GENERAL
Welding is the process of joining two or more piece of material together by bringing
the atom of each piece into such close contact that an atomic bond takes place the
separate piece fuse together to form one.
Fusion welding processes require a local application of heat in order to bring the
Material to a temperature at which it will fuse, for steels is approximately 1400 C
to 1500 C. The temperature in the molten weld pool may be in the 2500 C to 3000 C
range . The average temperature in the are is 6000 C .
TYPE OF WELDING
The them oxy- gas welding is a genetic term for a fusion welding process which uses a
fuel and oxygen to provide a flame hot enough to weld the material to be joined.
Oxy – acetylene welding is suitable for the welding of most metals including
Carbon steels , stainless , cast iron , bronze , copper , aluminums .
The main area of application for Oxy – gas welding is on metals than less 5mm
thickness , although , thicker section may be welded. The main disadvantage for this
welding is slow speed travel and the therefore heat input
Process technique
Two main welding techniques are used for Oxy – gas welding
1) Forehand technique
The filler wire precedes the blowpipe along the seam to be welded. This technique is
for general purpose work.
2) Backhand technique
The backhand technique is vice versa to forehand example blowpipe precedes the
filler wire along the welded joint. It can be use on thicker and with modifications on
positional work
The are three main distinct flame type can be set with oxy – acetylene
THE END
WELDING PROCESSES
Manual metal arc welding is the most versatile of the welding processes, suitable for
almost all thickness and type of ferrous and most non – ferrous metal. Welding can
carry out in all positions relatively, economic with reasonable ease of use.
Manual metal arc welding used an electric arc between a flux covered metal electrode
and the metal being welding welded (base metal).Heat from the electric are melts both
the end of the electrode and the base metal to be joined. The is temperature 6000
C.
POWER REQUIREMENT
M.M.A welding is carried out using either AC or DC current. Power for M.M.A can
be obtained from either transformers, transformers –rectifiers, generator or
inverters.
CURRENT (AMPERAGE)
Welding current measure in amperes, to control electrode burn off rate and depth
of penetration. The possible effects of having an incorrect amperage when
using the MMA welding is
Amperage too low: Poor penetration or fusion, unstable arc, irregular bead shape,
Slag inclusion, porosity, electrode freezes to the weld and
Arc strikes.
VOLTAGE
The welding potential (voltage) to control the weld pool fluidity. The possible effects
Of having incorrect voltage when using MMA welding is
Voltage too low: Poor penetration, electrode freezes to work, arc strikes, fusion,
Slag inclusion, unstable arc and irregular bead sharpe.
Voltage too high: Porosity, spatter, arc wander, irregular bead slag inclusion,
Positional welding difficult.
SPEED OF TRAVEL
The speed of travel effects heat input and therefore also affects metallurgical and
mechanical condition. The possible effects of having an incorrect welding speed is
Travel speed to fast: Narrow thin bead, slag inclusion, fast cooling, undercut,
Poor fusion/penetration and metallurgical effects.
Travel speed to slow: Excessive deposition, cold laps, slag inclusion and
Irregular bead shape.
CONSUMABLE ELECTRODE
3) BASIC : E6018
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WELDING PROCESSES
MIG and MAG welding may be considered together because welding equipment
including power source is essentially the same.(shielding gas and filler wire)
The MIG/MAG welding process uses a bare wire consumable electrode to provide
the arc and weld metal. The wire typically 0.8-1.6 mm diameter, is continuously fed
from a coil through a specially designed welding gun.
SHIELDING GASES