Henrry Diaz Sevilla UNIT 13: Welding Technology

MIG Welding

 Types of welding processes:

1. Manual: Metal active gas (MAG) welding, is a welding process in which an electric arc
forms between a consumable wire electrode and the workpiece metal(s), which heats the
workpiece metal(s), causing them to melt and join. One of the most common types of arc
welding is shielded metal arc welding (SMAW) it is also known as manual metal arc
welding (MMA) or stick welding. Electric current is used to strike an arc between the base
material and consumable electrode rod, which is made of filler material (typically steel)
and is covered with a flux that protects the weld area from oxidation and contamination
by producing carbon dioxide (CO2) gas during the welding process. The electrode core
itself acts as filler material, making a separate filler unnecessary.
2. Automated: MIG/MAG welding is a semi-automatic process where the welding arc is
formed between the material being welded and the welding wire fed through the welding
gun. Furthermore, Automatic MIG welding machines are custom designed for each
application and include single and dual-head design; multi-station designs; rotary head
styles; and multiple torches. Single-head designs are ideal for lighter fabrication tasks
while the dual-head design welding machines are better suited for industrial production
or fabrication. Automatic MIG welders are custom designed for each application and
include single and dual-head design; multi-station designs; rotary head styles; and
multiple torches.
 MIG Welding: Metal Inert Gas (MIG) is a welding process in which an electric arc forms
between a consumable wire electrode and the workpiece metal, which heats the workpiece
metal, causing them to melt and join. A MIG is a lot easier to learn and makes a good, strong
weld. A MIG welder with enough capacity and properly equipped can weld anything from thin
sheet metal.

 Advantages and disadvantages: One advantage of MIG

Welding is that it has better weld pool visibility also in order
to use this welding process is not needed to be skilled which
anyone can use this processes however the person that is
going to use this machine must know the basics and must
have knowledge of health and safety, furthermore another
advantage of using welding process is that is high in productivity which saves time moreover
this process is clean and efficient because a shielding gas to protect the arc, there is very little
loss of alloying elements as the metal transfers across the arc, also this processes is faster
because the continuously fed wire keeps both hands free for MIG welding, which improves
the welding speed, quality of the weld, and overall control, however an a disadvantage for
this process is that is very expensive because the equipment used in this process is more
complex which can be hard to get the equipment maybe a piece has to be shipped and extra
cost can be charged, furthermore another disadvantage is that before welding a metal you
must prepared which it takes a quiet long time to prepare, the metal must be free of rust or
dirt in order to get a good weld and for the safety of the welder.

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 Henrry Diaz Sevilla UNIT 13: Welding Technology

Butt joints are used where high strength is

demanded, they are reliable and can survive
stress better than any other type of weld joint,
in order to accomplish full stress value, the
weld must have 100% penetration through the
joint, which can be done by welding
completely through from one side.

Corner joints are used to join two members located

approximately at right angles to each other in the
form of an L. The closed corner joint is used on lighter
sheets when high strength is not required at the joint.
In making the joint by oxyacetylene welding, the
overlapping edge is melted down, and little or no filler
metal is added, however as high strength is been
demanded I will not use this type of welding joint.

 Research the welding properties for mild steel, and stainless steel, and justify which in is the
best for welding: mild steel: the properties for mild steel is that the melting point is of 1600°C,
furthermore, mild steel has more properties such as tough, ductile, malleable, good tensile
strength, poor resistance to corrosion. Stainless steel: Stainless steels are picked due to their
improved consumption protection, high temperature oxidation protection or their quality.
The different sorts of stainless steel are distinguished and direction given on welding
procedures and methods which can be utilized in manufacturing stainless steel parts without
disabling the consumption, oxidation and mechanical properties of the material or bringing
deserts into the weld
 Preparation of metal for welding carbon steel: The best welds come from pure clean metal
to metal contact, any foreign materials in the welding area can cause welding imperfections.
Even brand new metal must be prepped before it can be welded because there is usually a
coating put on new metal so it does not rust or oxidize during the shipping process.
Furthermore, to start, the type of welding you are doing will determine how you prep the
metal. Inherently MIG welding steel does not need the metal to be perfectly clean. On the
other extreme, TIG welding aluminium requires contaminant free metal to create a strong
clean weld.
 storage of electrodes: it is stored in a box.
 short circuit transfer mode for MIG welding: Short racing circuit circle carry-over is a transfer
used when a lower potential drop is used for MIG welding. Short circuit transfer occurs when
the conducting wire electric arc s and link the metal creating short circuit circuits. During this
short circuit, the wire contacting the metal heats up and drips into the joint by creating a pool
. Then another arc begins and the process keeps repeating many times a second. The easiest
way to tell if the transfer is short circuit is by the auditory sensation . The sound greatly
resembles, an ballock Synonyms/Hypernyms (Ordered by Estimated Frequency) of noun hit
an extremely hot frying pan. It is a very crisp and fast crackling sound. Typically short circuit
transfer is used on thin metals or flat solid metals.

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Henrry Diaz Sevilla UNIT 13: Welding Technology

 safe handling and storage of shielding gases: COSHH Control of substances Hazardous to
health and BOC Collect ad replace bottles.
 power source/current: MIG welding unlike most other welding processes has one standard
voltage type and polarity type. The voltage used is D/C direct current, much like the current
in a car battery. Direct current flows in one direction, from the negative (-) to the positive
(+). The polarity used is also standard and that is D/C electrode (+) positive. This means that
the handle is the positive side of the circuit, or it may be said, the electricity flows from the
metal in to the welding handle.
 welding stainless nickel alloys: Stainless steels are chosen because of their enhanced
corrosion resistance, high temperature oxidation resistance or their strength. The various
types of stainless steel are identified and guidance given on welding processes and techniques
which can be employed in fabricating stainless steel components without impairing the
corrosion, oxidation and mechanical properties of the material or introducing defects into the
weld.
 power source/voltage HAZ (heat affected zone when welding nickel & nickel alloys, and
stanilees steel) (use the benefit of using filler rod electrode: these steels are alloyed with
chromium and because of their low carbon content the structure is almost completely
ferritic. They are magnetic and though easier to weld than the martensitic group because
they are not hardenable to any extent by heat treatment they suffer from grain growth and
embrittlement at temperatures above 900C and form of intergranular corrosion in the HAZ.
 HAZ (heat affected zone when welding steel): The heat-affected zone (HAZ) is the area of
base material, either a metal or a thermoplastic, which is not melted and has had its
microstructure and properties altered by welding or heat intensive cutting operations. ...
Alternatively, a low diffusivity leads to slower cooling and a larger HAZ

Oxy-Acetylene Welding

 Types of welding:
1. Manual: Gas Welding is a welding process utilizing heat of the flame from a welding
torch. The torch mixes a fuel gas with Oxygen in the proper ratio and flow rate providing
combustion process at a required temperature. The hot flame fuses the edges of the
welded parts, which are joined together forming a weld after Solidification.
2. Automatic: Oxyhydrogen Welding is a Gas Welding process using a combustion mixture
of Hydrogen (H2) and oxygen (O2) for producing gas welding flame.
 Oxy-Acetylene Welding: Oxyacetylene gas welding is commonly used to
permanently join mild steel. A mixture of oxygen and acetylene, burns
as an intense / focussed flame, at approximately 3,500 degrees
centigrade. When the flame comes in contact with steel, it melts the
surface forming a molten pool, allowing welding to take place.
Oxyacetylene can also be used for brazing, bronze welding, forging /
shaping metal and cutting.

http://www.technologystudent.com/equip_flsh/acet1.html

 Advantages and Disadvantages: One advantage of using Oxy-Acetelyne is that is easy to learn
which gives the opportunity to people to use this process moreover this process is cheap, the
equipment that is used in this process is cheap than must of other welding process e.g. MIG
Welding, furthemore the equipment is more portable than most other types of welding rings
moreover the equipment can also be used to ‘flame-cut’ large pieces which is versatile

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 Henrry Diaz Sevilla UNIT 13: Welding Technology

suitable for small objects and big objects, another advantge for this process is that is adaptable
to many different jobs in welding positions, however there is disadvantages for this process,
one of the disadvantages is that unsuitable for welding high alloy steel in harden conditions
moreover fluxes are required for welding most material, moreover not all metals can be weld.

http://www.acastronovo.com/ClassHtms/Weld01.htm

 Consumables Equipment: fluxes is one of the consumables in the process of Oxy-acetelyne

welding, this means that it describes the quantity which passes through a surface or
substance
 Equipment: The equipment used in the process are as follow; Fuel gas cylinder with pressure
regulator; Oxygen cylinder with pressure regulator; Welding torch; Blue oxygen hose; Red fuel
gas hose; Trolley for transportation of the gas cylinders.

I have used this table in order to help

me to identify the voltage that’s
been asked which is 230v, one of the
reason is because it has a lot of
information and is accurate.

I have used this table because shows

the thickness of the workpiece which
is 2.0 – 3.0, furthermore the table
also shows the welding position
which helps a lot more over the
table shows the wire speed
adjustment.

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 Henrry Diaz Sevilla UNIT 13: Welding Technology

This diagram shows us a MIG Welding

machine which is been label with the
letters A,B,C which in the table that I
have talked before we can also see this
letters which this helps to minimize
any mistakes that can be made when
welding furthermore this is also useful
because you can adjust it to the
accurate sizes.

Tee joints are used to weld two plates or

sections whose surfaces are located
approximately 90° to each other at the joint.
This type of welding joint is perfect because it
has full strength if is been weld properly
which is stronger than other welding joint,
moreover I will be using this type of welding
joint.

I have used this table to help me to identify

what type of gas supply I need in MIG
Welding machine, this table is very specific
because it tells you what kind of gas supply
need in different types of materials and as am
going to use Mild Steel I would be using
Carbon Dioxide (CO2).

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Henrry Diaz Sevilla UNIT 13: Welding Technology

Health & Safety for both types of welding:

 You must wear protective clothes at all times when welding- gauntlet gloves designed for
use in welding, apron, and protective shoes. Button shirt collar and pocket flaps, and wear
cuffless trousers to avoid entry of sparks and slag. You must wear a helmet or protective
goggles in order to prevent radiant energy, furthermore make sure you don’t wear any
jewellery or headphones when welding to prevent any problems moreover wear gloves to
prevent major burns in your hand due to the piece of metal will be hot, also make sure you
always check for full free air circulation around in order to prevent inhaling the gases that
the MIG welding can release, furthermore you must check that the pressure regulator and
gauges are working correctly also remove all flammable materials that’s around however a
extinguisher must be close to you in case of a fire the correct extinguisher in case of a fire
are ‘dry powder, CO2 or BCF and in case of an emergency a first aid staff member qualified
in first aid should be supervising around the workpiece.
What it should not been done when welding:
 One of the things that you should never do when welding is not to remove any of the panels
unless the machine is disconnected from the supply also you should not try to repair any
mechanical problem unless you are qualified technician, when using the MIG welding
machine you should make sure you use the right gas and not use any unknown gas that can
be a risk for you and others moreover you should not point with the MIG flame to anyone
because it can prevent major burns.
The type of joint I will be using for the two pieces of metal.

This is the type of joint I would be using to

join the two pieces of metal, which it has the
shape of an L. I think this type of welding joint
is the best one to join the two pieces of metal
because it has more strength than other
types and because is more easy to weld and
is fast.

Conclusion.
The best way to weld this two pieces of metal (20mm x 90mm x3mm) mild steel is by using the MIG
welding, this is because the area of the flame is smaller than Oxy-Acetylene which by having a small
are of flame will allow me to work more easily and more accurate than Oxy-Acetylene, furthermore
in order to weld this successfully I would be using the L welding joint which it has more strength and
is more easy to work on with the MIG welding machine, in addition the advantage of using the MIG
weld is that you don’t need to wear any explosion safety which this would make the student more
comfortable and more secure however using the Oxy-Acetylene is dangerous because you must use
gas which this is a high risk in case of an incident due that can explode and cause injuries to other
students that are around whereas the MIG welding machine doesn’t use any type of gas and is not
dangerous to use.

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Henrry Diaz Sevilla UNIT 13: Welding Technology

Assignment 2

 Ferrous non alloyed (steel): Steel is made by adding iron to carbon which hardens the iron.
Engineering steel becomes even tougher as other elements like chromium and nickel are
introduced. Steel is made by heating and melting iron ore in furnaces. The steel can is tapped
from the furnaces and poured into moulds to form steel bars. Steel is widely used in the
construction and manufacturing industries. Ferrous metals have a high carbon content which
generally makes them vulnerable to rust when exposed to moisture. There are two exceptions
to this rule: wrought iron resists rust due to its purity and stainless steel is protected from rust
by the presence of chromium.
 Alloyed (stainless): Stainless steels are steels possessing high corrosion resistance due to the
presence of substantial amount of chromium. Furthermore the properties for stainless are;
strength, hardness, toughness, wear resistance, corrosion resistance, hardenability, and hot
hardness. To achieve some of these improved properties the metal may require heat treating.
 Non-ferrous (aluminium): Nonferrous metals are specified for structural applications
requiring reduced weight, higher strength, nonmagnetic properties, higher melting points, or
resistance to chemical and atmospheric corrosion. They are also specified for electrical and
electronic applications. Aluminium is a metal with a much lower density than iron, making it
a vital material in applications that need strength without weight, such as the aerospace
industry. It is corrosion resistant because aluminium, like stainless steel, reacts to oxidization
by creating a metal oxide shell that protects it. Aluminium also has a lower melting point than
many of the steels or irons it might replace, which makes it easier to cast than steel, needing
less oversight for complex forms.
 TIG & Titanium welding: TIG welding is an arc welding process that uses a non-consumable
tungsten electrode to produce the weld. The weld area and electrode is protected from
oxidation or other atmospheric contamination by an inert shielding gas (argon or helium), and
a filler metal is normally used, though some welds, known as autogenous welds, do not
require it. A constant-current welding power supply produces electrical energy, which is
conducted across the arc through a column of highly ionized gas and metal vapors known as
a plasma. Gas tungsten arc welding is most commonly used to weld stainless steel and
nonferrous materials, such as aluminium and magnesium, but it can be applied to nearly all
metals, with a notable exception being zinc and its alloys. Its applications involving carbon
steels are limited not because of process restrictions, but because of the existence of more
economical steel welding techniques, such as gas metal arc welding and shielded metal arc
welding.
For each: Ferrous non alloyed (Steel), alloyed (Stainless) and a non-ferrous (aluminium). You should
consider changes in properties, the effects of heat input (Melting Temperature) and cooling rates
(Thermal Conductivity).
 Changes in properties temperature non-alloyed (steel): Low temperatures can adversely
affect the tensile toughness of many commonly-used engineering materials. Tensile
toughness is a measure of a material’s brittleness or ductility; it is often estimated by
calculating the area beneath the stress-strain curve. Ductile materials absorb significant
amounts of impact energy before fracturing, resulting in tell-tale deformations. Brittle
materials, on the other hand, tend to shatter on impact. Furthermore, the electrical, magnetic
and structural properties of metals can be changed through heat. As the applications of metal
are varied, different environments prioritize different qualities. For example, in engineering
applications, toughness is desired; in electrical applications, low electrical resistivity is
important. Electrical resistance: Electrical resistance is the measure of how strongly the metal
impedes the passage of electrical current. As electrons pass through the metal, they scatter

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Henrry Diaz Sevilla UNIT 13: Welding Technology

as they collide with the metallic structure. When the metal is heated, the electrons absorb
more energy and move faster. This leads to more scattering, thus increasing the amount of
resistance. Structure: Metals are comprised of a symmetrical structure of atoms known as an
allotrope. Heating the metal will displace atoms from their position and the displaced atoms
form a new structure. Moreover Heat treatment is a process designed to alter the properties
of the metal to better suit its intended use. The main types of heat treatment are annealing,
normalising, hardening and tempering. Steel is just the element iron that has been processed
to control the amount of carbon. Iron, out of the ground, melts at around 1510 degrees C
(2750°F). Steel often melts at around 1370 degrees C (2500°F).
http://www.totalmateria.com/page.aspx?ID=CheckArticle&site=kts&NM=48=
 Changes in properties at high and low temperatures (stainless): Stainless steels have good
strength and good resistance to corrosion and oxidation at elevated temperatures. Stainless
steels are used at temperatures up to 1700° F for 304 and 316 and up to 2000 F for the high
temperature stainless grade 309(S) and up to 2100° F for 310(S). Stainless steel is used
extensively in heat exchangers, super-heaters, boilers, feed water heaters, valves and main
steam lines as well as aircraft and aerospace applications. With time and temperature,
changes in metallurgical structure can be expected with any metal. In stainless steel, the
changes can be softening, carbide precipitation, or embrittlement. Softening or loss of
strength occurs in the 300 series (304, 316, etc.) stainless steels at about 1000° F and at about
900° F for the hardenable 400 (410, 420, 440) series and 800° F for the non-hardenable 400
(409, 430) series.
 Changes in properties at high and low temperatures (aluminium): Mechanical and physical
properties of aluminium and aluminium alloys change when working temperature change
from cryogenic (-195oC) to elevated temperatures (max. 400oC). These changes are not so
intensive compared to another materials such as steel and others. Changes of properties of
aluminium alloys with temperature depend on chemical composition and temper. Strength at
temperatures above about 100 to 200 °C is improved mainly by solid-solution strengthening
or second phase hardening. Another approach to improve the elevated-temperature
performance of aluminium alloys has been the use of rapid solidification technology to
produce powders or foils containing high supersaturations of elements such as iron or
chromium that diffuse slowly in solid aluminium. Low-Temperature Properties. Aluminium
alloys represent a very important class of structural metals for sub-zero-temperature
applications and are used for structural parts for operation at temperatures as low as -270oC.
Below zero, most aluminium alloys show little change in properties; yield and tensile strengths
may increase; elongation may decrease slightly; impact strength remains approximately
constant. Consequently, aluminium is useful material for many low-temperature applications.
Describe the HAZ in the different materials and what changes does it make to the
properties and the microstructure of the metal.
The heating -affected zone (HAZ) is the expanse of foot cloth, either a metal lick element or a
thermoplastic, which is not melted and has had its microstructure and properties altered by welding
or heat intensive 20 senses of cut operations. The heat from the welding mental process and
subsequent re-cooling causes this change from the weld port to the final result of the sensitizing
temperature in the cornerstone metal. The extent and magnitude of property change depends
primarily on the base material, the weld filler metal, and the amount and concentration of heat input
by the welding process During welding operations, the HAZ may orbit from small to large depending
on the rate of heat comment . Theodore Dwight Welding mental summons with heights rates of heat
input (i.e. fast heat ) have faster cooler rates compared to welding processes with depression rates of
heat input (i.e. slow heating) and thus, have smaller HAZs. Conversely, a process with low rates of heat
input will result in a larger HAZ. The size of a HAZ also growth as the speed of the welding process
decreases. HAZ problems can be mitigated by performing a pre- and/or military post -weld heat

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Henrry Diaz Sevilla UNIT 13: Welding Technology

treatment. Weld geometry also plays a role in the size of the HAZ. Because the HAZ experiences
sufficient heat for a long enough period of time, the layer undergoes microstructure and property
changes that differ from the parent metal. These property changes are usually undesirable and
ultimately serve as the weakest part of the component. For example, the microstructural changes can
lead to residual stresses, reduced material strength, increased brittleness, and decreased resistance
to corrosion and/or cracking. As a result, many failures occur in the HAZ. During high-temperature
cutting operations, the depth of the HAZ is associated with the cutting process, cutting speed, material
properties, and material thickness. Similar to the results of welding processes, cutting processes that
operate at high temperatures and slow speeds tend to lead to large HAZs. Furthermore, cutting
processes that operate at high speeds tend to reduce the width of the HAZ.

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