Topics covered

• WELDING PROCESSES.• WELDING CONSUMABLES• WELDING EQUIPMENTS• WELDING EQUIPMENTS• WELDING PROCEDURE• WELDING DEFECTS ITS CAUSES

AND REMIDIES• SAFETY

WELDING PROCESSWELDING PROCESS

Types Of Welding

Welding

Gas Welding Arc Welding

Normal practiced process

Manual Metal Arc Welding MMAW Gas Tungsten Arc Welding GTAW Gas Metal Arc Welding GMAW Gas Metal Arc Welding GMAW Flux Cored Arc Welding FCAWSub Merged Arc Welding SAW

WELDING PROCESS

• The present process of welding used tomanufacture various components generally are asfollows

• MMAW- Manual Metal Arc Welding Process• MMAW- Manual Metal Arc Welding Process• GMAW- Gas Metal Arc Welding process• GTAW - Gas Tungsten Arc Welding• FCAW- Flux Cored Arc Welding• SAW- Submerged Arc Welding

SMAW/MMAW

GTAW

GMAW(MIG/MAG)

FCAW

SAW

Advanced process• Narrow Gap Welding• Laser Beam Welding• Electron Beam Welding• Friction Stir Welding• Friction Stir Welding• Plasma Welding• Plasma Transfer Arc Technique (PTA)• Robotic Welding• Orbital Welding

Selection of Welding process

• Type of Base Material• The Joint Design• The place of welding• The place of welding• Welding Position• Type of consumables availability• The skill availability of personnel• The types of equipment availability

WELDING CONSUMABLESWELDING CONSUMABLES&

WELDING EQUIPMENTS.

RECOMMEDATIONSThe selection of the correct welding consumables depends on the following parameters

• Base materials composition• The weld ability of the steel• The weld ability of the steel• Selection of the welding consumables as per

ASME section-II- C• Acceptance of AWS or any other standards

depends on the clients requirements.

WELDING CONSUMABLES• The Welding consumables like the welding electrodes and

filler wires that are required and are recommended are asfollows

• E-6013 Welding Electrodes for Welding in MMAWprocess for Carbon steel, Mild steel, For the generalpurpose welding applications up to thickness 18 mm or3/4th inch.

• For thickness over the above mentioned must be weldedwith Low Hydrogen electrodes as per AWS E 7018 orE7018-1 Type of welding consumables.

Welding consumables for various steels.

• General Mild steel Up to 18mmAWS 6013 class welding electrodes, ER 70 SG Filler wires in case of GTAW & ER 70 SG Filler wires in case of GTAW & ER 70 S-6 in case of GMAW process.

• General Mild steel Above 18mmAWS 7018class ER 70 S2 & ER 70 S-6

Selection contd.

• For Radiography jointsThe following grades consumables are mandatory.mandatory.• AWS E6013 & E7018 classified Electrodes• ER 70 S2 TIG welding filler wires• ER 70 S-6 MIG Welding continuous filler

wires.

Consumables- gases

• ER –70 S-6 Solid wire for welding the GMAW (MAG) welding process

• ER 70-S-2 TIG filler applications incase of • ER 70-S-2 TIG filler applications incase of carbon steel welding .

• The use of 100 % CO2 gas for MAG welding and 100 % pure Argon gas for TIG welding applications are the main criteria.

Alloy steels

AWS class of low alloy electrodes & wires

Consumables- LAS

• In the case of use of Low alloy steels whereC, Mo, Cr and other alloys are involved theC, Mo, Cr and other alloys are involved thecreep properties are important and hence thematching composition of the weld metalsare mandatory

Consumables –S.S.

• Welding of Stainless steels like commonlyused steels such as 304, 304L, 308L, 309,316. and other categories such as 310, 321,316. and other categories such as 310, 321,347, Duplex, Super Duplex Steels, therespective grade of Electrodes and the Fillerwires to be used with proper shieldinggases.

Stainless steel

• 301,304,308 ClassAWS E 308 & 308 L grades Electrodesand ER 308 L TIG/ MIG welding wires.and ER 308 L TIG/ MIG welding wires.

• 316 and 316 L-AWS E- 316 & 316 L-ER 316 L TIG and MIG fillers

SS Contd.

• For 309 Grade steelsAWS E 309 Electrodes ER 309 L WiresER 309 L Wires

• Dissimilar metals of SS and SS-MS AWS 309L and 309 MoLER 309L & ER 309 MoL

SS Contd.

• Stabilized steels of 321, 347Namely Niobium/Columbium, Ti and Ta stabilized steels the use of AWS E- 347 electrodes and wires of AWS E- 347 electrodes and wires of ER 347 grade is recommended.

• For other grades like 310,312, 317 the respective grades of consumables be used.

Other metals

• Cast Iron

• Non-Ferrous Alloy: • Non-Ferrous Alloy: Aluminium, Copper, Nickel, Magnesium etc.

Welding Position

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Proper Arc Length

• Long arc results in:– Large globules melting– Wavering arc– Wide spatter and irregular bead

• Short arc results in:• Short arc results in:– Electrode sticks– Poor penetration– Convex bead– Slag inclusions– Irregular bead

• Use short length for vertical welds

Speed of Travel

• Travel speed influences:– Bead width– Penetration– General shape of the bead– General shape of the bead

• Use a uniform speed• Both hands on the electrode holder

– Operator comfort• Bead should be about twice the diameter of the

electrode wire

Read the Bead

WELDING EQUIPMENTWELDING EQUIPMENT

TYPES OF EQUIPMENTS

Standard Type of welding Equipments• Arc Welding Transformers• D.C. Rectifiers• D.C. Rectifiers• Thyristor controlled Welding Rectifiers• Welding Invertors• TIG Welding Equipments• MIG/MAG Welding machines• Sub Merged Arc Welding machines

MMA Power sources

Transformer RectifierWelding generator

category of MIG Welding

• Pulsed MIG Welding Machines,• Inverter based MIG Welding Machines• Synergic Pulsed MIG Welding Machines • Synergic Pulsed MIG Welding Machines • Surface Tension Transfer Machines (STT)

Cont…

Under TIG Welding category we can have • DC Pulsed welding machines• AC/ DC TIG welding machines• AC/ DC TIG welding machines• AC Square wave pulsing machines

Advanced Welding Machines:

Electron Beam Welding machinesNarrow Gap welding machinesNarrow Gap welding machinesLaser cutting and welding Plasma Welding

Selection of the correct equipment

• Selection of the right type of equipment is important to get the desired welding properties.

• The selection decides the feasibility of the use of the process.the process.

• The selection should be based on the availability of the equipment,

• The acceptance of the process• The convenience of the operation.

Welding Defects

TYPE OF DEFECTS

• Lack of fusion • Lack of Penetration• Undercut• Undercut• Crack• Porosity• Slag inclusion

Lack of Penetration

Lac of Fusion

Undercut

Porosity

Crack

ITS CAUSES AND REMIDIES

• Re-drying of Consumables/ Proper Storage• Base metal Cleaning.• Flow rate of Shielding GAS• Flow rate of Shielding GAS• Welding Parameter.• Use of correct welding consumables.

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