Gas Metal Arc Welding or MIG welding .
Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) welding or metal active gas (MAG) welding, is a welding process in which an electric arc forms between a consumable wire electrode and the workpiece metal(s), which heats the workpiece metal(s), causing them to melt and join
pulsed spray
globular spray
Welding Processes
Two Categories of Welding Processes
Arc Welding
Resistance Welding
Oxy-fuel Gas Welding
Other Fusion Welding Processes
Solid State Welding
Shielded Metal Arc Welding
Gas Metal Arc Welding
Flux‑Cored Arc Welding
Electro gas Welding
Submerged Arc Welding
Gas Tungsten Arc Welding (GTAW) or TIG
Resistant Welding
Brazing and Soldering
Explained Molten metal transfers in GMAW process ( MIG / MAG)
and equipments used in GMAW process and set up images are arranged in this welding process
Basic knowledge of Gas Tungsten Arc Welding (GTAW) for freshers in the field. This is one of the welding process that produces one of the highest quality of weld for high integrity structures...
Welding Processes
Two Categories of Welding Processes
Arc Welding
Resistance Welding
Oxy-fuel Gas Welding
Other Fusion Welding Processes
Solid State Welding
Shielded Metal Arc Welding
Gas Metal Arc Welding
Flux‑Cored Arc Welding
Electro gas Welding
Submerged Arc Welding
Gas Tungsten Arc Welding (GTAW) or TIG
Resistant Welding
Brazing and Soldering
Explained Molten metal transfers in GMAW process ( MIG / MAG)
and equipments used in GMAW process and set up images are arranged in this welding process
Basic knowledge of Gas Tungsten Arc Welding (GTAW) for freshers in the field. This is one of the welding process that produces one of the highest quality of weld for high integrity structures...
Welding process
Arc Welding
Resistance Welding
Oxy fuel Gas Welding
Other Fusion Welding Processes
Solid State Welding
Weld Quality
Weld ability
Design Considerations in Welding
this ppt pdf beneficial for 1st year engineering student who studying workshop technology. in this pdf types of joining, gas welding, arc welding, spot welding, tig welding, mig welding, soldering brazing and different welding defect has been discussed.
An introduction to various welding processes, suitable for all welding students and welding professionals like welder, supervisor, inspector, engineer.
One of the welding processes that used in Engineering field is the TIG welding. There are several types of welding processes similar to this, but tig welding has its unique features.
Thanks for the colleagues who give this slides to publish.
MIG Welding. Gas metal arc welding (GMAW), also known as MIG (metal inert gas) welding or MAG (metal active gas) welding, is a process in which an electric arc forms between an electrode and a metal workpiece, heating the metals and causing them to melt, and be joined.
One of the welding processes that used in Engineering field is the resistance projection welding. There are several types of welding processes similar to this, but resistance projection welding has its unique features.
Thanks for the colleagues who give this slides to publish.
One of the welding processes that used in Engineering field is the plasma arc welding. There are several types of welding processes similar to this, but plasma arc welding has its unique features.
Thanks for the colleagues who give this slides to publish.
Welding process
Arc Welding
Resistance Welding
Oxy fuel Gas Welding
Other Fusion Welding Processes
Solid State Welding
Weld Quality
Weld ability
Design Considerations in Welding
this ppt pdf beneficial for 1st year engineering student who studying workshop technology. in this pdf types of joining, gas welding, arc welding, spot welding, tig welding, mig welding, soldering brazing and different welding defect has been discussed.
An introduction to various welding processes, suitable for all welding students and welding professionals like welder, supervisor, inspector, engineer.
One of the welding processes that used in Engineering field is the TIG welding. There are several types of welding processes similar to this, but tig welding has its unique features.
Thanks for the colleagues who give this slides to publish.
MIG Welding. Gas metal arc welding (GMAW), also known as MIG (metal inert gas) welding or MAG (metal active gas) welding, is a process in which an electric arc forms between an electrode and a metal workpiece, heating the metals and causing them to melt, and be joined.
One of the welding processes that used in Engineering field is the resistance projection welding. There are several types of welding processes similar to this, but resistance projection welding has its unique features.
Thanks for the colleagues who give this slides to publish.
One of the welding processes that used in Engineering field is the plasma arc welding. There are several types of welding processes similar to this, but plasma arc welding has its unique features.
Thanks for the colleagues who give this slides to publish.
Mig welding process is semi automatic when used for manual welding . It can be used in welding automation systems for high quality welds and high productivity.
Gas Metal Arc welding is an arc welding process that uses an arc between a continuously-fed filler metal electrode and the weld pool.
Shielding from an externally supplied gas and without the application of a pressure.
It is also known as MIG welding (Metal Inert Gas) refers to the use of an inert gas while MAG (Metal Active Gas) welding involves the use of an active gas (i.e. carbon dioxide and oxygen).
High-frequency welding is included in a group of resistance welding process variations that use high-frequency welding current (1kHz to 800kHz) to concentrate the welding heat at the desired location.
The heat produces the coalescence of metals, and an upsetting force usually is applied to produce a forged weld.
High-frequency resistance welding is an automated process and is not adaptable to manual welding.
High-frequency resistance welding was developed during the late 1940s and early 1950s to fill the need for high-integrity butt joints and seam welds in pipe and tubing.
But today the process is also used in the manufacture of products such as spiral-fin boiler tubes, closed roll form shapes, and welded structural beams.
A wide range of commonly used metals can be welded, including low-carbon and alloy steels, ferritic and austenitic stainless steels, and many aluminum, copper, titanium, and nickel alloys.
HFW is based on two main electrical phenomena
Skin effect
Proximity effect
A shuttle valve is a type of valve which allows fluid to flow through it from one of two sources. Generally a shuttle valve is used in pneumatic systems, although sometimes it will be found in hydraulic systems.
Reciprocating engine cylinders are often classified by whether they are single- or double-acting, depending on how the working fluid acts on the piston.
For a system involving two variables (x and y), each linear equation determines a line on the xy-plane. Because a solution to a linear system must satisfy all of the equations, the solution set is the intersection of these lines, and is hence either a line, a single point, or the empty set
'The Road Not Taken' is one of the most famous poems written by the American poet, Robert Frost. The poem describes a person standing at a fork in the road in a wood, unsure which one to take. Frost uses the road as a metaphor for the journey of life
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Event Management System Vb Net Project Report.pdfKamal Acharya
In present era, the scopes of information technology growing with a very fast .We do not see any are untouched from this industry. The scope of information technology has become wider includes: Business and industry. Household Business, Communication, Education, Entertainment, Science, Medicine, Engineering, Distance Learning, Weather Forecasting. Carrier Searching and so on.
My project named “Event Management System” is software that store and maintained all events coordinated in college. It also helpful to print related reports. My project will help to record the events coordinated by faculties with their Name, Event subject, date & details in an efficient & effective ways.
In my system we have to make a system by which a user can record all events coordinated by a particular faculty. In our proposed system some more featured are added which differs it from the existing system such as security.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
3. Introduction
• GMAW is defined as arc welding using a
continuously fed consumable electrode and
a shielding gas.
• GMAW is also known as Metal Inert Gas
(MIG) or metal active gas (MAG) welding.
• Produces high-quality welds.
• Yields high productivity.
4. Equipment
To perform gas metal arc welding, the basic
necessary equipment is
• a welding gun
• a wire feed unit
• a welding power supply
• an electrode wire
• a shielding gas supply.
5. GMAW Circuit diagram
(1) Welding torch
(2) Workpiece
(3) Power source
(4) Wire feed unit
(5) Electrode source
(6) Shielding gas supply
6.
7. Welding Gun
The typical GMAW welding gun has a number of key parts—a
control switch, a contact tip, a power cable, a gas nozzle, an
electrode conduit and liner, and a gas hose.
• The control switch, or trigger, when pressed initiates the wire
feed, electric power, and the shielding gas flow, causing an
electric arc to be struck.
• The contact tip, normally made of copper transmits the
electrical energy to the electrode while directing it to the weld
area.
• The gas nozzle directs the shielding gas evenly into the
welding zone.
• The electrode conduit and liner help prevent buckling and
maintain an uninterrupted wire feed.
• A gas hose from the tanks of shielding gas supplies the gas to
the nozzle.
8. GMAW Torch Nozzle Cutaway Image
(1) Torch handle
(2) Molded phenolic dielectric
(white) and threaded metal nut
insert (yellow)
(3) Shielding gas diffuser
(4)Contact tip
(5) Nozzle output face
10. Wire Feed Unit
• It supplies the electrode to the work, driving it
through the conduit and on to the contact tip.
• Most models provide the wire at a constant feed rate,
but more advanced machines can vary the feed rate in
response to the arc length and voltage.
• Some wire feeders can reach feed rates as high as
30.5 m/min (1200 in/min), but feed rates for
semiautomatic GMAW typically range from 2 to 10
m/min (75–400 in/min).
12. Tool Style
• The top electrode holder is a semiautomatic air-cooled holder.
Compressed air circulates through it to maintain moderate
temperatures.
It is used with lower current levels for welding lap or butt
joints.
• The second most common type of electrode holder is
semiautomatic water-cooled, where the only difference is that
place of air.
It uses higher current levels for welding T or corner joints.
• The third typical holder type is a water cooled automatic
electrode holder—which is typically used with automated
13. Power Supply
• A constant voltage power supply.
• As a result, any change in arc length (which is directly
related to voltage) results in a large change in heat
input and current.
• sometimes a constant current power source is used in
combination with an arc voltage-controlled wire feed
unit.
• In rare circumstances, a constant current power source
and a constant wire feed rate unit might be coupled.
• Alternating current is rarely used with GMAW; instead,
direct current is employed and the electrode is
generally positively charged.
15. Electrode
• Electrode selection greatly influences the mechanical
properties of the weld and is a key factor of weld quality.
• Electrodes contain deoxidizing metals such as silicon,
manganese, titanium and aluminum in small percentages to
help prevent oxygen porosity.
• Some contain denitriding metals such as titanium
and zirconium to avoid nitrogen porosity.
• Depending on the process variation and base material
being welded the diameters of the electrodes used typically
range from 0.7 to 2.4 mm (0.028–0.095 in) but can be as
large as 4 mm (0.16 in).
• 1.14 mm (0.045 in) - short-circuiting metal transfer process.
• 0.9 mm (0.035 in) - spray-transfer process mode
16. Shielding Gas
• Purpose of shielding gas is the protect
the weld area from the contaminants in
the atmosphere.
• Gas can be Inert, Reactive, or Mixtures of
both.
• Gas flow rate is between 25-35 CFH.
• Argon, Helium, and Carbon Dioxide are
the main three gases used in GMAW
19. Globular Transfer
• Welding current and wire speed are increased above
maximum for short arc.
• Welding speeds of up to 110 mm/s (250 in/min).
• Droplets of metal have a greater diameter than the wire
being used
• Spatter present
• It can only be used on ferrous metals.
• Welding is most effectively done in the flat position when
using globular transfer
20. Globular transfer is often a
high voltage, high
amperage, high wire feed
speed transfer, and is the
result of using CO2
shielding gas (or 75% AR-
25% CO2) with parameters
higher than the short-
circuiting range
21. Short Circuit (Short Arc)
• Operates at low voltages and welding current.
• Small fast-freezing weld puddle obtained.
• Useful in joining thin materials in any position, as well as
thick materials in vertical and overhead positions.
• The weld process parameters (volts, amps and wire feed
rate)- between 100 to 200 amperes at 17 to 22 volts.
• Metal transfer occurs when an electrical short circuit is
established.
• It can only be used on ferrous metals.
22. Short Circuit
A - Electrode is short circuited to base metal. No
arc, and current is flowing through electrode wire
and base metal.
B - Resistance increases in electrode wire causing
it to heat, melt and “neck down”.
C - Electrode wire separates from weld puddle,
creating an arc. Small portion of electrode wire
is deposited which forms a weld puddle.
D - Arc length and load voltage are at maximum.
Heat of arc is flattening the puddle and increasing
the diameter tip of electrode.
E - Wire feed speed overcomes heat of arc and
wire approaches base metal again.
F - Arc is off and the short circuit cycle starts again.
23. Spray Transfer
• Occurs when the current and voltage settings are increased
higher than that used for Globular Transfer.
• Used on thick sections of base material, best suited for flat
position due to large weld puddle.
• Spatter is minimal to none.
• Generally used only on workpieces of thicknesses above
about 6.4 mm (0.25 in).
• The maximum deposition rate is relatively high- about 60
mm/s (150 in/min).
• Well-suited to welding aluminum and stainless steel
24. Spray arc transfer “sprays” a stream
of tiny molten droplets across the
arc, from the electrode wire to the
base metal.
Spray arc transfer uses relatively
high voltage, wire feed speed and
amperage values, compared to short
circuit transfer.
25. Pulsed-Spray
• A variation of the spray transfer mode.
• Uses a pulsing current to melt the filler wire and allow one small
molten droplet to fall with each pulse.
• The pulse provides a stable arc and no spatter, since no short-
circuiting takes place.
• The smaller weld pool gives the variation greater versatility, making
it possible to weld in all positions.
• Maximum speed (85 mm/s or 200 in/min).
• Required shielding gas - primarily argon with a low carbon dioxide
concentration.
• Requires a special power source capable of providing current pulses
with a frequency between 30 and 400 pulses per second.
• It requires lower heat input and can be used to weld thin
workpieces, as well as nonferrous materials.
26. In pulse spray transfer (GMAW-P) the
welding power source’s pulse control
pulses the welding output with
high peak currents (amperage) which
are set at levels which will cause the
transfer to go into a spray. The
background current (amperage) is set at
a level that will maintain the arc,
but is too low for any metal transfer to
occur.
27. Advantages
• High deposition efficiency when used in certain transfer
modes.
• No Slag to chip as compared to SMAW and FCAW.
• The process can be used on thin materials with relative ease if
properly set.
• Low Hydrogen weld deposit with all electrodes.
• High production factor since no slag is required to be removed
and uses a continuous electrode.
• With the parameters properly set for the application, anyone
can weld after a very short amount of practice.
• One given electrode size can be used on various thicknesses of
materials productively.
28. Disadvantages
• Requires a Wire Feeder which is difficult to move and
can sometimes be a maintenance/repair burden.
• Needs Shielding Gas so welding in windy conditions
can be difficult.
• No slag system so out of position welds are sometimes
more difficult.
• Increased chance of lack of fusion if parameters and
welding technique is not controlled.
• The gun is difficult to get into tight places.
• Is not suitable for windy conditions and underwater
welding.