant to further chemical or
physical change. This film, known as the passive film, forms practically instantaneously
in ordinary atmospheres and has the remarkable property of being self-healing and
rebuilding when it has been removed.
This large group of Stainless Steels can be divided into four major groups, namely
Austenitic, Ferritic, Martensitic and Duplex.
Martensitic
This group contains a minimum of 12% Chrome and usually a maximum of 14% with
Carbon 0. 08%-2.00%. Due to the high Carbon content of the Steel it is heat treatable.
Types include 410, 416 and 431. Martensitic steels are magnetic.
Ferritic
Contains a minimum of 17% Chrome and Carbon 0.08%-0.20%. The Ease in Chromium
imparts increased resistance to corrosion at elevated temperatures, but the lack of
mechanical properties due to the fact that it cannot be heated treated, limits its
applications. Like Martensitic steels they are magnetic and the welding of this group
should be carried out with the necessary precautions. 430 is the most common type of
Martensitic Stainless Steel.
Austenitic
Contains Chromium normally in the range 17-25% and Nickel in a range with various
additional elements. In the fully annealed they exhibit a useful range of mechanical and
physical properties. The mechanical properties can be increased with cold working.
Welding of this group must be carried out with the correct methods but the low Carbon
content results in fewer welding problems than with the Ferritic and Martensitic grades.
Normally these steels are non-magnetic. The most commonly used Austenitic Stainless
Steel was the 302 grade or 18/8 st/st (18% chromium, 8% nickel). The nearest available
equivalent is now the 304 grade. Note that NIOBIUM is added to st/st electrodes in order
to prevent weld decay.
Type 304
An economic balance of alloying elements ensures good formability, corrosion
resistance, toughness and mechanical properties. Its corrosion resistance in unpolluted
atmospheres and freshwater environments is excellent but some attack may occur in
coastal/marine locations and damp industrial atmospheres. Not recommended for use in
seawater environments.
Type 304L
A low carbon form of 304 with 0.030-0.035% carbon maximum, designed primarily to
avoid intercrystalline corrosion after welding. The tensile strength is somewhat lower
than type 304.
Type 321
A variation of 304 with titanium added in proportion to the carbon content to avoid
intercrystalline corrosion and improve high temperature properties. Corrosion resistance
is similar to 304. Not recommended for bright or mirror polishing.
Type 347
Very similar to 321 but uses Niobium (Columbium) as the stabilising element instead of
Titanium.
Type 316
The addition of 2-3% Moybdenum in this grade confers increased corrosion resistance in
industrial and coastal environments, together with improved elevated temperature
properties. The resistance to pitting when actually immersed in cold seawater is limited.
A higher nickel content of 1 2% is used to maintain an austenitic structure.
Type 316L
Similar to 316 but with a lower carbon content of 0. 030-0.035% maximum to avoid
intercrystalline corrosion after welding.
Type 317
Similar to 31 6 but the 3-4% Moybdenum content gives adequate pitting resistance in
cold seawater. Crevice corrosion can still occur and designs for seawater use should
take this into account.
UNS S31254
Often known simply as 6 MoIy, this is a super-austenitic steel in which the high levels
of Chromium, Molybdenum and Nitrogen give high resistance to seawater attack.
L Grades
With the exception of the stabilised varieties, most of the above grades can be obtained
as low carbon or L versions, e.g. 304L. The carbon is usually restricted to a max. of
0.030 or 0.035% to avoid the risk of intercrystalline corrosion after welding and/or slow
cooling. The tensile strength is somewhat lower then the standard grades.
H Grades
The late 1950s saw the development of the first H Grade, 321H, which had a specified
20000F minimum heat treatment and a restricted carbon content of 0.04-0.10%, to
improve creep resistance at elevated temperatures.
N Grades
Several grades may have controlled high Nitrogen contents, e.g. 316N. Nitrogen is
usually restricted to the range 0.08-0. 1 5% and gives higher tensile strengths than the
standard grades. Resistance to pitting corrosion is improved.
Duplex
This group has a balance of Chromium, Nickel, Molybdenum and Nitrogen to give
a near equal mix of austenite and ferrite. They combine high strength with
excellent corrosion resistance. Tensile and yield.
Strengths are approximately double those of a straight austenitic steel and resistance to
stress-corrosion cracking in chloride solutions is superior to Type 316.
UNS S31803
This is the most widely used of the duplex steels and typifies the standard description
above. The nominal composition is 0.03% max. C, 22% Cr, 5.5% Ni, 3.0% Mo and 0.1
5% N.
UNS 532304
A low alloy duplex containing 0.03% max. C, 23% Cr, 4% Ni and 0. 1 % N. It has similar
or slightly superior corrosion resistance to Type 31 6 in most acid environments, but with
approximately double the tensile properties. Its primary use is as a structural stainless
steel where mechanical strength is important.
UNS S32750
A super-duplex containing 0.03% max. C, 25% Cr, 7% Ni, 4% Mo and 0.28% N. The
higher alloy content of this steel gives enhanced corrosion resistance in the same class
as the super-austenitics and nickel base alloys but with much higher mechanical
properties.
A flammable gas
An active gas
A reducing gas
A totally inert gas
4. MAGS welding is a: a)
b)
c)
d)
2m
8m
6m
4m
Pure nitrogen
Pure argon
Carbon dioxide
An argon / carbon dioxide mix (5 or 20% CO2)
10. Which one of the following elements is added to filler wire as a deoxident: a)
b)
c)
d)
Carbon
Silicon
Helium
Hydrogen
Steel
Chromium
A copper alloy
Plastic
12. When producing welds on low carbon steel using the MAGS process one
purpose of the inductance control is to reduce: a)
b)
c)
d)
Porosity
Penetration
Undercut
Spatter
13. Which gas can be added to argon in order to improve the weldability or fluidity
on stainless steel: a)
b)
c)
d)
Carbon dioxide
Helium
Oxygen
Nitrogen
14. A lack of shielding gas coverage would cause which of the following defects
a)
b)
c)
d)
Oxidisation
Penetration
Excess reinforcement
Lack of one side wall fusion
15. Dip transfer is most suitable for welding in the flat position: a)
b)
c)
d)
Thick plate
Sheet metal
Aluminium
Galvanised steel
Metal transfer
Stabilising the arc to produce less spatter
Explaining how the equipment works to new learners
Stopping porosity
18. If the drive rolls on a wire feed unit are fastened too tight, which of the
following faults could result?
a)
b)
c)
d)
20. Vessels that have contained flammable materials, prior to welding, should be
a)
b)
c)
d)
Flame cleaned
Steam cleaned and then checked with an explosimeter
Welded from a distance
Thoroughly washed out with hot water and allowed to stand in the open air for
one hour
21. The welding lead that forms the circuit during M.A.G.S welding is connected to
the:
a)
b)
c)
d)
22. A suitable grade of filter lens for MAGS welding with a current of 120 amps
would be: a)
b)
c)
d)
E.W. 11
E.W. 14
G.W.12
E.W. 8
23. Output voltages for most MAGS welding sets are more likely to be used in the
range of: a)
b)
c)
d)
10-12 volts
14-50 volts
50-110 volts
110-200 volts
24. Which of the following modes of transfer relies totally on semi-short circuiting:
a)
b)
c)
d)
Pulsed
Globular
Dip
Spray
Nitrogen
Oxygen
Carbon dioxide
Hydrogen
26. Which of the following standards covers wire electrodes and deposits for gas
shielded metal arc welding of non-alloy and fine grained steels: a)
b)
c)
d)
BS EN 4872
BS EN 287
BS EN 288
BS EN 440
27. What should be removed in order to ensure a good electrical contact when
making welding repairs to steel gates?
a)
b)
c)
d)
The nuts and bolts that would form part of the welding circuit
Paint and rust
The handles
The hinges
28. The secondary lead connecting the work to the power source unit is called the
welding:
a)
b)
c)
d)
Earth
Mains
Return
Output
29. The glass tube situated adjacent to the regulator on MAGS unit is a
a)
b)
c)
d)
Contents gauge
Heater unit
Filter unit
Flowmeter
30. When using liquid CO for the MAGS welding process, which of the following
should be connected to the cylinder?
a)
b)
c)
d)
A filter
A heater
A cooler
An explosimeter
31. A cylinder painted black with a grey shoulder and a vertical white line
contains: a)
b)
c)
d)
Oxygen gas
CO2 gas
CO2 liquid
Argon gas
32. The gas supplied in the blue cylinders with a light green shoulder contains a
mixture of argon and: a)
b)
c)
d)
Oxygen
Helium
Hydrogen
CO2
33. The filler wire used in MAGS welding is fed in to the weld pool from a: a)
b)
c)
d)
Spool
Heater
Regulator
Solenoid
34. The slope angel of MAGS gun when making a bead in the flat position should
be: a)
b)
c)
d)
30 to 40 deg
40 to 50 deg
50 to 60 deg
75 to 85 deg
35. Which of the following ancillary items of equipment would be most useful for
using the MAGS welding process?
a)
b)
c)
d)
A spark lighter
A powered flux
A pair of cutters
A pair of welding goggles
37. The type of edge preparation most suited for use with MAGS welding of low
carbon steel plate 20 mm thick is:
a)
b)
c)
d)
38. Which one of the following 15 mm thick joints would require the minimum
number of runs for the economy of materials and labour?
a)
b)
c)
d)
39. A double vee preparation would be the most suitable when MAGS welding
plate of thickness
a)
b)
c)
d)
3 mm
6 mm
10 mm
20 mm
40. The best technique for joint surface cleaning to remove oil would be
a)
b)
c)
d)
Grinding
Wire wool cleaning
Degreasing
Wire brushing
Edge preparation
Fit up
Root face
Material cleaning
42. A small amount of the weld metal deposited during MAGS welding maybe lost
through
a)
b)
c)
d)
Spatter
Faster welding speeds
Poor joint preparation
Low quality plate
43. Which of the following components would be found within the MAGS welding
system:
a)
b)
c)
d)
Tungsten electrode
High Frequency Unit
A DC constant potential type power source
Oxygen cylinder
44. Which one of the following materials produces a high melting point protective
oxide layer on its surface:
a)
b)
c)
d)
45. Which of the following MAGS wires would be most suitable for a pull type
system of wire feed:
a)
b)
c)
d)
MIG only
MIG and TIG
MMA and MIG
MMA and TIG
48. The term MIG welding could be used when welding with the shielding
gas(es)
a)
b)
c)
d)
pure Argon
Argon plus Carbon Dioxide
Helium plus Carbon Dioxide
Pure Hydrogen
49. The term MAG welding could be used when welding with the shielding
gas(es)
a)
b)
c)
d)
pure Argon
pure Helium
Argon plus Helium
Argon plus Carbon Dioxide
Brown
Black
Green
Red
Brown
Black
Green
Red
52. Which shielding gas(es) can be used when MIG welding aluminium?
a)
b)
c)
d)
Argon or Helium
Argon or Hydrogen
Nitrogen
Helium and Hydrogen
56. When working in confined spaces there is a greater risk of asphyxiation when
using the shielding gas:
a)
b)
c)
d)
Nitrogen
Helium
Hydrogen
Argon
58. A rectifier
a)
b)
c)
d)
changes DC to AC
changes DC positive to DC negative
changes AC to DC
steps down the voltage
59. Unequal leg lengths of a tee fillet welded in the horizontal/vertical position is
most likely to be caused by:
a)
b)
c)
d)
61. Which one of the following may be regarded as a hazard when carrying out a
risk assessment on mechanical lifting equipment?
a)
b)
c)
d)
Maintenance schedule.
Operator training.
Defined gangways.
Warning signs.
63. The Manual Handling Operations Regulations (1992) are concerned with
a)
b)
c)
d)
65. What is the maximum safe voltage for mains operated portable electrical tools
on site?
a)
b)
c)
d)
12 volts
420 volts
230 volts
110 volts
66. The COSHH regulations are MAINLY involved with the protection of the
a) environment
b) workplace
c) person
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ASSESSORS NAME _________________________
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RESULT ______ %
DATE _______
ANSWERS
ANSWER SHEET: MIG/MAGS Welding
a
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a
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