INTRODUCTION TO WELDING

WELDING IS THE MOST EOCONOMIC & EFFICIENT WAY TO

MAKE PERMANENT JOINT IN METALS
ECONOMICAL WELDED JOINT

EXCESS METAL TO MAKE

SLEEVE JOINT IN PIPE LINE
 INTRODUCTION TO WELDING

ADVANTAGES OF WELDING

LOWEST COST JOINING METHOD

AFFORD LIGHTER WEIGHT THROUGH BETTER UTILIZATION
OF MATERIALS
CAN JOIN ALL COMMERCIAL METALS
CAN BE USED ANYWHERE
PROVIDE DESIGN FLEXIBILITY

LIMITATIONS

WELDING DEPENDS ON HUMAN FACTOR

IT OFTEN REQUIRES INTERNAL INSPECTION i.e Q.C IS
REQUIRED.
 INTRODUCTION TO WELDING
ALL METALS COMMERCIALLY USED FOR STRUCTURAL OR
STRENGTH PARTS ARE WELDABLE.

SOME METALS EASY TO WELD.

SOME METALS DIFFICULT TO WELD.

REQUIRES SPECIAL PROCEDURES
& TECHNIQUES.

WELDABILITY

“THE CAPACITY OF MATERIALS TO BE WELDED UNDER THE IMPOSED

FABRICATION CONDITIONS INTO A SPECIFIC SUITABLE DESIGNED
STRUCTURE AND TO PERFORM SATISFACTORY IN THE INTENDED
SERVICE.”
 FUNDAMENTALS OF WELDING
WELDMENT

An assembly, whose component parts are joined by welding.

Can be made of : many or few metal parts

May contain : metals of different Compositions,

Pieces may be : in the form of sheet, plate, pipe etc.

Example : Boiler Structure,

Pipes,
Bunker etc.
 FUNDAMENTALS OF WELDING

JOINT
“Junction of members or the edges of members
that are to be joined or have been joined”

FIVE BASIC TYPES OF THE WELD JOINTS

A. BUTT JOINT.
B. TEE JOINT.
C. LAP JOINT.
D. CORNER JOINT.
E. EDGE JOINT.
 FUNDAMENTALS OF WELDING

BUTT JOINT
Two parts in approximately the same plane
 FUNDAMENTALS OF WELDING
CORNER JOINT Two parts located approx.
at right angle to each other

T - JOINT
Parts approximately at
right angles in the form of T
 FUNDAMENTALS OF WELDING
LAP JOINT Between overlapping parts
in parallel plane

EDGE JOINT
Between the edge of two or
more parallel parts.
 FUNDAMENTALS OF WELDING
DIFFERENT TYPES OF WELDS
They are best described by their shapes

FILLET WELD
A weld of approximately triangular cross - section
joining two surfaces approximately at right angle to
each other.
 FUNDAMENTALS OF WELDING

GROOVE WELD A weld made in the groove

between two members joined.

FLANGE WELD Primarily used for light gauge

or sheet metal joint
 TYPES OF WELD JOINTS
1. GROOVE WELDS.
• SQUARE GROOVES.
• SINGLE - VEE GROOVE.
• DOUBLE - VEE GROOVE.
• SINGLE - BEVEL GROOVE
• DOUBLE BEVEL GROOVE
• SINGLE - U- GROOVE.
• DOUBLE - U- GROOVE.
• SINGLE - J- GROOVE.
• SINGLE - K- GROOVE.

2. FILLET WELDED JOINT

• SINGLE FILLET WELDED JOINTS.
• DOUBLE FILLET WELDED JOINTS.
• COMBINED GROOVE AND FILLET WELDED JOINT.
EDGE SHAPES

Square Edge Shape

Single - Bevel Edge Shape

Double - Bevel Edge Shape

Single - J Groove Edge Shape

Double - J Groove Edge Shape

 JOINT EDGE PREPARATION

Why is edge preparation done?

TO PROVIDE ACCESS TO JOINT INTERIOR

HELP IN PROPER FUSION

How the edge preparation done ?

BY GAS(FLAME) CUTTING
PLASMA ARC CUTTING
GRINDING
EDGE PREPARATION TERMINOLOGY

GROOVE ANGLE
BEVEL DEPTH

BEVEL ANGLE

ROOT FACE SIZE

ROOT OPENING

V - GROOVE JOINT
 SELECTION OF JOINT PREPARATION

What determines which joint preparation geometry to

use?

Kind of joint loads (Tension, Compression, etc)

Level of Joint Loading
Static or Dynamic loading
Thickness & Type of Metal Joined
Welding Position
One side/ both sides access to the weld
Skills of the welders
 PARTS OF THE GROOVE WELD

TERMS USED TO DESCRIBE THE PARTS OF A

GROOVE WELD

LEG OR SIZE OF THE WELD

FACE

TOE

REINFORCEMENT

ROOT PENETRATION
 GROOVE WELD

FACE REINFORCEMENT

TOE TOE

DEPTH OF FUSION
WELD SIZE FUSION
(leg) FACE
FUSION ZONE

ROOT
WELD REINFORCEMENT
INTERFACE
ROOT
 PARTS OF THE FILLET WELD

TERMS USED TO DESCRIBE THE PARTS OF A

FILLET WELD

LEG OR SIZE OF THE WELD

FACE

TOE

REINFORCEMENT

ROOT PENETRATION

ACTUAL THROAT & THEORETICAL THROAT

 FILLET WELD

TOE

WELD INTERFACE

ACTUAL THROAT

WELD THEORETICAL THROAT

SIZE
(Leg)
TOE

ROOT
WELD FUSION FACE

DEPTH OF FUSION

FUSION ZONE
 WELDING TERMINOLOGY
AXIS OF THE WELD
AN IMAGINARY LINE DRAWN PARALLEL TO THE WELD
BEAD THROUGH THE CENTER OF THE WELD.

TRAVEL ANGLE
SMALLEST ANGLE FORMED BETWEEN THE
ELECTRODE AND THE AXIS OF THE WELD

WORK ANGLE
THE SMALLEST ANGLE FORMED BY A PLANE, DEFINED
BY THE ELECTRODE AND THE AXIS OF THE WELD, AND
THE WORK PIECE.
 WELDING TERMINOLOGY

PUSH ANGLE DURING FOREHAND WELDING

TRAVEL ANGLE, WHEN THE ELECTRODE IS POINTING
TOWARDS THE DIRECTION OF WELD PROGRESSION

DRAG ANGLE DURING BACKHAND WELDING

TRAVEL ANGLE, WHEN THE ELECTRODE IS POINTING
AWAY FROM THE DIRECTION OF WELD PROGRESSION
WELDING TERMINOLOGY
 WELDING POSITIONS
FLAT POSITION – “1G” HORIZONTAL POSITION – “2G”

PLATE - VERTICAL
AXIS OF WELD - HORIZONTAL

PLATE & AXIS OF WELD - HORIZONTAL

FLAT POSITION – “3G” OVERHEAD POSITION – “4G”

PLATE - VERTICAL
PLATE & AXIS OF WELD - HORIZONTAL
AXIS OF WELD - VERTICAL

WELDING POSITIONS FOR GROOVE WELD :- PLATE

 WELDING POSITIONS
FLAT POSITION – “1F” HORIZONTAL POSITION – “2F”

AXIS OF WELD
HORIZONTAL

AXIS OF WELD
HORIZONTAL

VERTICAL POSITION – “3F” OVERHEAD POSITION – “4F”

AXIS OF WELD
VERTICAL

AXIS OF WELD
HORIZONTAL

WELDING POSITIONS FOR FILLET WELD :- PLATE

 WELDING POSITIONS
PIPE POSITION PIPE POSITION
FLAT – “1G” HORIZONTAL – “2G”

AXIS OF CYLINDER
VERTICAL

AXIS OF CYLINDER – HORIZONTAL

PIPE SHALL BE TURNED WHILE WELDING

PIPE POSITION PIPE POSITION – “6G”

HORIZONTAL FIXED – “5G”

V
450 ± 50

AXIS OF PIPE
AT 450
AXIS OF CYLINDER – HORIZONTAL
PIPE SHALL NOT BE TURNED OR
ROLLED WHILE WELDING H

WELDING POSITIONS FOR GROOVE WELD :- PIPE

 PERCENTAGE OF CARBON

ALLOY % OF CARBON
WROUGHT IRON NO CARBON ( < 0.08%)
LOW CARBON STEELS 0.15 % CARBON (MAX)
0.25 - 1.5 % MANGANESE
MILD STEEL 0.15 - 0.29 % CARBON

MEDIUM CARBON STEEL 0.25 - 0.50 % CARBON

0.60 - 1.65 % MANGANESE
HIGH CARBON STEELS 0.50 - 1.03 % CARBON
0.30 - 1.00% MANGANESE
LOW ALLOY STEELS 0.29 % CARBON (MAX.)
TOTAL METAL ALLOYS <= 2.0 %
CAST IRON 2.1 % CARBON
 CARBON EQUIVALENT

%C % Mn % Ni % Cr + % Mo % Cu
C.E. = + + + +
6 20 10 40

if C.E. < 0.40% MATERIAL IS READILY WELDABLE

C.E. > 0.40% SPECIAL CONTROLS REQUIRED

PREHEATING

LOW HYDROGEN PROCESSES

PROCEDURE SHOULD BE QUALIFIED

 WELDER TEST

Non IBR - Structural Welding.

IBR - Pipe & Tube Welding - High Pressure welding.
Separate Test Weld pieces for change of material, Electrode & Procedure.
Plate welding -
Size not less than 229 X381X16 ,
Edge preparation - Double V & Double U Groove ( Single V or Single U for structural welding).
Welding Position:
Flat position - XIII / 6 (1G) plate in horizontal plane with the weld metal deposited from above.
Horizontal Position: - XII/7 (2G) plate in a vertical plane with the axis of the horizontal weld.
Vertical Position - XIII/8 (3G): - Plate & weld in vertical plane welding from underneath.
Overhead: - XIII/9 (4G) plate in horizontal plane with the weld metal deposited from overhead.
NOTE: - If a welder is a qualified for 3G & 4G is also qualified for all position.
If welder is qualified for alloy steel is also qualified for carbon steel.
If welder is qualified for tube & pipe is also qualified for plate.
If welder is qualified for 6G position in tube is also qualified for all position for tube
welding.
NATURE OF WELDING INVOLVEE IN POWER PLANT AT SITE

1. STRUCTURE WELDING.

• MANUAL METAL ARC WEALDING (MMAW).

2. HIGH PRESSURE WELDING.

• TUNGSTEN INERT GAS WELDING (TIG).

• MANUAL METAL ARC WELDING (MMAW).

3. BUS BAR WELDING.

• MIG / MAG WELDING(Metal Inert Gas / Metal Active Gas)

4. REPAIR / MAINTENANCE WELDING (RE-CLAMINATION)

• MANUAL METAL ARC WEALDING (MMAW).

• TUNGSTEN INERT GAS WELDING (TIG).

• THERMAL SPRAYING TECHNIQUES.

 WELDING CODES

WELDING CODES, STANDARDS & SPECIFICATIONS

WELDING CODES, STANDARDS & SPECIFICATIONS

INCLUDE A PLAN TO ASSURE THAT PRODUCTION

WELDS PROVIDE THE QUALITY REQUIRED FOR THE

PRODUCT.
 WELDING CODES

WELDING CODES INCLUDE METHODS FOR

WELDING PROCEDURE

WELDER QUALIFICATION TESTS

CERTIFICATION
 WELDING CODES
WHERE DO WELDING CODES COME FROM ?

WELDING CODES ARE ISSUED BY PROFESSIONAL BODIES SUCH

AS

AMERICAN WELDING SOCIETY (AWS)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

AMERICAN PETROLEUM INSTITUTE (API)

 WELDING CODES
WHERE DOES THE QUALIFICATION AND CERTIFICATION
CYCLE BEGIN & HOW IT IS DONE?

DESIGN OF THE JOINT, PROCESS

DEVELOP WELDING PROCEDURE SPECIFICATION (WPS)

QUALIFICATION OF WPS

RECORDED AS PROCEDURE QUALIFICATION RECORD (PQR)

WELDER PERFORMANCE QUALIFICATION

 WELDING CODES
WHAT WELDING VARIABLES ARE DESCRIBED IN WPS?

WELDING PROCESS
BASE MATERIAL
BASE MATERIAL THICKNESS/ PIPE DIAMETER
FILLER METAL
WELD TYPE
WELDING POSITION (S)
SHIELDING GAS
PREHEAT CONDITIONS
 WELDING CODES
WHAT WELDING VARIABLES ARE DESCRIBED IN WPS?

POST WELD HEAT-TREATMENT

ELECTRICAL CHARACTERISTICS
POLARITY
CURRENT, VOLTAGE
TRAVEL SPEED
WIRE FEED SPEED
ELECTRODE SIZE
BACKING
 WELDING PROCEDURE SPECIFICATION
(QW 201.1 SECTION – IX, ASME PRESSURE VESSEL CODE)

COMPANY NAME ABC PRESSURE VESSEL COMPANY PREPARED BY FRANK JONES, WELDING ENGR.
WPS NO. 1 DATE AUGUST 11, 1991 REVISION NO. DATE SUPPORTING PQR NO.
WELDING PROCESS(ES) GMAW TYPE SEMI – AUTOMATIC
JOINT (QW – 402) DETAILS
75O
JOINT DESIGN SINGLE VEE
BACKING (YES) (NO)
BACKING MATERIAL (TYPE)
METAL NONFUSING METAL 2 MM 2 MM

NONMETALLIC OTHER V - GROOVE JOINT

BASE METALS (QW 403)

P. NO. 1 GROUP NO. 1 TO P. NO. 1 GROUP NO. 1
OR SPECIFICATION, TYPE AND GRADE TO SPECIFICATION, TYPE AND GRADE
OR CHEM. ANALYSIS & MECH. PROPERTIES TO CHEM. ANALYSIS & MECH. PROPERTIES
THICKNESS RANGE BASE METAL GROOVE 4 MM TO 25 MM FILLET
PIPE DIA. RANGE GROOVE UNLIMITED FILLET OTHER

FILLER METALS (QW – 404)

SPECIFICATION NO. (SFA) 5.18
AWS NO. (CLASS) ER 70S – 3
F. NO. 6
A. NO. 1
SIZE OF FILLER METAL 2 MM
THICKNESS RANGE
ELECTRODE FLUX (CLASS) NONE
FLUX TRADE NAME ~
CONSUMABLE INSERTS, OTHER NONE
 WELDING PROCEDURE SPECIFICATION
(QW 201.1 SECTION – IX, ASME PRESSURE VESSEL CODE)

POSITIONS (QW 405) POST WELD HEAT TREATMENT (QW 407)

POSITION(S) OF GROOVE 2G TEMPERATURE RANGE NONE
WELDING PROGRESSION UP DOWN TIME RANGE ~
POSITION(S) OF FILLET GAS (QW – 408)

PREHEAT (QW – 406) PERCENT COMPOSITION

PREHEAT TEMPERATURE (MINIMUM) 45O C GAS(ES) (MIXTURE) FLOW RATE
INTERPASS TEMPERATURE (MAXIMUM) 100O C SHIELDING CO2 WELDING GRADE 20 CFH
PREHEAT MAINTENANCE 45O C TRAILING NONE
(CONTINUOUS OR SPECIAL HEATING WHERE APPLICABLE SHOULD BE RECORDED BACKING NONE
ELECTRICAL CHARACTERISTICS (QW 409)
CURRENT AC or DC DC POLARITY DCEP AMPS (RANGE) 150 – 170 VOLTS (RANGE) 21 - 23
(AMPS AND VOLTS RANGE SHOULD BE RECORDED FOR EACH ELECTRODE SIZE, POSITION, AND THICKNESS, ETC. THIS INFORMATION MAY BE LISTED IN A TABULAR FORM SIMILAR TO THAT SHOWN BELOW)

TUNGSTEN ELECTRODE SIZE AND TYPE NONE MODE OF METAL TRANSFER FOR GMAW SHORT CIRCUIT MODE
ELECTRODE WIRE FEED SPEED RANGE 750 CM / MINUTE

TECHNIQUE (QW – 410)

STRING OR WEAVE BEAD WEAVE ORIFICE OR GAS CUP SIZE 12.5 MM ID
INITIAL AND INTERPASS CLEANING (BRUSHING, GRINDING ETC) BRUSH TO CLEAN METHOD OF BACK GAUGING NONE
OSCILLATION AS REQUIRED CONTACT TUBE TO WORK DISTANCE 12.5 MM TO 18 MM
MULTIPLE OR SINGLE PASS (PER SIDE) MULTIPLE MULTIPLE OR SINGLE ELECTRODES SINGLE
TRAVEL SPEED (RANGE) 600 MM/MIN PEENING NONE
OTHER ALL TACK WELDS TO GROUND TO FEATHER EDGE. ALL STARTS AND STOPS TO BE GROUND TO SOUND METAL. ALL
SURFACE CRACKS OR HOLES TO BE REMOVED BEFORE CONTINUING.

WELD LAYER (S) PROCESS FILLER METAL CURRENT VOLT TRAVEL REMARKS
CLASS DIA TYPE POLARITY AMP RANGE RANGE SPEED RANGE
1 GMAW ER70S-6 2 MM DC DCEP 150-170 21-23 600 MM/MIN
SUBSEQUENT LAYERS GMAW ER70S-6 2 MM DC DCEP 150-170 21-23 600 MM/MIN
 WELDING CODES
HOW THE TEST SPECIMEN IS PREPARED?

STEP – 1
PREPARE A SINGLE V - GROOVE BUTT JOINT TEST PIECE

TEST PIECE DIMENSIONS

 WELDING CODES
HOW THE TEST SPECIMEN IS PREPARED?
STEP – 2

A WELDER TO DO WELDING AS PER APPLICABLE WPS

 WELDING CODES
TESTS ON QUALIFICATION WELD TEST SPECIMEN

IN MOST CASES, TESTING INCLUDES ONE OR

MORE OF THE FOLLOWING:
VISUAL INSPECTION
GUIDED BEND TEST
TENSILE TESTS
FRACTURE TEST
MACRO - ETCH TEST
RADIOGRAPHIC TESTS
 WELDING CODES
WHAT ARE THE VISUAL EXAMINATION CRITERIA ?

REFERENCE STANDARD AWS D1.1, SECTION 4.8.1

ACCEPTANCE CRITERIA

WELD SHALL BE FREE OF CRACKS

HAVE ALL CRATERS FILLED TO FULL C.S. OF WELD

UNDERCUT SHALL NOT EXCEED 1 MM

 WELDING CODES
WHAT ARE THE VISUAL EXAMINATION CRITERIA ?

REFERENCE STANDARD AWS D1.1, SECTION 4.8.1

ACCEPTANCE CRITERIA

WELD REINFORCEMENT NOT TO EXCEED 3 MM

ROOT – NO EVIDENCE OF CRACK, INCOMPLETE

FUSION

MAXIMUM ROOT CONCAVITY = 1.6 MM

 WELDING CODES
IF THE VISUAL EXAMINATION IS GOOD, WHAT OTHER
TESTINGS ARE NEEDED ?

TEST THE INTEGRITY OF THE WELD BY

1. NDT METHODS

RADIOGRAPHIC TEST

ULTRASONIC TEST

GOVERNING CODE IS AWS D1.1, SECTION 6 PART C

 WELDING CODES
IF THE VISUAL EXAMINATION IS GOOD, WHAT OTHER
TESTINGS ARE NEEDED ?

TEST THE INTEGRITY OF THE WELD BY

2. MECHANICAL TESTS

ROOT AND FACE BEND TESTS

SIDE BEND TEST

 WELDING CODES

What positions can this weld be made in?

Welding can be performed in any of the four positions.

Welding Position Qualification Range

Flat Flat, Groove & Fillet
Horizontal Flat & Horizontal
Vertical Flat, Horizontal & Vertical
Overhead Flat & Overhead
Overhead & Vertical All Positions
 TESTING QUALIFICATION WELDS

What type of weld testing is required for

qualification?

Groove Weld Cut Guided bend test specimens from

specified location of test piece
Bend in Specified Jigs
Fillet Weld Weld Break Test
Macro - Etch Test
HEAT TREATMENT
Residual stresses arise from the thermal contraction which occurs as the temperature decreases. Heat

treatment is used to eliminate residual stresses in order to reduce brittle fracture or stress corrosion cracking

by plastic deformation.

1) PRE – HEATING :

Carbon Steel - Over 30 mm wall thickness 100°C

Alloy Steel - Over 10 mm wall thickness 200°C – 250°C

Austenitic Steel - Over 6 mm 300°C – 350°C

Heating Area Wall Thickness

< 50mm each side of weld < 30 mm

< 150mm > 30 mm

Heating by gas burners is permitted only for < 20 mm wall thickness otherwise Electric heating
2) POST WELD HEAT TREATMENT

To raise the ductility and stable fineness of structure.

Heat treatment should be carried just after welding is over for Austenitic Steel (Before

cooling weld below 3000C)

Thickness > 25 mm for 600mm.

Heating width should be 6 times of thickness ( 6 x t)

POST WELD HEAT TREATMENT
ANNEALING

SOAKING TEMPEMPERATURE IS ABOVE

CRITICAL TEMPERATURE ( + 38O C)

COOLING IS DONE IN THE FURNACE

POST WELD HEAT TREATMENT
NORMALIZING

SOAKING TEMPEMPERATURE IS ABOVE

CRITICAL TEMPERATURE ( + 38O C)

COOLING IS DONE IN THE STILL AIR

STRUCTURE OBTAINED IS OF GREAT STRENGTH
BUT LESS DUCTILITY
POST WELD HEAT TREATMENT
TEMPERING

SOAKING TEMPEMPERATURE IS BELOW

CRITICAL TEMPERATURE ( + 38O C)

IT IS 566O C TO 649O C

COOLING IS DONE BY QUENCHING

POST WELD HEAT TREATMENT
STRESS - RELIEVING
SOAKING TEMPEMPERATURE IS BELOW
CRITICAL TEMPERATURE ( + 38O C)

IT IS 566O C TO 649O C

SOAKING TIME IS 1 HOUR / 25 MM THICKNESS

COOLING & HEATING RATE

144OC / Hr. – 179OC / Hr.
 WELD DEFECTS

WELDING CURRENT ARC TOO WELDING SPEED PROPER CURRENT

TOO LOW TOO HIGH LONG TOO FAST TOO LOW VOLTAGE & SPEED

WELDING EXAMPLES RELATED TO BAD PRACTICES

 NON DESTRUCTIVE TESTING

WHY IT IS REQUIRED ?

TO ENSURE PRODUCT RELIABILITY.

TO ENSURE WELD DTENGTH FOR THE SERVIC CONDITION.

TO DETECT DEFECTS IN THE WELD.

TO PREVENT ACCIDENTS & SAVE HUMAN LIFE.

TO ENSURE CUSTOMER SATISFACTION AND TO MAINTAIN THE MANUFACTURER’S “GOOD

NAME”.

TO AID IN BETTER PRODUCT DESIGN.

TO CONTROL MANUFACTURING PROCESSES

TO LOWER MANUFACTURING.

TO MAINTAIN A UNIFORM QUALITY LEVEL.

 NON DESTRUCTIVE TESTING

TYPICAL NONDESTRUCTIVE TEST METHODS WHICH CAN BE REQUIRED AT

FIELD ARE
1. VISUAL INSPECTION.

2. LEAK TEST.

3. LIQUID PENETRANT TEST.

4. MAGNETIC PARTICLE TEST.

5. RADIOGRAPHY.

6. ULTRASONIC TEST.

7. EDDY CURRENT TEST.

8. VIBRATION ANALYSES.

9. COATING THICKNESS TEST.

10. HARDNESS TEST.

 ESSENTIALS FOR PROPER WELDING PROCEDURES

1. CORRECT ELECTRODE SIZE.

2. CORRECT CURRENT.
3. CORRECT ARC LENGTH OR VOLTAGE.
4. CORRECT TRAVEL SPEED
5. CORRECT ELECTRODE ANGLE.

BESIDES THE STEADY SIZZLING SOUND THAT A CORRECT ARC PRODUCES, THE SHAPE OF THE

MOLTEN POOL AND THE MOVEMENT OF THE METAL AT THE REAR OF THE POOL SERVE AS A

GUIDE IN CHECKING WELD QUALITY. IN A CORRECTLY MADE DEPOSIT THE RIPPLES

PRODUCED ON THE BEAD WILL BE UNIFORM AND THE BEAD WILL BE SMOOTH, WITH NO

OVERLAP OR UNDERCUT.
1. CORRECT ELECTRODE SIZE.
THE CORRECT CHOICE OF ELECTRODE SIZE INVOLVES CONSIDERATION OF A VARIETY

OF FACTORS, SUCH AS THE TYPE, POSITION AND PREPARATION OF THE JOINT, THE

ABILITY OF THE ELECTRODE TO CARRY HIGH CURRENT VALUES WITHOUT INJURY TO

THE TO THE WELD METAL OR LOSS OF DEPOSITION EFFICIENCY, THE MASS OF WORK

METAL AND ITS ABILITY TO MAINTAIN ITS ORIGINAL PROPERTIES AFTER WELDING, THE

CHARACTERISTICS OF THE ASSEMBLY WITH REFERENCE TO EFFECT OF

STRESSES SET UP BE HEAT APPLICATION, THE PRACTICABILITY OF HEAT TREATMENT

BEFORE AND / OR AFTER WELDING, THE SPECIFIC REQUIREMENTS AS WELDING QUALITY

AND COST OF ACHIEVING THE DESIRED RESULTS.

2. CORRECT CURRENT
IF CURRENT ON EQUIPMENT IS TOO HIGH OR LOW, YOU ARE CERTAIN TO BE

DISAPPOINTED IN YOUR WELD. IF TOO HIGH, THE ELECTRODE MELTS TOO FAST AND

YOUR MOLTEN POOL IS LARGE AND IRREGULAR. IF TOO LOW, THERE IS NOT ENOUGH

HEAT TO MELT THE BASE METAL AND YOUR MOLTEN POOL WILL BE TOO SMALL, WILL

PILE UP, LOOK IRREGULAR.

3. CORRECT ARC LENGTH OR VOLTAGE
IF THE ARC IS TOO LONG OR VOLTAGE TO HIGH THE METAL MELTS OFF THE ELECTRODE

IN LARGE GLOBULES WHICH WOBBLE FROM SIDE TO SIDE AS THE ARC WAVERS, GIVING

A WIDE, SPATTERED AND IRREGULAR BEAD-WITH POOR FUSION BETWEEN ORIGINAL

METAL AND DEPOSITED METAL. IF THE ARC IS TOO SHORT, OR VOLTAGE TOO LOW,

THERE IS NOT ENOUGH HEAT TO MELT THE BASE METAL PROPERLY AND THE

ELECTRODE QUITE OFTEN STICKS TO THE WORK, GIVING A HIGH, UNEVEN BEAD, HAVING

IRREGULAR RIPPLES WITH FUSION.

4. CORRECT TRAVEL SPEED

WHEN YOUR SPEED IS TOO FAST YOUR POOL DOES NOT LAST LONG ENOUGH IMPURITIES

AND GAS ARE LOCKED IN. THE BEAD IS NARROW AND RIPPLES ARE POINTED. WHEN

SPEED IS TOO SLOW THE METAL PILES UP, THE BEAD IS HIGH AND WIDE, WITH A RATHER

STRAIGHT RIPPLE.
5. CORRECT ELECTRODE ANGLE
THE ELECTRODE ANGLE IS OF PARTICULAR IMPORTANCE IN FILLET WELDING AND DEEP

GROOVE WELDING. GENERALLY SPEAKING, WHEN MAKING A FILLET WELD, THE

ELECTRODE SHOULD BE HELD SO THAT IT BISECTS THE ANGLE BETWEEN THE PLATES

(AS SHOWN AT RIGHT) AND IS PERPENDICULAR TO THE LINE OF WELD. IF UNDER CUT

OCCURS IN THE VERTICAL MEMBER, LOWER THE ANGLE OF THE ARC AND DIRECT THE

ARC TOWARDS THE VERTICAL MEMBER.