ELECTRIC ARC WELDING TECHNIQUES & SELECTION OF ELECTRODES

ARC WELDING ARC WELDING PPE TYPES OF ARC WELDING

SELECTION CRITERIA OF ELECTRODES

WELDING INSPECTION TECHNIQUES

DEFECTS IN ARC WELDING

ARC WELDING
The fusing of two or more pieces of metal together by using the heat produced from an electric arc welding machine.

ARC WELDING PPE

TYPES OF ARC WELDING

SHEILDED METAL ARC WELDING (SMAW) GAS TUNGSTEN ARC WELDING PLASMA ARC WELDING GAS METAL ARC WELDING FLUX CORED ARC WELDING SUBMERGED ARC WELDING ELECTROSLAG WELDING (GTAW) (PAW) (GMAW) (FCAW) (SAW) (ESW)

SMAW
SMAW is a process that melts and joins metals by heating them with an arc established between a sticklike covered electrode and the metals, as shown in Figure. It is often called stick welding.

ADVANTAGES & DISADVANTAGES

The welding equipment is relatively simple, portable, and inexpensive as compared to other arc welding processes. For this reason, SMAW is often used for maintenance, repair, and field construction. Welding can be carried out in any position with highest weld quality.

SMAW is not clean enough for reactive metals such as aluminium and titanium.
The limited length of the electrode requires electrode changing, and this further reduces the overall production rate.

GTAW
GTAW is a process that melts and joins metals by heating them with an arc established between a nonconsumable tungsten electrode and the metals, as shown in Figure.

ADVANTAGES & DISADVANTAGES

GTAW is suitable for joining thin sections because of its limited heat inputs. This process can weld in all positions and produces smooth and sound welds with less spatter.

GTAW process is a very clean welding process, it can be used to weld reactive metals, such as titanium and zirconium, aluminium, and magnesium. The deposition rate in GTAW is low.
Excessive welding currents can cause melting of the tungsten electrode and results in brittle tungsten inclusions in the weld metal.

PAW
PAW is an arc welding process that melts and joins metals by heating them with a constricted arc established between a tungsten electrode and the metals, as shown in Figure.

ADVANTAGES & DISADVANTAGES

PAW is less sensitive to unintentional arc length variations during manual welding and thus requires less operator skill than GTAW. Keyhole is a positive indication of full penetration, and it allows higher welding speeds to be used in PAW. PAW torch is more complicated. The equipment cost is higher in PAW than in GTAW.

GMAW
GMAW is a process that melts and joins metals by heating them with an arc established between a continuously fed filler wire electrode and the metals, as shown in Figure.

ADVANTAGES & DISADVANTAGES

GMAW can be very clean when using an inert shielding gas.

The main advantage of GMAW over GTAW is the much higher deposition rate, which allows thicker workpieces to be welded at higher welding speeds. GMAW can produce joints with deep penetration.
GMAW equipment is more complex, more costly and less portable. GMAW guns can be bulky and difficult-to-reach small areas or corners.

FCAW
FCAW is similar to GMAW, however, the wire electrode is flux cored rather than solid; that is, the electrode is a metal tube with flux wrapped inside.

ADVANTAGES & DISADVANTAGES

When using FCAW, a welder does not have to stop and change rods as in SMAW. FCAW can be used with or without shielding gas. Excellent weld appearance, smooth and uniform welds, less liable to porosity. Used only to weld ferrous metals, primarily steels.

FCAW produces a slag covering which has to be removed.

SAW
SAW is a process that melts and joins metals by heating them with an arc established between a consumable wire electrode and the metals, with the arc being shielded by a molten slag and granular flux, as shown in Figure.

ADVANTAGES & DISADVANTAGES

The protecting and refining action of the slag helps produce clean welds in SAW. The arc is submerged, spatter and heat losses to the surrounding air are eliminated even at high welding currents.

Both alloying elements and metal powders can be added to the granular flux to control the weld metal composition and increase the deposition rate, respectively. The relatively large volumes of molten slag and metal pool often limit SAW to flat-position welding and circumferential welding (of pipes).
The relatively high heat input can reduce the weld quality and increase distortions.

SELECTION CRITERIA OF ELECTRODES

FUNCTIONS OF ELECTRODE COVERING
The covering of the electrode contains various chemicals and even metal powder in order to perform one or more of the functions. PROTECTION

FLUIDITY OF FILLER METAL

DEOXIDIZERS

ARC STABILIZATION
METAL ADDITION

AWS CLASSIFICATION SYSTEM

The AWS system distinguishes the tensile strength, weld position and, coating and current. Manufactures may and do use there own numbering system and produce electrodes that do not fit in the AWS system.

SELECTION OF ELECTRODE MATERIAL

TYPE OF THE WELDING

BASE METAL MATERIAL

TENSILE STRENGTH WELDING POSITION

WELDING INSPECTION TECHNIQUES

DESTRUCTIVE TESTING
Transverse Tension Testing Fillet Weld Break Testing

Guided Bend Testing

Macro Etch Testing

NON-DESTRUCTIVE TESTING
Visual Inspection Radiographic Inspection Magnetic Particle Inspection Liquid Penetrant Inspection Ultrasonic Inspection

DEFECTS IN ARC WELDING

GEOMETRIC IMPERFECTION CRACKING INCLUSION POROSITY

WELD DAMAGE
CRATERS

INCOMPLETE FUSION / PENETRATION

SPATTER

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