Arc

Welding Process
Introduction

Shanghai

March 31th~April 1st, 2005

For the benefit of business and people

 Introduction
1 Arc Welding Process

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1

• Electric Arc

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1 Arc Welding Process Electric Arc

An electric arc is an electric discharge passing through the space existing between
two conductors slightly separated, when the air or gas located in this space
becomes conductor.
The arc produces big light and heat and is the heat source used in many welding
processes called arc-welding process.
In order to produce the arc we need two electrodes and between them a gas
conductor called plasma.

Electrode
Liquid Slag Filler Rod
Solid
Slag Flux Coating
Arc
Crater
Solid Welding Metal Molten Metal

H.A.Z
Welding Progress

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2

• The Plasma Column

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 2 Arc Welding Process The Plasma Column

The electric arc is an electric discharge, Gas (Insulating)

relatively high, maintained through a gas
column.
But gases, in normal conditions are
insulating. Protons
The gas has to become conductor in order Neutrons
the arc can be established. Electrons

For it, the atoms of the gas have to separate

into ions and electrons.
This process is called ionization.
The ionization is obtained by the shock with Plasma (Conductor)
the gas of the electrons going out of one of (b) And (d)
the electrodes. are ions
A ionized or partially ionized gas is called (c)
Plasma. electrons

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 2 Arc Welding Process The Plasma Column

During welding the electrodes are :

- A metallic rod (usually called electrode),
and
Electrode
-The piece to be welded (base metal)
In order to pull out the electrons from the
negative electrode (cathode), it is Cathode
necessary to communicate and activating Elections
energy. Plasma Arc
Positive Ions Column Length
The easiest procedure to provide the Anode
activating energy is to produce a short-
circuit by touching the piece with the Base
electrode. Metal

Separating immediately the electrode, a low

voltage is enough for the arc to be maintained.
The electrons leaving the Cathode follow its
way towards the Anode (positive terminal),
and the ions from the plasma make its way
to the Cathode.

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3

• Characteristic Zones of
the Welding Arc

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 Characteristic Zones of the
3 Arc Welding Process Welding Arc
The Welding Arc is divided in three zones: Electrode

- Cathode (Negative Terminal)

Cathode
- Plasma Column (Ionized Gas) Electrons
Plasma Arc
Positive Ions
- Anode (Positive Terminal) Column Length
Anode
Base
The emission of electrons is produced in the Cathode. Metal

The electrons ionize the gas transforming it into plasma. The ions produced in the
plasma column bombard the cathode, heating it and allowing the emission of
electrons.
In the Cathode, part of the energy is used to take out the electrons.
The temperature is lower in the Cathode than in the Anode.
The Anode receives the electrons coming from the Cathode and is hotter than the
Cathode.
The Plasma Column has a very high temperature, about 3000º C.
The gas ionized could be the air, the vapors detached from the coating of the covered
electrodes and/or the shielding gases.

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4

• Type of Current /
Polarity

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4 Arc Welding Process Type of Current / Polarity

Direct Current or Alternating Current could be used to create the electric arc between
the electrode and the piece to be welded.
When using Direct Current we can have Straight or Reverse Polarity:
We have Direct Current Straight Polarity (DCSP) when the electrode is connected to the
negative terminal (Cathode) and the piece to the positive (Anode).
We have Direct Current Reverse Polarity (DCRP)when the electrode is connected to the
positive terminal (Anode) and the piece to the negative (Cathode).
The selection of the polarity depends on the welding process, type of electrode, base
material, etc.

Positive Semicycle

Current (I)
Current (I)

Amplitude
Time
Time
Period
Negative Semicycle

Direct Current Alternating Current

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4 Arc Welding Process Type of Current / Polarity

Electrode Holder

Electrode Electrode Cable

Power Source

Positive

Piece Connection
Piece Cable Negative

Earth Connection

Direct Current Straight Polarity (DCSP)

Electrode connected to the negative terminal

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4 Arc Welding Process Type of Current / Polarity

Electrode Holder

Electrode Electrode Cable

Positive

Piece Connection
Piece Cable Negative

Earth Connection

Direct Current Reverse Polarity (DCRP)

Electrode connected to the positive terminal

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4 Arc Welding Process Type of Current / Polarity

¾ Polarity Effects
The hottest zone is the Anode (positive terminal).
When Reverse Polarity (DCRP) is used, the hottest zone is the electrode.
Positive ions shocking with the Cathode produce a scaling effect.
When Reverse Polarity is used the piece is scaled, this is very important for the welding
of Aluminum or Magnesium alloys, as these materials are covered with refractory layers
with high melting point.

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5

• Characteristics of
(DCRP) Direct Current
Reverse Polarity

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 Characteristics of (DCRP) Direct
5 Arc Welding Process Current Reverse Polarity

Electrons
Anode Electrode
Positive ions

Hottest Zone

Power
Source

Cathode
Piece

- Melting bath relatively wide with low penetration.

- Excessive heating of the electrode that can be damaged.
- Scaling and cleaning of oxides in the piece, making easier the welding
of Aluminum and Magnesium alloys.

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6

• Characteristics of
(DCSP) Direct Current
Straight Polarity

17
 Characteristics of (DCSP) Direct
6 Arc Welding Process Current Straight Polarity

Cathode
Electrode
Electrons

Positive ions

Power
Source

Anode

Piece
Hottest Zone

- The piece is highly heated.

- Narrow beads with high penetration are produced.
- The electrode can bear bigger currents than with reverse polarity
(about 8 times higher).
- No Scaling effect is produced in the piece to be welded.
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7

• Different Arc Welding

Process

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7 Arc Welding Process Different Arc Welding Process

Type of
Welding Process
Protection
SMAW (Shielded Metal Arc Welding) (Covered Electrode)

Flux SAW (Submerged Arc Welding)

FCAW (Flux Core Arc Welding)

MIG (GMAW) (Gas Metal Arc Welding) (Metal Inert Gas)

Gas MAG(GMAW) (Gas Metal Arc Welding) (Metal Active Gas)

TIG (GTAW) (Gas Tungsten Arc Welding) (Tungsten Inert Gas)
PAW (Plasma Arc Welding)

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8

• Shielded Metal Arc

Welding (SMAW)

21
 Shielded Metal Arc Welding (SMAW)
8 Arc Welding Process Process
¾ (SMAW)
In arc welding with covered electrodes,
the metal melting is achieved with the heat
generated by the electric arc. established Enveloping
Gas Shield
between the end of the covered electrode Solid Slag
Liquid Slag
and the base metal to be welded. Filler Rod
Flux Coating
Filler Metal Drop
The filler metal is produced by the fusion
of the electrode in small drops.

The shielding is gotten by decomposition

of the flux coating into gases and liquid
Base Metal Solid Welding Liquid Welding Metal
Slag. Metal
(Molten Weld Pool)

The liquid slag floats on the molten weld

pool and later solidifies. Also Called: Arc Welding with Covered
Electrode or Manual Metal Arc Welding

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 Shielded Metal Arc Welding (SMAW)
8 Arc Welding Process Equipment
• Advantages
The welding equipment is relatively simple, not very expensive and portable.
The filler metal and the shielding means are included in the electrode. No necessary
additional protection with gas or granulate flux.
Less sensible to the wind than the process with gas shielding.
Not necessary cooling water or shielding gas bottles, it can be used far away from
the power source.
Can be used for a large variety of thickness above 2mm.

Mains Connection Electrode Electrode Holder

Power Source Cable

Electrode
Arc

Piece Electric Piece

Cable Connection

(Also Called Manual Metal Arc Welding and Arc Welding with Covered Electrode)

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 Shielded Metal Arc Welding (SMAW)
8 Arc Welding Process Equipment

• Limitations
This is a slow process due to its low deposition and the need to take out the slag.
It needs high skilled welders.
Deposition rate is lower than that of continuous wire electrode, FCAW or GMAW,
loosing each time at least 5cm length of electrode.
The productivity is not good with thickness bigger than 38mm.

Mains Connection
Power Source Electrode
Electrode Holder
Cable

Electrode

Arc

Piece Cable Electric Piece

Connection

(Also Called Manual Metal Arc Welding and Arc Welding with Covered Electrode)

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9

• Submerged Arc Welding

(SAW)

25
 Submerged Arc Welding (SAW)
9 Arc Welding Process Process
¾ (SAW)

A - Welding Bead
B - Solid Slag
C - Flux Suction
D - Electrode Support Guide
E -Electrode(Rod)
F - Flux Powder
G- Flux Feeder
H - Roof Bead
I - Base Metal

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 Submerged Arc Welding (SAW)
9 Arc Welding Process Process
¾ (SAW)
It consists in the melting of a continuous bare wire shielded by the slag generated
from a flux, granulated or in powder, supplied through a pipe from a flux store.
It has a high deposition rate.
It can be automatic or semiautomatic. (Semi-automatic is almost not used)
With the automatic system a high performance is obtained in the production.
The electric arc is established between the metallic wire and the piece to be welded.
One or more wires can be used simultaneously.
The arc and the molten weld pool are protected from the atmosphere covered with the
flux in such a way that they are invisible during the process
A part of the flux is melted in the same way as for the coating of covered electrodes,
protecting and stabilizing the arc and producing a viscous slag. The rest of the flux is
recovered and used again.

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 Submerged Arc Welding (SAW)
9 Arc Welding Process Process
¾ (SAW)
Filler Wire Automatic Feed

To the Flux Store

Flux Conduction
Pipe
Solid
Welding Bead Slag Flux Screen Guide Flux
Finished
Bevel in V

Filler Wire Base Metal Piece Electric

Connection
Welding Progress
Backing Run-on Plate
Plate

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 Submerged Arc Welding (SAW)
9 Arc Welding Process Process / Equipment
¾ (SAW)
• Advantages
Big deposition and high performance.
High quality of welded joints.
Easy automation of the process.
Is used to weld Carbon Steel, Low Alloy Steels and Stainless Steel.

• Limitations
Can be used only in Flat Position (Down-hand Position).
Normally needs a Backing.
Used only for long welding joints.

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10

• Gas Metal Arc Welding

(GMAW)

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 Gas Metal Arc Welding (GMAW)
10 Arc Welding Process Process
¾ (GMAW)
Electrode

Shielding Gas Pipe Electric Cable

Contact Pipe
Welding Progress

Nozzle

Gas Protection
Electrode/Consumable Wire
Arc Welding Bead
Base Metal

Also Called: (MIG) Metal Inert Gas

(MAG) Metal Active Gas

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 Gas Metal Arc Welding (GMAW)
10 Arc Welding Process Process
¾ (GMAW)
The arc welding with gas protection is a welding process in which the heat is generated
by the arc established between a consumable electrode and the piece to be welded.

The electrode is a solid bare wire, feed in a continuous and automatic way.

The electrode, arc, molten metal and adjacent zones are protected from the
atmospheric gas contamination by a gas flow, concentric to the wire/electrode,
supplied through the nozzle of the gun.

If an inert gas is used as shielding gas, the process is called MIG (Metal Inert Gas).

If an active gas is used as shielding gas, the process is called MAG (Metal Active Gas).

This process can be automatic or manual.

The manual process is called semi-automatic .

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 Gas Metal Arc Welding (GMAW)
10 Arc Welding Process Equipment
¾ (GMAW)
Reduce Valve
Wire
Supply
Wire Feed
Unit
Shielding
Gas Supply

Welding
Gun Power
Cooling
Water
Supply
Supply
Piece (Optional)

Piece Cable Cable

Water to the Gun Shielding Gas from Cylinder
Water from the Gun Control Connection
Gun Connection Gun Cable
Shielding Gas to the Gun Power Supply

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 Gas Metal Arc Welding (GMAW)
10 Arc Welding Process Process
¾ (GMAW)
• Advantages
It can be used for the welding of any kind of material.
The electrode is continuous, the performance and the deposition rate are increased
as it is not necessary to replace the electrode.
The welding speed is much bigger than SMAW process.
It is possible to weld in any position.
Long welding joints can be made without interruption.
No need to take out the slag as there is no slag.

• Limitations
The welding equipment is expensive, complicated and the transport more difficult
than for SMAW.
Difficult to be used in small spaces.
Needs piping for the gas and cooling water and shielding gas bottles.
Is sensitive to the wind and air currents, must be protected against it.

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 Gas Metal Arc Welding (GMAW)
10 Arc Welding Process Process
¾ Wire Feed System

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 Gas Metal Arc Welding (GMAW)
10 Arc Welding Process Process
¾ Wire Feeder with Four Roller

1 Wire Feeding Nozzle 4 Wire Guide

2 Pulling Rollers 5 Wire Outlet Nozzle

3 Pressure Rollers

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11

• Flux Core Arc Welding

(FCAW)

37
 Flux Core Arc Welding (FCAW)
11 Arc Welding Process Process (without Gas Shielding)
¾ (FCAW) without Gas Shielding
The arc established between a consumable tubular-wire-electrode and the piece to be
welded generates the heat.
The protection is given by the flux contained inside the tubular wire.
It can be used with or without additional gas protection.

Tubular Core Electrode

Contact Pipe Flux With Metal Powder
Solid Slag Molten
Slag Shielding Gas

Arc and Metal

Transfer

Liquid Welding
Metal
Solid Welding
Metal

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 Flux Core Arc Welding (FCAW)
11 Arc Welding Process Process (with Gas Shielding)
¾ (FCAW)
In this process, the characteristics of the welding with covered electrode, submerged
arc and MIG/MAG are combined.
The difference with MIG/MAG is that, if we weld with a hollow wire filled with Flux,
when it melts a fine layer of slag is deposited above the molten metal.
If it is used without additional gas protection (shelf-shielding or inner-shielded), the
protection is produced by the decomposition and vaporization of the flux.
It if has additional gas protection (gas-shielded or outer-shielded), normally the gas
is CO2 or mixture of CO2 with Argon.

In both cases a fine layer of slag is produce, protecting the welding metal until it
solidifies.

In both cases the arc can resist the wind and atmospheric conditions better than
other process with gas shielding (MIG/MAG and TIG).
Is a semi-automatic process, but can also be automated.

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 Flux Core Arc Welding (FCAW)
11 Arc Welding Process Process (with Gas Shielding)
¾ (FCAW) with Gas Shielding

Nozzle

Contact Pipe
Solid Slag
Shielding Gas
Tubular Core Electrode
Flux With Metal Powder

Molten
Slag
Molten
Solid Weld
Weld Arc and Metal
Metal
Pool Transfer

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12

• Gas Tungsten Arc

Welding (GTAW)

41
 Gas Tungsten Arc Welding (GTAW)
12 Arc Welding Process Process
¾ (GTAW) or (TIG)
The arc established between a non-consumable electrode and the piece to be welded
generate the heat.
A shielding gas protects the arc and the molten weld pool.
If filler metal is used, a metallic rod is introduced in the arc. Filler metal is independent
from the electrode.
The non-consumable electrode is made with Wolfram W (also called Tungsten).

A Gas Nozzle E Welding Bead

Contact Pipe F Molten Metal

B
Electrode Support
G Arc
C Tungsten Electrode
Not Consumable H Filler Metal

D Shielding Gas I Base Metal

Also Called : Tungsten Inert Gas (TIG)

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 Gas Tungsten Arc Welding (GTAW)
12 Arc Welding Process Process
¾ (GTAW) or (TIG)
• Advantages
Can be used to weld most of the metals.
The arc is stable and concentrated.
Is essentially a manual process, but can also be used automated for mass
production and pipe welding.
No slag production.
Produces smooth and regulars joints.
Can be used with or without filler metal.
Can be used for all type of joints and positions.
High quality welds. Excellent control of root penetration bead.
Not too expensive equipment.
Allows for an independent control of the power source and the filler metal.

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 Gas Tungsten Arc Welding (GTAW)
12 Arc Welding Process Process
¾ (GTAW) or (TIG)
• Limitations
Lower deposition rates than with other process (with manual process).
Manual application requires high skilled welders.
Not economic for thickness bigger than 10 mm.
Is sensitive of the wind and air currents, must be protected against it.

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END

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