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electrode and
base metal ,
which leads an
arc .
Shielded metal arc welding
joins metals
by heating with
an electric arc
between a
covered
metal
electrode
Filler metal
comes from the electrode core wire and covering,
and the work.
which is made up of iron powder and alloying elements.
It has maximum flexibility and welds most metals in a wide range
of thicknesses.
Welding with this process can be done almost anywhere and
under extreme conditions.
Equipm
ent
more versatile.
Electrode negative (straight polarity)
DCEN
Characteristics of Electrode:
1. It provides a gas that shields the arc from
atmospheric contamination.
2. It provides scavengers, de-oxidisers, and
fluxing agents to clean the weld and
prevent excessive grain growth.
3. It establishes the electrical characteristics
of the electrode, meaning that the electrode
covering determines if ac or dc power
supplies are to be used.
4. It provides a blanket of slag that protects
the metal while it is cooling, and controls
the cooling rate.
5. It provides a way to add alloying elements
to strengthen the weld.
metal.
and
GMAW
equipment
Advantages
Higher deposition rates than SMAW and reduction of smoke
and fumes.
High versatility and broad application ability.
Welds a wide range of thicknesses and metals.
GMAW can also be used for surfacing applications. This
fortifying
the metal .
Advantages:
1. High weld metal quality and strength
Equipment
Automatic welding:
o A travel mechanism moves either the torch or the work.
Advantage (GTAW):
There is little or no spatter and little or
no smoke. The as-welded bead is
smooth and uniform, requiring little
finishing, if any.
The GTAW process can be used to
make high quality welds in almost all
metals and alloys. There is no slag and
the process can be used in all
positions.
It also is the slowest of the
non- mechanized processes
Equipment
Welding with a non-consumable tungsten electrode shielded with
an inert gas is generally a manual process, but may be mechanized
or even automated.
(cont..)
Equipment
The power source for ac and dc gas
tungsten arc welding is usually a
drooping voltage type. In this type
of power supply, the shape of the
volt-ampere curve is steep so that
a
change in arc length will not create a
major change in current.
They affect the amount, distribution,
and control of arc-produced heat and
also play a role in arc stability and in
the removal of refractory oxide from
the surfaces of certain metals.
Electrode Nomenclature:
AWS 5.1 SPECIFICATION FOR C-STEEL ELECTRODES
Designation :
First two digits :
E XXXX X
Tensile strength in ksi
Electrode Nomenclature
The nomenclature for weld electrode is defined in AWS standards.
E7018-A1 (SMAW):
E = electrode, 70 = 70 ksi ultimate strength, 1 = all positions,
18= AC or DC current,
electrode.
F7P6-EM12K (SAW):
F = flux, 7 = 70 ksi ultimate strength, P = PWHT (1150F1
hr.), 6 = Charpy toughness >
K = Silicon
E70T-1 (FCAW):
E = electrode, 70 = 70 ksi ultimate strength, 0 = flat position,
T= tubular flux core electrode, 1 = CC>2 shielding, spray transfer
mode, DC current, electrode +.
Welding Parameters
process.
Welding position,
Fixture
Weld backing,
Type of electrode,
Electrode diameter.
Travel speed.
and stopping),
Arc voltage.
Preheat.
g Parameters
Thickness 0.25"
Voltage 12 volts
elding Variables
Essential variables
2G Vertical position
6G Inclined position
Position 6G
It is also for the pipes, when the
pipe axis is at 45 deg. to the
horizontal plate and the
circumferential seam is welded
without rotating the pipe. It is a
Stress Relief:
Heating below the critical temperature (the phase transformation
temperature, for example the ferritic-austenitic transformation
temperature in carbon steel, Figure ).
Holding the temperature long enough to reduce residual stresses
and then cooling slowly.
Stress relieving reduces residual stresses, and generally improves
ductility and toughness, and reduces fabrication distortions.
Stress Relief:
Annealing (normalizing but with furnace cooling):
"a generic term covering any of several heat
treatments" [ASTM A 941]. The objectives of
annealing include reducing hardness, facilitating
machining and cold working, producing a desired
microstructure, or desired mechanical properties.
Quenching (rapid cooling in oil or water):
"rapid cooling" [ASTM A 941]. Quenching hardens
the steel, but at the expense of a loss of ductility.
cont
Stress Relief:
Solution annealing: "Heating to and holding at a suitable
temperature to place constituents into solid solution, and
then cooling rapidly to hold the constituent in solution"
[ASTM A 941]. Typical heat treatment for austenitic stainless
steel to place chromium into solution and then cooling
rapidly to avoid the precipitation of chromium carbides.
Tempering (stress relieving after quenching or normalizing):
"reheating a quench hardened or normalized steel object to a
temperature below the transformation range, and then
cooling at any desired rate" [ASTM A 941]. The objective of
tempering is to restore ductility to steel.
Case Hardening and carbonizing (carburization): Heating
carbon steel above the critical temperature in a carbon rich
IN-SERVICE WELDING
It may become necessary to weld on a piping system or
pipeline while the line is in
hot tap, or
slowly; therefore, the heat input should not be too low, a small hot
spot
will cool too quickly, particularly with the rapid cooling effect of the
flowing
fluid. To
low
the
is often
order to
in-
IN-SERVICE WELDING
In conclusion, before welding in service, it is essential to
(1) Know the chemistry of the in-service pipe to assure
compatible weld
thickness.
(3) know the fluid pressure and flow rate to select the
heat input accordingly.
IN-SERVICE WELDING
Reducing the operating pressure also reduces the risk of
burn-through and
blow-out. It is also useful to have some flow in the
line, because if the fluid in the
line is not flowing, the weld heat will increase the pressure of
the trapped fluid to a
potentially dangerous level. The heat input must be kept
sufficiently low. If the
heat input is too large, the weld will burn through the pipe
wall, and fluid will
burst out under the effect of internal pressure. It is therefore
for socket
requirements are
ASME
Boiler
& Pressure Vessel code Section IX (typical for power and chemical
process
applications), as specified in
section.
(e) Weld end preparation: the ASME B31 codes will typically address
heat treatment (PWHT) temperature, hold time and heating and cooling rate
are
chemistry), wall
and means of
induction, electric
resistance jacket, fuel fired ring burners, fuel fired torch, furnace,
followed by hardness testing to verify the efficiency of the heat treatment process
(soundness of
(g) Choice of welding consumables: Guidance for the selection of consumables (filler metal)
is
cutting.
AWS A 5.01 - Filler metal procurement guidelines.
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