WELDING

05 08 JULY 2010

Zainal Nazri Mohd Yusuf

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Course Outcome
1. To describe and conduct the joining process using arc based welding
equipments.
2. To identify and analyze causes of weld defect as a result of welding
process.
3. To Indentify destructive testing method used in weldment test.
4. To apply non-destructive inspection methods to detect the surface and
subsurface defect.

SAFETY IN WELDING

Safety precautions that should

be observed in the use of the arc
welding equipment.

 Make sure machine is properly grounded.

Never permit live parts of the electric welder to touch bare skin or
wet clothing.
Do not cool electrode holders by emersion in water.
Turn off power supply when welder is not in use.
Do not stand on wet areas while welding.
Wear leather gloves.
Make sure cable are covered and in good condition.
Make certain that electrode holders are properly insulated.
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 Protect eyes and face from flying particles of slag by use of safety
glasses or face shield.
Wear adequate protective clothing.
Always wear leather gloves.
Wear high top shoes.
Keep collar, shirt pockets, etc buttoned.
Do not touch the electrode or metal where welding has taken place.
Handle hot metal with pliers.
Keep electrode stubs properly disposed of.
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 Use a welding helmet with the correct shade lens in good condition.
Wear suitable clothingdo not leave bare skin exposed to the rays of
the arc.
Do not strike the arc without covering the face and eyes. Give
warning to others before striking the arc.
Avoid looking directly at the arc where others are welding without
proper eye protection.

 Work only in well-ventilated areas.

Use great care when working on metals covered with lead or zinc.
If working in a confined area use respirator or other approved
breathing devices.

 Keep shop clean in areas where welding is to be done.

Do not weld near combustible materials of any kind.
Place at least 10 meter away from the welding area.
Never weld on covered containers which may have held combustible
materials without first taking adequate safety precautions.

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 Be familiar with location and types of fire extinguishers.

Report any unsafe conditions that might start a fire.
Do not weld near inflammable materials.
Do not weld on containers that have held inflammable materials.
Do not weld near electrical fittings or lines.

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WELDING
WELDING

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Definitions
Welding is a material joining process in which two or
more parts are coalesced (joined together) at their
contacting surfaces by a suitable application of heat
and/or pressure.
Metals that is to be joined is called base metal
Most of the welding uses arc welding process in which
fusion is obtained by heating base metal to form a weld
puddle filler material is added to facilitate coalescence.

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Terms
Arc voltage the voltage across the welding arc
Arc Length the distance between the tip of the electrode and the
weld puddle
Bead Result of the weld deposited on the metals being joined.
Weld puddle the molten metal form a pool
Slag outer layer of the weld bead deposited during welding
(SMAW)
Deposited Metal- Filler metal that has been added during a welding
operation
Depth of Fusion the distance from the original surface of the base
metal to that point at which fusion ceases in a
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welding operation.

Arc length
Weld puddle / weld pool

Weld Bead

Depth of fusion/ weld penetration

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leg

The distance from the root to the toe of the fillet weld. The size of the fillet weld is
determined by the length of its legs.

Throat

The shortest distance between the weld root and the weld face. The throat
determines a fillet weld's size and strength.

Toe

A point at which the weld face and the base metal meet.

Face

The exposed surface of a weld on the side from which welding occurs.

Root

The depth that a weld extends into the joint root

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Welding Position
There are essentially 4 different fundamental welding positions, namely flat,
horizontal, vertical and overhead.

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Definition of welding position for fillet and groove weld as given in BS EN 287-1
AWS designation.
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Horizontal position 2G

Incline position 6G
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Vertical position

Overhead position

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Type of Joint

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Alternating Current (AC)

Alternating current constantly change its polarity 120 times,
producing 60 positive half cycle and 60 negative half cycle.
This can reduce the arc blow due to magnetic field.

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DCEP (DCRP)
In direct-current arc welding, the arrangement of leads where the
surface to be welded is the negative and the electrode is the
positive relative to the welding arc.

+ve

-ve

Current flow

Work piece

deeper penetration is needed

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DCEN (DCSP)
the arrangement of direct current arc welding leads in which the
electrode is the negative pole and the work piece is the positive
pole.

+ve

-ve

Work piece

Shallow penetration
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Welding Techniques
There are two techniques for moving the torches, gun or electrode holder;
Forehand the flame is directed against the base metal ahead of the completed weld.

Backhand the flame is directed towards the completed weld.

Base metal

Base metal

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Manipulation Techniques

Manipulation techniques can control

bead size, shape, penetration
Bead results depends on the weave
motion applied during welding
operation.
There are few types of weave
patterns could be practiced to
obtain the good weld bead.
Straight drag
Number 8 style
Crescent style
Z style
Whip and pause style
And etc.

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Welding Symbol

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Welding Symbol

Reference Line
Leader and arrow
Basic weld symbol (location & depth of weld)
Finish symbol
Weld symbol
Dimensions
Supplementary symbols
Tail and specifications
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Contd
Welding symbol is based on ANSI/AWS A2.4, Standard and symbols for
welding , Brazing and Non-destructive testing

Reference Line
Leader

Tail

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34

Frequently Used Symbol Elements For

Structural Welding

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Example
Fillet Weld
Opposite side

Weld around

Arrow side
Specification

Result

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Butt Joint

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Weld symbol (Fillet joint)

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Weld symbol (Corner Joint)

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Arc Welding Process

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SMAW
Shielded Metal Arc Welding (SMAW) is a
welding process in which the base
metals are heated to fusion or melting
temperature by an electric arc
The arc is created between a covered
metal electrode and the base metals.
A shielding gas is use to protect the
weld area from the atmosphere. The gas
is not pressurized. As the flux covering
on the electrode melts, it creates the
shielding gas. The melting electrode
were furnishes filler metal to the weld.

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Application of SMAW

Principle of SMAW

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Advantages
1.1.
2.2.
3.3.
4.4.
5.5.
6.6.
7.7.
8.8.

Ability
Abilityto
toweld
weldininall
allposition
position
Ease
Easeininwelding
weldingmany
manydifferent
different
metals
and
alloys
metals and alloys
Ability
Abilityto
toweld
weldthin
thinand
andvery
verythick
thick
metals
metals
Very
Veryportable
portableand
andgood
goodfor
forfield
field
work
work
Good
Goodchoice
choicefor
forrepair
repairwork
work
Low-cost,
Low-cost,low
lowmaintenance
maintenance
equipment
equipment
Good
Goodarc
arcvisibility
visibility
Good
Goodaccessibility
accessibilityininrestricted
restricted
areas
areas

Limitations
1.1.
2.2.
3.3.
4.4.
5.5.

High
Highpotential
potentialfor
forweld
weld
contamination
contamination
Frequent
Frequentinterruptions
interruptionsdue
dueto
to
electrode
length
electrode length
Need
Needto
toremove
removespatter,
spatter,smoke
smoke
and
slag
and slag
Unsuitability
Unsuitabilityfor
forvery
verythin
thin
material
material
Electrode
Electroderequires
requiresspecial
specialcare
care
totoprevent
moisture
pickup
prevent moisture pickup

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44

45

GMAW
GMAW uses a continuous, consumable electrode wire, fed from a
spool, to provide the needed filler metal. Shielding of hot and molten
metal is provided by a protective gas flowing from proper containers.

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Advantages

Increase arc time

Improve productivity
Reduced operator
fatigue
No need to chip away
slag
Reduced smoke and
fumes
Skills easily learned
Cleaner work area

Limitations

Possible lack of fusion

Material thickness
limitation
Porosity when there is no
shielding gas.

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Regulator
controller

Shielding gas

Power source

Cable
Ground Clamp

Gun / Torch
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Electrode wire

Wire feeder
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Shielding Gas

Trigger the button will activate the gas and current delivery

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Gas Tungsten Arc Welding (GTAW)

Non consumable arc welding processes use tungsten
electrodes and shielding is provided by an inert gas around the
weld area. Once such process, the Gas Tungsten Arc Welding
(GTAW) is also called as Tungsten Inert Gas (TIG) welding.
It uses tungsten alloy electrode and helium gas shield. Because
of inert gas atmosphere tungsten is not consumed. Filler materials
supplied by a separate rod or wire.

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Advantages

THE
THEWELD
WELDARE
AREVERY
VERYCLEAN
CLEAN
AND
HAVE
GOOD
QUALITY
AND HAVE GOOD QUALITY
ARC
ARCHEAT
HEATIS
ISINTENSE
INTENSEAND
AND
HIGHLY
CONCENTRATED
HIGHLY CONCENTRATED
NO
NOSMOKE,
SMOKE,FUMES,
FUMES,
SPATTER,
SPATTER,OR
ORSLAG
SLAGIS
IS
CREATED
CREATED
WELD
WELDZONE
ZONEIS
ISHIGHLY
HIGHLY
VISIBLE
VISIBLE
GTAW
GTAWCAN
CANBE
BEUSED
USEDTO
TO
WELD
WELDMOST
MOSTINDUSTRIAL
INDUSTRIAL
METALS
METALS

Limitations

SLOW
SLOWWELDING
WELDINGSPEED
SPEED
EXPENSIVE
EXPENSIVEEQUIPMENT
EQUIPMENT
COSTLY
COSTLYUSED
USEDOF
OFINERT
INERT
GASES
GASES
REQUIREMENT
REQUIREMENTOF
OFHIGHLY
HIGHLY
SKILLED
SKILLEDWELDER
WELDERFOR
FOR
MANUAL
MANUALWELDING
WELDING

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AC current

DCEN

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Welding Defect

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Undercut
undercutting is a defect that appears as a groove in the parent metal directly
along the edges of the weld. It is most common in lap fillet welds, but can also
be encountered in fillet and butt joints. This type of defect is most commonly
caused by improper welding parameters; particularly the travel speed and arc
voltage.
The arc length should be kept short, not only to avoid undercutting but to
increase penetration and weld soundness

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Porosity

The most common causes of porosity are atmosphere contamination, excessively

oxidized work piece surfaces, inadequate deoxidizing alloys in the wire and the
presence of foreign matter. Atmospheric contamination can be caused by:
1) Inadequate shielding gas flow.
2) Excessive shielding gas flow. This can cause aspiration of air into the gas
stream.
3) Severely clogged gas nozzle or damaged gas supply system (leaking hoses,
fittings, etc.)
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Incomplete Fusion

Incomplete fusion weld pool did not wet surface of workpiece due to
fast traveling speed. The molten material solidified rapidly and not enough
Fusion form.

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Overlap

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Under fill

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Spatter
Spatter- surface damage caused by molten metal from arc or weld pool.
Arc length too long.

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EXCESSIVE CONVEXITY

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EXCESSIVE CONCAVITY

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Excessive weld reinforcement

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Slag inclusion

pieces of slag trapped inside solidified weld pool; may result from
excessive stirring in weld pool, or failure to remove slag from prior weld
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Incomplete Penetration
This type of defect is found in any of three ways:
1) weld bead does not penetrate the entire thickness of the base plate.
2) Two opposing weld beads do not interpenetrate.
3) weld bead does not penetrate the toe of a fillet weld but only bridges across it.
Causes:
Low welding current.
Slow a traveling speed and an incorrect torch angle.
Both will allow the molten weld metal to roll in front of the arc, acting as a cushion
to prevent penetration. The arc must be kept on the leading edge of the weld
puddle.

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Incomplete penetration insufficient heating during welding for weld pool to penetrate
to opposite side (or centerline) of weld; results in a gap behind/under weld

Excessive penetration

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THE END
THANK YOU

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