ELECTRIC

ARC
WELDING

1- E

ELECTRIC ARC WELDING

PROCESS DEFINITION
Arc welding is a group of welding processes that produce
coalescence of work-pieces by heating them with an arc.
The processes are used with or without application of
pressure and with or without filler metal

Contd.

2- E

LAY OUT FOR METAL ARC WELDING

Contd.

3- E

COMMON TYPES OF ARC WELDING

Following types of arc welding are very common in
industries like fertilizer, petrochemical, refineries, oil and
gas purification plants, etc.;

Arc welding with consumable electrodes

Arc welding with non-consumable electrodes

Contd.

4- E

EQUIPMENT AND ACCESSORIES

(ELECTRIC ARC WELDING)

Following equipment and accessories are required for an

electric arc welding;
EQUIPMENT

ACCESSORIES

Power source

Shielding Gases and regulators

Power cable

Hoses, clamps, thimbles

Ground cable

Electrodes

Electrode holder

Oven

Earth clamp

Welding gadgets

Contd.

5- E

EQUIPMENT

(ELECTRIC ARC WELDING)

TYPES OF POWER SOURCES (WELDING MACHINES)

Following types of welding machines are commonly used to
supply power for electric arc welding:

Welding Generators

Welding Rectifiers

Welding Transformers

Welding Invertors

Contd.

6- E

WELDING GENERATOR

Contd.

7- E

WELDING GENERATOR

Welding generator is a dynamo, which is driven by an

electric motor or an auto engine that produces electricity
(AC/DC)

Welding generator produces high current (Upto 400/500

Amps) at low potential (72 Volts)

Current produced by generator is steady and is used for

arc welding processes e.g. in SMAW or GTAW

Direct current straight polarity (DCSP) and direct current

reverse polarity (DCRP) are obtained from welding
generators
Contd.

8- E

WELDING GENERATOR (CUT- VIEW)

Contd.

9- E

WELDING RECTIFIER

Rectifier type arc welding machine consists of a

transformer and a rectifier that converts alternating
current (AC) into direct current (DC)

Straight and reverse polarities can be obtained from

rectifier

Very quiet in operation because of no moving parts

(except cooling fan)

It is used for various arc welding processes e.g. in

SMAW or GTAW

Contd.

10- E

WELDING RECTIFIER

Contd.

11- E

WELDING TRANSFORMER
A welding transfer is a step down transformer which uses
single phase 220 volts or 3 phase 440 volts supply. It
produces AC current with high amperage and low voltage.

A transformer consists of primary and secondary coils

Primary terminals are connected to power source

(Main supply)

Secondary terminals are connected to electrode

holder and ground cable

Its use is limited to only SMAW

Contd.

12- E

WELDING TRANSFORMER

Contd.

13- E

CABLES

Welding cables or leads carry welding current from

welding machine to workpiece and back to welding
machine

Lead from welding machine

to work is called electrode
lead or power lead

Lead from work to welding

machine is called ground or
work lead
Contd.

14- E

ELECTRODE HOLDERS AND EARTH CLAMPS

Electrode holder is part of arc welding equipment that

holds electrode firmly when welding. Different styles and
models are available.
Holders are specified according to:

Types of insulation on the jaws

Current capacities

Good ground connections are important when welding

with AC or DC. Work lead is permanently fastened to
work bench or table by earth clamp.
Contd.

15- E

ELECTRODE HOLDERS AND EARTH CLAMP

ELECTRODE HOLDER

ELECTRODE HOLDER

EARTH CLAMP
Contd.

16- E

ACCESSORIES
SHIELDING GAS

The purpose of the shielding gas is to protect the arc

area from atmosphere

Shielding gas displaces air and does not allow

atmospheric gases e.g. nitrogen, oxygen, CO2 and
water vapors to come into contact with molten metal,
the electrode or the arc

Contd.

17- E

TYPES OF SHIELDING GASES

Shielding gases are classified as inert or active

Inert gases do not combine with other elements

Most commonly used gases are argon and

helium

Inert gases are used in TIG and GMAW

welding processes

Active shielding gases include CO2 and others

Contd.

18- E

SHIELDING GAS REGULATORS

Shielding gas cylinders are filled at
high pressure . For shielding, inert
gas is required at low pressure and
controlled flow.
To let-down cylinder high
pressure

into

workable

pressure, gas regulator with

flowmeter is used.

Contd.

19- E

TERMINAL CONNECTIONS/THIMBLES

To carry consistently heavy

currents of welding, all parts in the
circuit
are
of
heavy
duty
construction and design
Welding leads are fastened to
various types of thimbles and lugs
to make connections with the
machine
Thimbles provide firm jointing of
lead to give smooth flow of current,
further,
current
losses
are
minimum
Possibilities of short circuiting and
sparking are minimum

Contd.

20- E

ELECTRODES
Welding electrode is the terminal point to which electricity is
brought in welding operation, from which arc is produced to
perform welding. Electrodes are classified into consumable
and non-consumable types :
a- CONSUMABLE ELECTRODES;

Covered electrodes

Bare electrodes
b- NON-CONSUMABLE ELECTRODES;

Carbon electrodes

Tungsten electrodes
It is evident that covered and bare electrodes are consumed
during welding process as compared to non-consumable
electrode.
Contd.

21- E

TYPES OF COVERINGS/FLUXES

(COVERED ELECTRODES)

There are four main groups of electrode coverings as given below.

Sometimes these coverings are added with Iron Powder to increase
electrode efficiency.

ACID COVERINGS;

Mainly composed of oxides and silicates

Give good profile and are easy to detach

Weld strength is low

Not widely used

CELLULOSIC COVERINGS;

Large variety of organic material

Penetration is better

Surface profile is poor and slag layer is thin

Mechanical properties are good

Contd.

22- E

RUTILE COVERINGS;
These are based on titanium oxide
Good slag forming properties
Widely used in fabrication industry
Profiles are acceptable and slag is easily removable
BASIC COVERINGS;
Contain calcium compounds calcium fluoride and calcium
carbonate (Lime Coated)
Used for welding of high strength steels
Minimizes weld cracking and Slag is difficult to remove

23- E

STORAGE OF COVERED ELECTRODES

Care and storage of covered electrodes is of extreme
importance. Electrodes should be protected from;

Cracking and peeling off covering

Moisture resulting bad quality weld

Aging to be used within recommended period after

opening of boxes
Following cares shall be taken to have better welds;

Loose electrodes to be heated in oven prior to start

welding

Paper packed electrodes shall be heated in oven

before use

Do not use moist and damaged covering electrodes

Avoid usage of unidentified electrodes

Contd.

24- E

BARE ELECTRODES
Electrodes without coating are called bare electrodes

These are used when post cleaning of weld joint is

difficult

Bare electrodes are used in Gas, TIG, MIG etc.

welding processes.

Carbon and low alloy steel electrodes are supplied with

thin layer of copper coating Current pick-up and
storage life are increased.
Contd.

25- E

NON-CONSUMABLE ELECTRODES
CARBON ELECTRODE;
Carbon electrode is a non filler metal electrode, used in arc
welding or cutting. Applications include carbon arc welding,
twin carbon arc welding, carbon cutting, gouging, etc.

TUNGSTEN ELECTRODE;
Tungsten is also a non filler metal electrode, used in arc
welding or cutting. Applications are GTAW, plasma

arc

welding, atomic hydrogen welding, etc.

Contd.

26- E

OVEN
Electrodes become unusable when exposed to moisture
for an extended length of time. Coating on some types of
electrodes absorbs moisture when exposed to humid
atmosphere
Cellulose, rutile, and acid electrodes
are fairly insensitive to moisture and
can tolerate quite high moisture
content
Coatings of low-hydrogen electrodes,
particularly EXX16, EXX18 types,
pickup
moisture
quickly
when
exposed to humid atmosphere
OVENS OR SPECIAL CONTAINERS ARE USED TO HEAT
27- E
OR KEEP DRY THE COVERED ELECTRODES
Contd.

WELDING GADGETS
Welding Helmet
Leather gloves

Leather Jacket
Welding Shoes

Welding Apron

Sleeves for arms

Contd.

28- E

FILTER SHADE NUMBER FOR EYE PROTECTION

Welding or Cutting
Operation

Electrode Size (mm)

or Metal Thickness

Welding
Current (A)

Minimum
protective
Shade

Suggested Shade
numbera (Comfort)

Shielded metal arc welding

Less than 3 (2.5)

3-5 (2.5-4)
5-8 (4-6.4)
More than 8 (6.4)

Less than 60
60-160
160-250
250-550

7
8
10
11

-10
12
14

Gas metal arc welding and

flux -cored arc welding

Less than 60
60-160
160-250
250-500

7
10
10
10

-11
12
14

Gas tungsten arc welding

Less than 50
50-150
150-500

8
8
10

10
12
14

Air carbon
Arc cutting
Plasma arc welding

(Light)
(Heavy)

Less than 500

500-1000
Less than 20
20-100
100-400
400-800

10
11
6
8
10
11

12
14
6 to 8
10
12
14

Plasma arc cutting

(Light)b
(Medium)b
(Heavy)b

Less than 300

300-400
400-800

8
9
10

9
12
14

----

----

3 or 4
2
14

Torch brazing
Torch soldering
Carbon arc welding
Plate Thickness
In.
Gas welding
Light
Medium
Heavy

Under 1/8
1/8 to 1/2
Over 1/2

mm
Under 3.2
3.2 to 12.7
Over 12.7

4 or 5
5 or 6
6 or 8

Oxygen cutting
Light
Under 1
Under 25
3 or 4
Medium
1 to 6
25 to 150
4 or 5
As a rule of thumb, start with
a shade that is too dark toOver
see 6the weld zone. Then
to a lighter shade which gives sufficient 5view
Heavy
Overgo
150
or 6 of the weld zone without

going below the minimum. In oxy-fuel gas welding or cutting where the torch produces a high yellow light, it is desirable to use a filter lens that absorbs the
yellow or sodium line in the visible light of the (spectrum) operation.
b

These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece.

29- E

ARC WELDING-CONSUMABLE ELECTRODES

DEFINITION
In this technique, electrode is melted and molten metal
is carried across the arc gap. A uniform arc length is
maintained between electrode melting end and weld pool
by feeding electrode into the arc as fast as it melts

Contd.

30- E

ARC WELDING-CONSUMABLE ELECTRODE

TYPES
Consumable electrodes

are used in following welding

processes;

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding

(GMAW)

Flux Cored Arc Welding

(FCAW)

Electro Gas Welding

(EGW)

Submerged Arc Welding

(SAW)
Contd.

31- E

SHIELDED METAL ARC WELDING (SMAW)

DEFINITION
Shielded Metal Arc Welding is an arc
welding process where in coalescence
is produced by heating with an arc
between covered metal electrode and
workpiece.

Contd.

32- E

SHIELDED METAL ARC WELDING LAYOUT (SMAW)

Contd.

33- E

OPERATION
Following procedure is used to perform welding with SMAW;

Set-up welding system as per layout and switch-on

machine

Select AC or DC type current and adjust current

amperage

Select polarity - straight or reverse

Maintain correct arc length and weld the weldments as

per joint details and design
Contd.

34- E

ARC WELDING-NONCONSUMABLE ELECTRODES

DEFINITION
In this technique, electrode is not melted and filler metal is
fed into the arc gap, generated between base metal and
non-consumable electrode.
TYPES
Following

welding

processes

use

non-consumable

electrode;

Gas Tungsten Arc Welding (GTAW)

Plasma Arc Welding(PAW)

Carbon Arc Welding

(CAW)

Contd.

35- E

GAS TUNGSTEN ARC WELDING (GTAW)

PROCESS DEFINITION
Gas Tungsten Arc Welding is a process where in
coalescence is produced by heating with an arc between
tungsten electrode (nonconsumable) electrode and the
workpiece. Shielding is obtained from an inert gas or inert
gases mixture. The process may or may not require filler
metal.
Contd.

36- E

SCHEMATIC DIAGRAM (GTAW)

Contd.

37- E

SMAW vs GTAW

38- E

ADDITIONAL EQUIPMENT-GTAW PROCESS

TIG welding torch -

Air or water cooled including

torch accessories

Tungsten electrode

Shielding gas and gas

control regulators

Soft leather gloves,

specially
for
TIG
welding

Contd.

39- E

ADVANTAGES OF GTAW
The outstanding features of arc welding process are:

It will make high quality welds in all metals and

alloys

Very little post cleaning is required

Arc and weld pool are clearly visible to welder

No filler metal carried across the arc, so no spatter

Welding can be performed in all positions

There is no slag produced that might be trapped in

the weld

Very good cleaning of the joint is required for good welding

by GTAW
40- E

SELECTION OF POWER SOURCE AND

WELDING PROCESSES
a- POWER SOURCE
The type of welding indicates type of welding machine
to be used. This depends on thickness, size, material,
application of technique to produce weldment.
Following are considered to select the right power
source;
Process selection - Welding process defined by the
weldments to be produced
Welding current

- Required type of current i.e. Dc,

Ac, steady state pulsed, etc.
Contd.

41- E

 Machine rating

- Job size governs machine rating,

heavier jobs require heavy currents

Type of power

- Electricity or engine driven

Oxiliary devices - water and shielding gas control

systems, current control systems,
wire feeders, etc.
Duty cycle

- Measure of amount of work that

the power source will do.
Categories are low duty, heavy
duty cycles. Duty cycle is the ratio
of arc time to total time.
Contd.

42- E

ARC WELDING POWER SOURCES

43- E

b- PROCESS SELECTION
All metals cannot be joined by each welding process,
some welding processes are developed to join
specific metals, certain metals are known as difficult
to weld, which means that specific precautions and
procedures are required. The given table shows
general selection of various processes against base
metals to be welded.

Contd.

44- E

45- E

WEAVING A BEAD
Weaving is a technique of depositing weld metal in which
the electrode is oscillated in a transverse motion along the
weld direction
Weaving provides following advantages

Improve penetration at both faces of weld joint

Allow slag to come on to surface of puddle

Avoid porosity

Allow gases to escape weld puddle

Keep metal in molten state for short time

46- E

TYPES OF WEAVING
Most commonly used weaving motions
are as following;
Rotary weave used for gas
welding
Curved weave good fusion,
used for root weld, hot pass
Straight bead to keep puddle
hot and cold at the same time
Whip to avoid undercut at
overhead or vertical positions
Box weave used for capping of
weld
Figure 8 weave used with tig
welding

47- E

TYPICAL WEAVING MOTIONS FOR A WELD JOINT

48- E

POWER SOURCE Vs WELDING PROCESSES

Welding Machine Output Characteristics
Direct (Dc):

Alternating (Ac):

CC
Drooping

CV
Flat

CC
Drooping

Pulsed:
CV or CC
Flat or Drooping

Gas tungsten arc welding (GTAW)

Yes

No

Yes

Yes

Plasma arc welding (PAW)

Yes

No

No

Yes

Carbon arc welding (CAW)

Yes

No

Two carbons

Not used

Stud welding (SW)

Yes

Possible

No

Not used

Yes

No

Yes

Not used

GMAW inert gas, nonferrous MIG

Possible

Yes

No

Yes

GMAW spray arc transfer MIG

Possible

Yes

No

Yes

GMAW globular transfer MIG

Possible

Yes

No

No

No

Yes

No

Yes

Special

Special

Possible

Yes

Flux cored arc welding (FCAW)

Yes

Yes

Experimental

Yes

Submerged arc welding (SAW)

Yes

Yes

Yes

Not used

Electrogas welding (EGW)

Possible

Yes

No

Not used

Electrogas welding (EW)

Possible

Yes

Yes

Not used

Arc Welding Process

Nonconsumable electrode process

Consumable electrode processes

Shielded metal arc welding (SMAW)

GMAW short circuiting transfer MIG

GMAW pulsed arc transfer MIG, pulsed

49- E

ARC WELDING - POLARITIES

Arc welding processes where
direct current (DC) supply
machines are employed, have
option of selecting polarities to
connect workpiece or electrode.
There are certain electrodes,
that work on only one polarity

Reverse Polarity
When electrode is connected to positive terminal of welding
machine, it is called reverse polarity
There is high heat input into the electrode, therefore,
reverse polarity is used for SMAW process
Straight Polarity
When electrode is connected to negative terminal of
welding machine, it is called straight polarity
There is less heat input in the electrode, therefore straight
50- E
Contd.
polarity is used for GTAW process

WELDING CURRENTS

Welding currents play important role in the arc welding

processes to get quality welds. Power source should be
able to supply current to have a stable arc during operation

Different current systems and combinations are obtained

from various welding machines. These are:

Constant - Current (CC);

It provides maximum flexibility in manual arc

welding to lengthen or shorten the arc, required to
get appropriate penetration.

This is rarely used for automatic welding processes

and small diameter electrodes.
51- E

Constant - Voltage (CV);

Voltage is maintained and current

depending on resistance of weldments.

varies

Stable arc is obtained when welding with different

electrode sizes and metals in varying welding
atmospheres.

Usage example - Semi automatic gas arc welding.

Pulsed Current;

It is a change from higher to lower current on

repetitive basis.

Used for materials having varied root opening,

different root faces or different thicknesses.

Usage example is in GMAW process.

52- E

HAZARDS AND
SAFETY MEASURES
OF
ELECTRIC ARC WELDING
53- E

HAZARDS TYPES
a.

Electric shock hazard

b.

Arc radiation hazard

c.

Air contamination hazard

d.

Compressed gases hazard

e.

Fire hazard:

54- E

HAZARDS

Electric arc welding has hazards like other operations

involved in fabrication of metals. These are hazardous
to the health of welder and other workers in the vicinity.
OSHA (Occupational Safety and Health Act) and
American National Standard safety in welding and
cutting classify following hazards of arc welding;
a. Electric shock hazard:

These hazards are associated with all electrical

equipments involved in the arc welding.

Electric shock occurs when a leaking current

flows through human body.

Contd.

55- E

b.

c.

Arc radiation hazard:

Bright light of arc emits high intensity ultraviolet

and infrared radiations. Ultraviolet radiations are
damaging to both eyes and skin.
Air contamination hazard:

Harmful gases are produced when metal and

fluxes are heated in the arc welding.

Heat generated during welding operation

depletes oxygen from atmosphere and produces
carbon mono oxide, which is poisonous for
human health.

High concentrations of small solid particles of

metal suspended in the air are extremely
dangerous for human health.

Lubricants and degreasing solvents produce toxic

fumes when heated during arc welding
operations.
Contd.

56- E

d.

Compressed gases hazard:

e.

Certain
arc
welding
processes
use
compressed gases for shielding. These gases
should be handled and stored carefully.

Fire hazard:

In arc welding, hot metal pieces or spatters

may produce fire when fall on any combustible
material.

Contd.

57- E

SAFETY MEASURES

Always use recommended cables for arc welding.

Make sure that welding equipment is installed,
grounded and connected properly, and is in good
working condition.
Check that insulation of electrode holder and cables are
in healthy condition.
Always use recommended filters for breathing in
contaminated atmosphere.
Always wear protective clothing suitable for type of
welding to be done.
Recommended eye protection to be used for grinding,
cutting and welding etc.
Keep the work area free from objects, flammable,
volatile or explosive materials.
Contd.

58- E

Handle all compressed gas cylinders with extreme

care.
Secure compressed gas cylinders with walls or
supports.
Do not weld in confined space without special
precautions.
Do not weld on containers that have hold combustibles
without special precautions.
Always use mechanical exhaust while welding lead,
cadmium, chromium, brass, or galvanized steel etc.
Always use rubber boots or wooden stand, when it is
necessary to weld in a damp or wet area.
When electrode holder is not in use, hang it on the
stand and never let it touch a compressed gas cylinder.
Dispose off electrode stubs in proper container.
59- E

APPENDICES: (1 10A/B)
Welding cables comparison table
2.
Table for welding cable size
3.
Current carrying capacities and voltage drops in
welding cables
4.
Power cable sizes for welding machines
5.
Electrode storage recommendations
6.
Inert gas properties
7.
Shielding gases for welding processes
8.
Samples for welding operator qualification test
(WPQ)
9.
Procedure qualification for welding process (PQR)
10.A/B Welding procedure specification (WPS)
1.

60- E

BASIC MATERIALS
Construction and maintenance Engineer is required to
have basic knowledge about the material or metals that
are going to be joined together.
American Welding Society (AWS) and American Society
of Mechanical Engineers (ASME) defines materials
under

different

P-Numbers

according

to

their

metallurgical characteristics;

Contd.

61- E

P-Numbers Materials
-1

Carbon Steels

-2

Wrought Irons

- 3 to 7

Alloy Steels

- 0.35% max. carbon

- having various combinations

of chrome and other alloying
elements in different %ages

-8

High Alloy Steels - Austenitic (300 series)

- 9 to 11

Nickle Alloy Steels- Having different %ages of Ni.

62- E

COVERED ELECTRODE IDENTIFICATION SYSTEM

66- E

OTHER WELDING PROCESSES

68- E