MMA1 Session 3 Arc Welding Basic Principles

Arc Welder Training
Arc Welding
Basic Principles
2
The National Focus for Rail Welding Technology and Practice Copyright © 2003
Basic Principles
The Welding Circuit
Consists of the following items
• power source
• welding lead
• electrode holder
• electrode
• workpiece
• welding return
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Arc Welder Training
The Welding Circuit
Electrode
holder
Electrode
Welding lead
+
Power Workpiece
Source
-
Welding return lead
4
Power Sources
Different types:
Mains transformer -reduces AC mains power to a lower

usable voltage
Generator - uses a prime mover (petrol or diesel

engine) to turn an alternator
• both types can either AC or DC

• normally, DC is created by rectifying and
smoothing AC
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Power Sources
Power sources for site work are usually generators
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Power Sources
AC (Alternating Current) and DC (Direct Current)
In an AC supply, the voltage (and

current) alternates between
positive and negative over time
and the resulting waveform shape
is a sine wave
In a DC supply, the voltage

stays at a fixed level all of
the time, like the voltage
from a battery
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Power Sources
The Parts of a Power Supply
A power system which converts an AC supply into a
DC supply has three main components
transformer rectifier smoothing capacitor
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Power Sources
Transformer
• a transformer consists of two

coils linked by an iron core
• alternating current in the input
coil creates a continually
changing magnetic field in the
iron core
• this field passes through the
output coil and the changing
strength of the magnetic field
inducing an alternating voltage
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Power Sources
Rectifier
• the purpose of a rectifier is to convert an AC
waveform into a DC waveform
• there are two different rectification circuits, known
as 'half-wave' and 'full-wave' rectifiers
• both use components called diodes to convert AC
into DC
• a diode is a device which only allows current to flow
through it in one direction
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Power Sources
Rectifier (half wave)
• half-wave rectification
is the simplest type as
it only uses one diode
• the output of the half-
wave rectifier is DC (it
is all positive)
• it is not be suitable for
a welding circuit
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Power Sources
Rectifier (full wave)
• the full wave rectifier

addresses this problem
since at no time is the
output voltage 0V
• full wave rectification
requires four diodes
arranged so that both the
positive and negative parts
of the AC waveform are
converted to DC
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Power Sources
Smoothing
• ‘smoothing' involves the use of
one capacitor
• in first half of the voltage peaks,
when the voltage increases, the
capacitor charges up
• while the voltage decreases to
zero in the second half of the
peaks, the capacitor releases its
stored energy to keep the output
voltage as constant as possible
• a smoothed output is perfectly
acceptable for DC welding
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AC vs DC
Welding current may be DC or AC

• some electrodes may be used with DC or AC
• others will be limited to DC only
• generally, all electrodes can be used with DC
Advantages Disadvantages
AC Less expensive Higher levels of porosity
equipment
DC steadier arc and smoother ‘arc blow’ where magnetic
metal transfer good effects influence the
wetting action and a direction of the arc making it
uniform weld bead shape difficult to control
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Welding with AC
Open Circuit Voltage (OCV)
• OCV is important when striking an arc using AC.
• higher OCVs make arc striking easier and establish
a shielding atmosphere more quickly
RMS (Root Mean Square) Values

• generally, higher current levels are required for AC
welding than DC welding for the same size of
electrode
• this is due to the equivalent AC voltage being
reduced by a factor of √2 (or 1.414) from the peak
value
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Welding Lead
• welding leads must conduct the
welding current without heating
or burning
• copper or aluminium core
• cables must be long enough to
reach the workpiece, but short
enough to be manageable
• Max length 18.5m DC, 14m AC
• 50mm2 cross sectional area
cables tend to provide the best
combination of size and weight
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Welding Lead
Layout
• cables must be fully laid out and not used coiled

• cables must be laid out in a manner that avoids the
creation of tripping hazards
• cables should not be laid out close to and parallel to
running lines for more than 10m
• cables must not be laid out across running lines
• when using AC, cables must be taped together
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Electrode Holder
The electrode holder provides a safe

method of holding the electrode during
welding
• connected to the welding lead

• electrically insulated from welder
• electrically conductive to electrode
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Electrode
The electrode is a discrete

length of wire that is coated
with flux
One end is left bare to

provide electrical connection
with the electrode holder
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Workpiece
• the workpiece is the

item to be welded
• in track maintenance
this can be
• rail
• crossing component
• switchblade
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Welding Return
Welding return (or earth)

consists of the return lead to
the power source and a
clamp that connects to the
workpiece
• a good electrical
connection is required
• can be spring loaded or
screwed to grip the
workpiece
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MMA1 Session 3 Arc Welding Basic Principles

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MMA1 Session 3 Arc Welding Basic Principles

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Arc Welder Training

The Welding Circuit

Consists of the following items

Mains transformer -reduces AC mains power to a lower

Generator - uses a prime mover (petrol or diesel

• both types can either AC or DC

Power sources for site work are usually generators

In an AC supply, the voltage (and

In a DC supply, the voltage

transformer rectifier smoothing capacitor

• a transformer consists of two

• the full wave rectifier

Welding current may be DC or AC

RMS (Root Mean Square) Values

• cables must be fully laid out and not used coiled

The electrode holder provides a safe

• connected to the welding lead

The electrode is a discrete

One end is left bare to

• the workpiece is the

Welding return (or earth)

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