EFFECT OF WELDING HEAT INPUT ON FUSION CHARACTERISTIC OF SMAW WELDING

A MINI PROJECT REPORT

Submitted by

V.BHARATH (070114801011) K.RAJASEKAR (070114801037) S.K.VISHWANATHAN (070114801058) In partial fulfillment for the award of the degree of BACHELOR OF ENGINEERING
in METALLURGICAL ENGINEERING GOVERNMENT COLLEGE OF ENGINEERING, SALEM

ANNA UNIVERSITY: COIMBATORE

APRIL 2010

ANNA UNIVERSITY COIMBATORE 641047

MAY 2010

ANNA UNIVERSITY COIMBATORE 641047

BONAFIDE CERTIFICATE
Certified that this project report EFFECT OF WELDING HEAT INPUT ON FUSION CHARACTERISTICS OF SMAW PROCESS is the bonafide work of V.BHARATH, K.RAJASEKAR AND S.K.VISHWANATHAN who carried out the project under my supervision.

SIGNATURE

SIGNATURE

SUPERVISOR Assistant professor Department of metallurgical engineering, Government college of engineering, Salem-636011.

HEAD OF THE DEPARTMENT Department of Metallurgical Engineering Government College Of Engineering Salem-636011.

(INTERNAL EXAMINER)

(EXTERNALEXAMINER)

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

We express our sincere gratitude to Prof. P.G.Venkatakrishnan , Head of the Department , Department of Metallurgy , for permitting us to do our mini project Salem Auto Mech, Salem . We express our sincere thanks to our guide Mr.P.Sundararaj, Assistant professor, Department of Metallurgical Engineering, Government College of Engineering for his kind advice and guidance throughout the project whenever needed. We also thank all the Manager, Supervisors and Works for providing us with good information about the plant and cooperate with us in doing our mini project. We convey our sincere thanks to the management for giving us this opportunity.

ABSTRACT

ABSTRACT

Shielded metal Arc welding is next in importance to shielded metal arc welding. It is an arc welding process wherein coalescence is produced by heating with an electric arc or arcs setup between a bare metal electrode/electrodes and the job. It provides a method of welding thick plates in a few passes because of high rate of deposition and deeper penetration. It is well suited for welding long plates Manual welding. Parameters like electrode melting rate, area of weld bead, arc penetration and weld dilution are considered as important. However, the weld bead geometry is also affected considerably by electrode-to-work angle, inclination of the work piece, joint edge penetration, electrode stick out, the kind of current and polarity, electrode diameter and the type and grain size of flux. The effects of these process variables are determined through their effects on weld bead geometry. In this project, by taking various mild steel plates we are analyzing the effect of welding speed on heat input. Thereby studying the variation in fusion characteristics of SMAW process. Since SMAW is widely used in heavy industries like ship building, pressure vessel fabrication, rail road tank cars, structural engineering, pipe welding and for storage tanks, we need to ensure the sound quality of the weld produced by SMAW.

TABLE OF CONTENTS

TABLE OF CONTENTS
1 2 INTRODUCTION EQUIPMENTS 2.1OPERATOR ACCESSORIES 2.2PROCESS CAPABILITY 2.3ELECTRODES 2.4VOLTAGE 2.5TRAVEL SPEED 3 PROBLEM IN WELDING 3.1CRACKING 3.2DISTORTION 3.3UNDERCUT 3.4SPATTER 3.5POROSITY 3.6SLAG 3.7ARC BLOW 4. 5. 6. 7. SMAW OPERATING PRINCIPLE OPERATION OBSERVATION FOR HEAT INPUT CALCULATION TABULATION 7.1FOR SPECIMEN NO: 1(DIAMETER OF 3MM) 7.2FOR SPECIMEN NO: 2(DIAMETER OF 3MM) 7.3FOR SPECIMEN NO: 3(DIAMETER OF 3MM) 7.4FOR SPECIMEN NO: 4(DIAMETER OF 5MM) 7.5FOR SPECIMEN NO: 5(DIAMETER OF 5MM) 8. GRAPH (3mm diameter of electrode) 8.1HEAT INPUT 8.2HEAT INPUT 8.3HEAT INPUT 8.4HEAT INPUT VS PENETRATION VS REINFORCEMENT VS PLANE FUSION AREA VS BEAD WIDTH

8.5HEAT INPUT 8.6HEAT INPUT 8.7HEAT INPUT 9.

VS HAZ VS DILUTION (%) VS WETTING ANGLE

GRAPH (5mm diameter of electrode) 9.1HEAT INPUT 9.2HEAT INPUT 9.3HEAT INPUT 9.4HEAT INPUT 9.5HEAT INPUT 9.6HEAT INPUT 9.7HEAT INPUT VS VS PENETRATION FUSION AREA VS REINFORCEMENT VS BEAD WIDTH VS HAZ VS DILUTION (%) VS WETTING ANGLE

10 11. 12. 13. 14.

ADVANTAGES OF SHIELDED METAL ARC WELDING DISADVANTAGES OF SHIELDED METAL ARC WELDING APPLICATIONS 12.1SPECIAL APPLICATIONS OF THE SMAW PROCESS RESULTS AND DISCUSSION REFERENACE

INTRODUCTION

1. INTRODUCTION
Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode coated in flux to lay the weld. An electric current, in the form of either alternating current or direct current from a welding power supply, is used to form an electric arc between the electrode and the metals to be joined. As the weld is laid, the flux coating of the electrode disintegrates, giving off vapors that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination. Because of the versatility of the process and the simplicity of its equipment and operation, shielded metal arc welding is one of the world's most popular welding processes. It dominates other welding processes in the maintenance and repair industry, and though flux-cored arc welding is growing in popularity, SMAW continues to be used extensively in the construction of steel structures and in industrial fabrication. The process is used primarily to weld iron and steels (including stainless steel) but aluminium, nickel and copper alloys can also be welded with this method.

2. EQUIPMENTS
Power source Connecting cables Electrode holder Cable connectors Ground clamp

2.1 OPERATOR ACCESSORIES

Chipping hammer Face shield

 Wire brush

2.2 PROCESS CAPABILITY

Shielded metal arc welding one of most used of various electric arc welding processes

2.3 ELECTRODES
Always choose the correct electrode for the job. Dont be tempted to make do with a substitute electrode. Electrodes are designed for use on specific metals, and their performance will be poor if they are used on metals other than intended. Learn the different electrode types and their intended operation. The electrode diameter selected will depend largely on the thickness of the material, the position of welding,

and type of joint. Generally, larger electrodes are selected for thicker materials and welding in the flat position

2.4 VOLTAGE

Voltage with shielded metal arc welding is dependent on arc length. Long arcs produce high voltage and short arcs produce low voltage. As a rule, the arc length should not exceed the diameter of the core wire of the electrode, although the length is shorter than this value for electrodes with thick coverings. A steady hand is important to prevent power fluctuations, which can be detrimental to the weld.

2.5 TRAVEL SPEED

Heat input, penetration, and bead shape are all affected by travel speed. The more slowly you move the electrode along the joint, the more heat is delivered to the weld pool, which affects the cooling rate. Cooling rate has an effect on the metallurgical structure of the weld metal and heat-affected zone. Moving faster reduces the heat input. If the speed is too much, the bead deteriorates and the penetration suffers. If the speed is too slow, the weld bead becomes wide and the penetration is shallow because the arc dwells on the weld pool rather than directed into the base metal. Speed should be adjusted so that the arc is slightly ahead of the weld pool.

3.PROBLEM IN WELDING
There are many in welding process some of them are mentioned below Cracking Distortion Undercut Spatter

 Porosity Slag Arc blow

3.1 CRACKING

Cracks can occur from moisture, use of the wrong electrode for the material, improper current settings, excessive restraint, and poor welding technique. Also, if the weld is too small for the pieces being joined and it cools quickly, the shrinking stresses may be too much for the strength of the weld to overcome. Hydrogen induced cracking is combated with the use of dry low-hydrogen electrodes and proper preheat.

3.2

DISTORTION
Distortion is often caused by improper heat input and joint restraint. If distortion

begins to appear, check to see if the welding current is too high. Also make sure the pieces

are tightly clamped. The welding heat may cause them to move. Using an alternating bead sequence will help balance the forces that cause distortion.

3.3

UNDERCUT
A groove in the base metal at the toes of the weld can be caused if the current is too

high for the application or improper techniques are used. High amperage, a long arc, incorrect electrode position, travel speed, and insufficient dwell time in a weave bead can all contribute to undercut.

3.4

SPATTER
Excessive current can cause spatter, as well as the wrong type or size of electrode.

Also, make sure the polarity is correct for the electrode. If all settings and materials are correct, you might try holding a shorter arc to trap more spatters in the molten weld pool. Some electrodes are more prone to spatter than others.

3.5

POROSITY
Usually porosity is the result of some type of contamination in the weld area, too

much current, or gas entrapment in the weld metal. Make sure the joint is properly cleaned before welding and the electrodes are in good condition. Follow recommended preheating and interpass temperatures. Using the recommended amperage and holding the proper arc length also will help prevent porosity.

3.6

SLAG
Slag can become trapped in the weld metal or between the weld metal and the base

metal. Be sure to thoroughly clean the weld between passes. Also check to make sure the

proper current is used. When it is too low, the molten weld pool might freeze before the slag completely floats to the top. Also, the slag may flow ahead of the arc if the welder is not careful. Take care when welding downhill and between a convex bead and the sidewall of a groove.

3.7

ARC BLOW
Arc blow can be a significant problem with DC when welding ferritic steel.

Unbalanced magnetic fields that arise can deflect the arc and eject the transferring metal droplets. If it presents a problem, try placing the workpiece lead connections as far as possible away from the joints to be welded. Positioning the electrode so that the arc force counteracts the arc blow also helps, as well as lowering the current and maintaining the shortest possible arc length. Alternating current rarely presents a problem with arc blow because the magnetic field is constantly reversing.

4. SMAW OPERATING PRINCIPLE

5. OPERATION

To strike the electric arc, the electrode is brought into contact with the workpiece by a very light touch with the electrode to the base metal then is pulled back slightly. This initiates the arc and thus the melting of the workpiece and the consumable electrode, and

causes droplets of the electrode to be passed from the electrode to the weld pool. As the electrode melts, the flux covering disintegrates, giving off shielding gases that protect the weld area from oxygen and other atmospheric gases. In addition, the flux provides molten slag which covers the filler metal as it travels from the electrode to the weld pool. Once part of the weld pool, the slag floats to the surface and protects the weld from contamination as it solidifies. Once hardened, it must be chipped away to reveal the finished weld. As welding progresses and the electrode melts, the welder must periodically stop welding to remove the remaining electrode stub and insert a new electrode into the electrode holder. This activity, combined with chipping away the slag, reduce the amount of time that the welder can spend laying the weld, making SMAW one of the least efficient welding processes. In general, the operator factor, or the percentage of operator's time spent laying weld, is approximately 25%.The actual welding technique utilized depends on the electrode, the composition of the workpiece, and the position of the joint being welded. The choice of electrode and welding position also determine the welding speed. Flat welds require the least operator skill, and can be done with electrodes that melt quickly but solidify slowly. This permits higher welding speeds. Sloped, vertical or upside-down welding requires more operator skill, and often necessitates the use of an electrode that solidifies quickly to prevent the molten metal from flowing out of the weld pool. However, this generally means that the electrode melts less quickly, thus increasing the time required to lay the weld.

EXPERIMENTAL WORK

6. EXPERIMENTAL WORK

OBSERVATION FOR HEAT INPUT CALCULATION

SI.No Current Voltage Travel (Amps) (volts) time (sec) 1. 2. 3. 4. 5. 120 120 120 230 230 20 20 20 24 24 49 66 76 45 63

Travel Speed (mm/sec) 3.06 2.27 1.97 3.33 2.38

Heat Input (KJ/mm) 0.784 1.057 1.218 1.657 2.319

7.

TABULATION
Specimen no 1 Specimen no 2 Specimen no 3 Specimen no 4 Specimen no 5

7.1

FOR SPECIMEN NO: 1(DIAMETER OF 3MM)

PARAMETER Wetting angle()) Depth of penetration(P) Reinforcement height(h) HAZ Width (W1) Bead Width(W2) Fusion Area(A) Dilution %

VALUES 430 1.3 mm 2.4 mm 12.5 mm 10.0 mm 80 mm2 34.04

7.2

FOR SPECIMEN NO: 2(DIAMETER OF 3MM)

PARAMETER Wetting angle() Depth of penetration(P) Reinforcement height(h) HAZ Width (W1) Bead Width(W2) Fusion Area(A) Dilution %
7.3

VALUES 370 1.4 mm 2.4 mm 14.2 mm 12.6 mm 115 mm2 36.5 mm

FOR SPECIMEN NO: 3(DIAMETER OF 3MM)

PARAMETER Wetting angle() Depth of penetration(P) Reinforcement height(h) HAZ Width (W1) Bead Width(W2) Fusion Area(A) Dilution %

VALUES 440 1.5 mm 2.8 mm 15.6 mm 12.6 mm 105 mm2 29.57 mm

7.4

FOR SPECIMEN NO: 4(DIAMETER OF 5MM)

PARAMETER Wetting angle() Depth of penetration(P) Reinforcement height(h) HAZ Width (W1) Bead Width(W2) Fusion Area(A) Dilution %
7.5

VALUES 350 2.0 mm 3.0 mm 18.4 mm 14.8 mm 160 mm2 33.68

FOR SPECIMEN NO: 5(DIAMETER OF 5MM)

PARAMETER Wetting angle() Depth of penetration(P) HAZ Width (W1) Bead Width(W2) Fusion Area(A) Dilution %

VALUES 400 1.7 mm 15.0 mm 12.2 mm 110 mm2 34.37

Reinforcement height(h) 2.8 mm

8.

GRAPH (3mm Diameter of Electrode)

HEAT INPUT HEAT INPUT HEAT INPUT HEAT INPUT HEAT INPUT HEAT INPUT HEAT INPUT Vs Vs Vs Vs Vs Vs Vs PENETRATION REINFORCEMENT PLANE FUSION AREA BEAD WIDTH HAZ DILUTION (%) WETTING ANGLE

8.1

HEAT INPUT

Vs PENETRATION

HEAT INPUT (Kj /mm)

In the above graph In X axis Heat Input is in the order of kj/mm In Y axis Penetration is in the order of percentage

8.2

HEAT INPUT Vs REINFORCEMENT

HEAT INPUT (Kj/mm)

In the above graph In X axis Heat Input is in the order of kj/mm In Y axis Reinforcement is in the order of millimeter at 10x magnification in the profile projector view.

8.3

HEAT INPUT Vs PLANE FUSION AREA

HEAT INPUT (Kj/mm)

In the above graph In X axis Heat Input is in the order of kj/mm In Y axis plane fusion area is in the order of square millimeter.

8.4

HEAT INPUT Vs BEAD WIDTH

HEAT INPUT (Kj /mm)

In the above graph In X axis Heat Input is in the order of kj/mm In Y axis Bead width is in the order of millimeter at 10x magnification in the profile projector view

8.5

HEAT INPUT Vs HAZ

HEAT INPUT (Kj/MM)

In the above graph In X axis Heat Input is in the order of kj/mm In Y axis HAZ Width is in the order of millimeter at 10x magnification in the profile projector view.

8.6

HEAT INPUT Vs DILUTION (%)

D IL UTION
40 35

30

25

20

DILUTION

15

10

0 0 0.2 0.4 0.6 0.8 1 1.2 1.4

HEAT INPUT (Kj /mm)

In the above graph In X axis Heat Input is in the order of kj/mm In Y axis Dilution is in the order of percentage(%)

8.7

HEAT INPUT Vs WETTING ANGLE

In the above graph In X axis Heat Input is in the order of kj/mm In Y axis Wetting angle is in the order of degree().

9.

GRAPH (5mm Diameter of Electrode)

HEAT INPUT HEAT INPUT Vs Vs PENETRATION REINFORCEMENT

 HEAT INPUT HEAT INPUT HEAT INPUT HEAT INPUT HEAT INPUT

Vs Vs Vs Vs Vs

PLANE FUSION AREA BEAD WIDTH HAZ DILUTION (%) WETTING ANGLE

9.1

HEAT INPUT

Vs PENETRATION

HEAT INPUT (Kj /mm)

In the above graph In X axis Heat Input is in the order of kj/mm In Y axis Penetration is in the order of percentage

9.2

HEAT INPUT Vs REINFORCEMENT

HEAT INPUT (Kj/mm)

In the above graph In X axis Heat Input is in the order of kj/mm In Y axis Reinforcement is in the order of millimeter at 10x magnification in the profile projector view.

9.3

HEAT INPUT Vs FUSION AREA

HEAT INPUT (Kj/mm)

In the above graph In X axis Heat Input is in the order of kj/mm In Y axis fusion area is in the order of square millimeter.

9.4

HEAT INPUT Vs BEAD WIDTH

HEAT INPUT (Kj /mm)

In the above graph In X axis Heat Input is in the order of kj/mm In Y axis Bead width is in the order of millimeter at 10x magnification in the profile projector view

9.5

HEAT INPUT Vs HAZ

HEAT INPUT (Kj/MM)

In the above graph In X axis Heat Input is in the order of kj/mm In Y axis HAZ Width is in the order of millimeter at 10x magnification in the profile projector view.

9.6

HEAT INPUT Vs DILUTION (%)

HEAT INPUT (Kj /mm)

In the above graph In X axis Heat Input is in the order of kj/mm In Y axis Dilution is in the order of percentage(%)

9.7

HEAT INPUT Vs WETTING ANGLE

In the above graph In X axis Heat Input is in the order of kj/mm In Y axis Wetting angle is in the order of degree().

10.

ADVANTAGES OF SHIELDED METAL ARC WELDING

Simple, portable and inexpensive equipment;

Wide variety of metals, welding positions and electrodes are applicable; Suitable for outdoor applications.

11. DISADVANTAGES OF SHIELDED METAL ARC WELDING

The process is discontinuous due to limited length of the electrodes; Weld may contain slag inclusions; Fumes make difficult the process control.

12. APPLICATIONS
Most manufacturing operations that require welding will strive to utilize the mechanized processes that offer greater productivity, higher quality, and, therefore, more cost-effective production. For these reasons, the SMAW process has been replaced where possible. However, the simplicity and ability of the SMAW process to achieve welds in areas of restricted accessibility means that it still finds considerable use in certain situations and applications. Heavy construction, such as shipbuilding, and welding "in the field," away from many support services that would provide shielding gas, cooling water, and other necessities, rely on the SMAW process to a great extent. Although the SMAW process finds wide application for welding virtually all steels and many of the nonferrous alloys, it is primarily used to join steels. This family of materials includes low-carbon or mild steels, low-alloy steels, high-strength steels, quenched and tempered steels, highalloy steels, stainless steels, and many of the cast irons. The SMAW process is also used to join nickel and its alloys and, to a lesser degree, copper and its alloys. It can be, but rarely is, used for welding aluminum.

12.1 SPECIAL APPLICATIONS OF THE SMAW PROCESS

Underwater welding began during World War I when the British naval force used it to make temporary repairs of leaking rivets on ship hulls. The introduction of covered electrodes enabled successful underwater welding and the production of welds having approximately 80% of the strength and 40% of the ductility of similar welds made in air. Because of the somewhat diminished weld properties, this SMAW application is generally restricted to salvage operations or underwater repair work. Underwater welding can be subdivided into two major categories: welding in a wet environment and welding in a dry environment. Wet Welding. The relatively poor quality of welds made in a wet environment is due primarily to the problem of heat transfer, welder visibility, and the presence of hydrogen in the arc atmosphere during the welding operation. When the base metal and the arc area are surrounded entirely by water, there is no temperature or heat buildup of the base metal at the weld, nor is preheating possible. This creates a weld-metal quench effect, which traps damaging amounts of hydrogen and also produces a weld solidification structure with reduced toughness and ductility. Both conditions contribute to the weld-metal cracking problems experienced when welding steels underwater. Another disadvantage is the restricted visibility, which is due to the equipment and the existing local contaminants in the water, as well as those generated by the welding arc. Under the most ideal conditions, welds produced in wet environments using covered electrodes are marginal, at best. They can be placed in service for short periods of time under reduced operating conditions, but should be replaced with quality welds as quickly as possible. The covered electrodes used for wet welding must be waterproofed prior to underwater use. This can be done by wrapping them with waterproof tape or by dipping them in special sodium silicate mixes and allowing them to dry. Dry Welding. The dry environment enables the production of high-quality welds that meet all code quality requirements. The SMAW process is not very popular for welding in the dry environment, because large amounts of smoke and fumes are produced. An extensive air moving, filtering, and refrigeration system must be employed when the SMAW process is used, because a dry-environment area will quickly fill with the welding fumes, making it impossible for the welder to see that weld area and

to function. For this reason, the gas-tungsten arc welding and gas-metal arc welding processes have broader use in dry welding applications. The article "Underwater Welding" in this Volume explores the topic in greater detail.

RESULTS AND DISCUSSION

RESULTS Here we study the effect of welding heat input on fusion characteristic of smaw welding with different electrode diameter

DISCUSSION

CORRECT ELECTRODE SIZE: The choice of electrode size should depend on the type of electrode, welding position, joint preparation, base-metal thickness, and welder skill. CORRECT CURRENT: If the current is too high, then the electrode melts too fast and the molten pool becomes large, irregular, and difficult to control. Current that is too low will not provide enough heat to melt the base metal, causing the molten pool to be sluggish, with a high, irregular, ropey weld bead. It should also be noted that the electrode has inherent current limits. If the current is too high, then the core wire overheats and the coating cracks. If the current is too low, then there is insufficient heat to maintain the arc and form the protective gas shield.

REFERENACE

References

 H.B. CARY, MODERN WELDING TECHNOLOGY, 2ND ED., PRENTICEHALL, 1989. "FILLER METAL COMPARISON CHARTS," AWS FMC-89, AMERICAN WELDING SOCIETY. "SAFETY IN WELDING AND CUTTING," ANSI/AWS Z49.1, AMERICAN WELDING SOCIETY. "TECHNICAL GUIDE FOR SHIELDED METAL ARC WELDING," HOBART BROTHERS.