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welding process
- 2. - is aprocess in which two or more pieces of metal- is a process in which two or more pieces of metal are joined together by the application of heat,are joined together by the application of heat, pressure or a combination of both.pressure or a combination of both. What is “welding”?What is “welding”? Forge Welding - It is the welding process where the pieces of the joint are heated in a forge, or furnace, and are fused together with pressure produced by hammer.
- 3. BASIC WELDING PROCESSBASICWELDING PROCESS SMAW – Shielded metal Arc WeldingSMAW – Shielded metal Arc Welding FCAW – Flux Cored Arc WeldingFCAW – Flux Cored Arc Welding GMAW – Gas Metal Arc WeldingGMAW – Gas Metal Arc Welding GTAW – Gas Tungsten Arc WeldingGTAW – Gas Tungsten Arc Welding SAW – Submerge Arc WeldingSAW – Submerge Arc Welding
- 4. Shielded Metal ArcWelding (SMAW)Shielded Metal Arc Welding (SMAW) 1. AC OR DC POWER SOURCE AND CONTROLS 2. ELECTRODE HOLDER 3. ELECTRODE 4. ARC 5. WORK 6. WORKPIECE LEAD 7. ELECTRODE LEAD 4 1 2 6 7 5 3
- 5. SMAWSMAW PROTECTIVE GAS FROM ELECTRODECOATING MOLTEN WELD METAL SLAG SOLIDIFIED WELD METAL ELECTRODE CORE WIRE ELECTRODE COATING ARC METAL DROPLETS BASE METAL DIRECTION OF TRAVEL
- 7. ADVANTAGES: - equipment isrelatively simple and inexpensive. - newer solid-state power sources are so small and light weight that they can be carried to the job. DISADVANTAGES: - relatively slow production - a layer of solidified slag must be removed. - low hydrogen-electrodes require special storage.
- 8. Gas Metal ArcWelding (GMAW) 1 6 2 3 4 5 7 9 10 8 Shielding Gas Regulator Shielding Gas Supply Power Source Electrode Supply Electrode Feed Unit Welding Gun Workpiece Water Circulator (optional) 1. .WORK LEAD 2. .WATER TO GUN 3. .WATER FROM GUN 4. .GUN SWITCH CIRCUIT 5. .SHIELDING GAS TO GUN 6. .CABLE ASSEMBLY 7. .SHIELDING GAS FROM CYLINDER 8. .WELDING CONTACTOR CONTROL 9. .POWER CABLE 10. .PRIMARY INPUT POWER
- 9. SHIELDING GAS MOLTEN WELD METAL SOLIDIFIEDWELD METAL NOZZLE ELECTRODE ARC BASE METAL DIRECTION OF TRAVEL GMAW
- 11. ADVANTAGES: - can beused successfully in situations where the presence of hydrogen could cause problems. - well suited for automatic and robotic welding or high production - Since there are little or no cleaning required following welding, overall operator productivity is greatly improved - This efficiency is further increased because the continuous spool of wire does not required changing as often as the individual electrodes used in SMAW - is clean process, because there is no flux present.
- 12. DISADVANTAGE: Since SMAW usesshielding gas alone to protect the puddle from the atmosphere excessive contamination of the base metal may cause porosity. Drafts or wind may disperse shielding gases, which makes GMAW unsuitable for field welding. The equipment used is more complex than that used for SMAW, increasing the possibility of mechanical problems that can lead to quality problems. The used of short-circuiting transfer can lead to lack of fusion discontinuities.
- 13. Flux Cored ArcWelding (FCAW) Shielding Gas Regulator Shielding Gas Supply Wire Feeder Electrode Supply Power Source Welding Gun Workpiece
- 14. FCAW GAS (OPTIONAL) MOLTEN METAL MOLTENSLAG SILIDIFIED WELD METAL SLAG NOZZLE (OPTIONAL) FLUX CORED ELEECTRODE ARC DIRECTION OF TRAVEL
- 16. ADVANTAGES Due to increaseddeposition rates and a high tolerance for contamination, FCAW has replaced SMAW and GMAW in many applications. FCAW can be used in both shop and field applications, and provides high productivity in the terms of the amount of weld metal that can be deposited in a given period of time, particularly for the hand-held process. FCAW can be used in all positions. DISADVANTAGES Because a flux is present during welding, a layer of solidified slag must be removed. The flux also generates a significant amount of smoke, which reduces the welder’s visibility and makes the weld puddle more difficult to observe.
- 17. Tungsten electrode Base metal Fillerrod GTAW Torch Shielding gas with flow meter regulator Ground cable Power supply Welding cable Gas Tungsten Arc Welding (GTAW)
- 18. SHIELDING GAS NOZZLE TUNGSTENELECTRODES ARC FILLER ROD SHIELDING GAS MOLTEN WELD METAL SOLIDIFIED WELD METAL BASE METAL DIRECTION OF TRAVEL GTAW
- 20. ADVANTAGES - The GTAWprocess is capable of welding virtually all metals, even extremely thin materials. - high-quality welds with excellent visual appearance can be produced. - the process is quite clean and there is no slag to remove after welding. DISADVANTAGES - The skill level necessary to produce high-quality welds is acquired only after much experience in manipulating the electrode and feeding the filler wire. - Because the process has a low tolerance for contamination, the base and filler metals must be extremely clean prior to welding. - among the slowest of the available welding processes.
- 21. Submerge Arc Welding( SAW ) POWER SOURCE CONTROL SYSTEM FLUX HOPPER TORCH FLUX WORKPIECE
- 22. SAW CONSUMABLE ELECTRODE CONTACT TUBE MOLTEN FLUX SLAG FROMFLUX HOPPER GRANULAR FLUX BLANKET BASE METAL ARC PATHMOLTEN WELD METALSOLIDIFIED WELD METAL DIRECTION OF TRAVEL FLUX RECOVERY
- 23.
- 24. ADVANTAGES - SAW canbe performed on numerous metals. - It can typically deposit more metal than any of the more common processes. - It has operator appeal– because of the lack of an arc, the operator has no need for a filter lens and other heavy protective clothing. - Another benefit is that there is less smoke generated than with the other processes. - SAW has very deep penetrating capabilities. DISADVANTAGES - Cleaning the work surfaces and aligning the machine travel with the joint are particularly important in submerged arc welding. Improper alignment will result in offset beads with incomplete joint penetration. - In a highly restrained joint, joint misalignment may also cause cracks.