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Welding Consumables
parent material.
When welding wrought materials in highly restrained joints,
preheat is normally applied locally in the weld area.
When welding castings, the preheat applied may be local
(heating in the area of the weld only), total (the whole casting
is heated), or indirect (heating a part of the casting away
from the weld area to balance the effects of expansion and
contraction).
Promote Fusion
Some alloy systems (e.g. copper and aluminium) have very high
thermal conductivity, and if a weld is attempted on thick, cold
Residual stresses present in a welded joint
plate, the parent material could chill the deposited weld metal
so quickly that it does not fuse with the parent metal. This may
be referred to as a cold start. The heat conduction away from
the joint area can be such that a weld may be impossible using a
conventional arc welding process.
Preheat is used in this case to raise the initial temperature of the
material sufficiently to ensure full weld fusion from the start. This
is particularly important when using a welding process/plate
thickness combination that is likely to produce a cold start.
Remove Moisture
Any metallic components left overnight in a cold workshop or
brought in from outside are likely to be damp or even wet. If they
are welded in that condition, problems can arise in the resultant
welds. For example, if the components are made of steel, then
the moisture will act as a source of hydrogen and the result could
be hydrogen cracking. Aluminium has a porous oxide layer, which
will absorb moisture from the atmosphere, and, if not removed
before welding, this can result in weld metal porosity and
subsequent rejection of the weld. 12
While not normally the main objective of preheating, its use for
removal of surface moisture prior to welding is not only advisable,
but very often essential.
Steel Type Combined Typical Preheat hardenability. These low alloy types may, additionally, need a
Welding Consumables
Welding Consumables
Classification
(MMA) Welding Afrox 7018-1 E7018-1 A premium quality,
all positional
Welding Technique
hydrogen-controlled
Successful MMA welding depends on the following factors: electrode for carbon
steels in pressure
Selection of the correct electrode vessel applications
Selection of the correct size of the electrode for the job and where high
integrity welding
Correct welding current is required; and for
free-machining steels
Correct arc length
containing sulphur
Correct angle of electrode to work
Correct travel speed Electrode Size
Correct preparation of work to be welded. The size of the electrode generally depends on the thickness of
the section being welded, and the thicker the section the larger
Electrode Selection the electrode required. In the case of light sheet, the electrode
size used is generally slightly larger than the work being
As a general rule, the selection of an electrode is straight- welded. This means that, if 2,0mm sheet is being welded,
forward, in that it is only a matter of selecting an electrode of 2,5mm diameter electrode is the recommended size.
similar composition to the parent metal. However, for some
metals there is a choice of several electrodes, each of which The following table gives the maximum size of electrodes that
has particular properties to suit specific classes of work. Often, may be used for various thicknesses of section.
one electrode in the group will be more suitable for general
applications due to its all round qualities. Recommended Electrode Sizes
12
Afrox Vitemax is suitable for welding mild steel in all positions 8,0 5,0
using AC or DC power sources. Its easy striking characteristics
and the tolerance it has for work where fit-up and plate Welding Current
surfaces are not considered good, make it the most attractive
electrode of its class. Correct current selection for a particular job is an important
factor in arc welding. With the current set too low, difficulty
Electrodes and Typical Applications is experienced in striking and maintaining a stable arc. The
electrode tends to stick to the work, penetration is poor and
beads with a distinct rounded profile will be deposited.
Name AWS Application
Classification Excessive current is accompanied by overheating of the
electrode. It will cause undercut and burning through of the
Afrox Vitemax
E6013 A premium quality
material, and will give excessive spatter. Normal current for
electrode for general
a particular job may be considered as the maximum, which
structural and sheet
can be used without burning through the work, over-heating
metal work in all
the electrode or producing a rough spattered surface (i.e. the
positions, including
current in the middle of the range specified on the electrode
vertical-down using
package is considered to be the optimum).
low carbon steels
Afrox Afrolux E7024 An iron powder In the case of welding machines with separate terminals
electrode for high for different size electrodes, ensure that the welding lead is
speed welding of connected to the correct terminal for the size electrode being
H-V fillets and flat used. When using machines with adjustable current, set on
butt joints. Medium the current range specified. The limits of this range should not
to heavy structural normally be exceeded. The following table shows the current
applications in low ranges generally recommended for Vitemax.
carbon steels