Welding Process for Steel Structure Welding

Shielded Metal Arc Welding (SMAW)

Fluxed Cored Arc Welding (FCAW)
Gas Tungsten Arc Welding (GTAW)
























MANUAL METAL ARC WELDING

MMAW (Manual Metal Arc welding) or SMAW (Shielded Metal Arc Welding) is:
An arc welding process in with coalescence of metals is produced by heat.
The heat comes from an electric arc that is maintained between the tip of a covered electrode and the surface of the base metal in the
joint being welded.
Always done with a consumable electrode with solid metal sheath and coated in flux to lay the weld.
Striking arc by short cutting.
Can be done inside or at open air.
The consumable electrode provides:
1. Gas protection to shield the arc and prevent atmospheric contamination of the molten filler metal.
2. Adding elements to change the mechanical properties and prevents excessive grain growth in the welded metal.
3. Enhance the mechanical properties and surface cleanliness of the weld metal
As the weld is laid, the flux coating of the electrode evaporates giving off vapors a layer of slag. The flux provides molten slag with
covers the filler metal as it travels from the electrode to the weld pool. Once part of the weld pool is formed, the slag floats to the
surface and protects the weld from atmospheric contamination as it solidifies. Once hardened, it should be chipped away to reveal the
finished weld.
During welding the current remains constant, even if the arc distance and voltage change. The MMAW machines have static dropping
characteristic.
Applications:
Maintenance and repair industries.
Construction of steel structures;
Weld carbon steel, low and high alloy steel, stainless steels, cast iron
Advantages:
Equipment cheap, versatile, simple and portable.
Welds any position.
Disadvantages:
Smokes prejudicial to health. Electrode type choice is crucial.
Need to remove slag immediately due inclusions problems.
Quality depends upon welder skill.


Fig-1.1: Shielded Metal Arc Welding


FLUX CORED ARC WELDING
General Description
Flux Cored Arc Welding (FCAW) is a welding process by fusion which is widely used on ferrous metal. The consumable electrode can
have an interior flux or a mix of flux and metal powder and has a tubular form. Its an easily automated process that is particularly
interesting in highdeposition rate processes.
Energy Source
FCAW has as its energy source an electrical arc that occurs between the fluxed cored wire and base metal in order to melt consumable
electrode and base metal.
Welding Zone Protection
Welding zone protection from atmosphere contamination is assured by the products in the electrodes flux (self shielded flux
cored arc welding) and sometimes by additional gaseous protection (gas shielded flux cored arc welding). The slag created by the flux
gives an additional protection during cooling time but has to be removed after that.
Equipment
FCAW uses a constant voltage welding machine and the process can use DCEP or DCEN polarity. For gas shielded flux cored arc
welding, a cylinder gas is required.
Advantages Disadvantages
A high-deposition rate process.

Irregular wire feed
High energy rates allow greater penetration and a l ower number
of melting defects.
Porosity when the gases (specifically those from the flux-
core) escape the welded area before the metal hardens,
leaving holes in the welded metal
Metallurgical benefits from the flux such as the weld metal being
protected initially from external factors until the flux is chipped
away.
More costly filler material/wire as compared to GMAW
It's an "all-position" process. Less suitable for applications that require painting.
No shielding gas needed making it suitable outdoor welding
andlor windy conditions.
for

Slag removal spending time
High operator skill is required

Safety
FCAW require adequate ventilation and the use of a sealed mask that will provide the welder with fresh air. Also eyes and skin should be
protected by appropriate goggles and clothes.


Fig-1.2: Fluxed Cored Arc Welding

GAS TUNGSTEN ARC WELDING
Gas Tungsten Arc Welding (GTAW), also known as Tungsten Inert Gas (TIG) welding, is a welding process that uses a non-
consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination by an inert shielding gas
(argon or helium), and a filler metal is normally used, though some welds, known as autogenous welds, do not require it. A constant-
current welding power produces energy which is conducted across the arc through a column of highly ionized gas and metal vapors known
as plasma.
GTAW is most commonly used to weld thin sections of stainless steel and non-ferrous metals such as aluminium, magnesium and
copper alloys. The process grants the operator greater control over the weld than competing processes such as shielded metal arc
welding and gas metal arc welding, allowing for stronger, higher quality welds. However, GTAW is comparatively more complex and
difficult to master, and furthermore, it is significantly slower than most other welding techniques. A related process, plasma arc welding,
uses a slightly different welding torch to create a more focused welding arc and as a result is often automated.
Advantages
Applicable to a very wide range of materials.
Especially good for welding thin sections and delicate work-pieces.
Capable of producing welds of high quality and appearance
Disadvantages
Generally restricted to flat or horizontal welding
Low welding rate
Relatively expensive


Fig-1.3: Gas Tungsten Arc Welding