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B.Tech. Semester- VI (Institute Elective), January 2013 2EE002: ELECTRICAL POWER UTILIZATION AND SAFETY HANDOUT on Electric Welding
INTRODUCTION
Electric welding is defined as that branch of welding in which electric current is used to produce the large heat required for joining together into firm union two pieces of metal. Electrically welded joints are being used to replace riveted bolted joints in the construction of ships, bridges steel frames, structures, tanks, pipe lines and for so many other purposes. In electric welding heat is produced either by striking an arc between an electrode and the metallic joint or by passing a heavy current through the joint. The former method is called Arc Welding and the later Resistance Welding.
Welding Accessories:
1. One electrode holder, fitted with a length of flexible cable for current to plant. 2. One length of flexible cable, for connecting the job to the plant. 3. One face screen complete with colored glasses. 4. Observers face screen with colored lasses. 5. One pair of leather gloves. 6. One chipping hammer to remove slag from weld. 7. One wire brush to clean the weld after chipping. ARC WELDING WITH DC AND AC The advantages of arc welding with dc lie in the higher arc stability and the degree to which the work is heated. It is best suited for thinner sheet metal and also for welding non-ferrous metals. Ac welding due to the absence of arc blow is considered superior for production welding involving large size electrodes. Ac welding has a number of economic advantages such as given below: 1) As power supply in factories is usually ac so a rotating dc generator or a rectifier is required for dc welding whilst for ac welding only transformer is required which is relatively cheaper in initial cost. 2) Maintenance of a transformer is less difficult and expensive than that of a dc generator. 3) Operating cost of ac equipment arc also lower than those of dc equipment.
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Advantages of short Arc 1. 2. 3. 4. 5. 6. Maximum penetration Slight overlap Maximum strength of weld Minimum porosity in the weld Maximum ductility in the weld Makes it possible to use alloy electrodes
Disadvantages of long Arc 1. 2. 3. 4. 5. 6. Minimum penetration Excessive overlap Minimum Strength Minimum Ductility Maximum Porosity Uncontrolled Deposit
Advantages of Resistance welding 1. 2. 3. 4. It is a quick method of joining two pieces. There is very little wastage of the metal. The process can be accurately controlled. The welds are consistently uniform.
1. Standard Method for D.C. Generators The Standard method of obtaining drooping characteristics from a D.C. Generator is based on reversed series winding. In this method the series coils are wound in a reverse direction to the shunt coils and therefore, the field created by the series field is in opposition to that created by shunt field. 2. Use of Reactance coil for A.C Equipment The drooping characteristics are obtained in case of A.C. equipment by means of a reactance coil in series with the arc. The voltage at the secondary side of transformer remains constant almost and is available for striking the arc but as the current flows the voltage drop across the reactance coil reduces the voltage at the arc to the required value. The reactance coil also controls the flow of current.