ASSIGNMENT-3 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

1. A. Explain briefly with schematic drawing for the metal transfer mode in MAG
welding.

B. Explain with schematic drawings for MAG welding at high current range, the
metal transfer mode globular of metal droplets when CO2 is fully used as a
shielding gas, while the mode of spray can be produced when the mixed gas of 80%
Ar + 20% CO2 are used.

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2. A. Describe briefly the difference between AC and DC welding power source.

AC (Alternating Current): the flow of electric charge is happening in both

direction to the cathode and to the anode.

DC (Direct Current): the flow of electric charge is only happening in one

direction.

B. Briefly explain the term of cleaning action in TIG power source.

Cleaning action means the removing process of the aluminium oxide layer on the surface
of welding area.
3. A. Explain briefly the term of stiffness of arc.
Stiffness of arc means the tendency of the arc to directly through along the extended path
of electrode due to the effect of the plasma jet during welding process.
B. In the case of arc blow tends to occur in the arc welding of carbon steel? Give
two examples and explain the cause of arc blow with schematic drawing.
Arc blow is a magnetic area formed in the weld area. It will pull the arc back and forth
keeping it from being concentrated directly ahead of the electrode.
Two examples: magnetic arc blow and thermal arc blow

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ASSIGNMENT-3 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

4. In MAG welding, the length of arc maintained stable through self-regulation in DC

power source. Describe the statement above about the mechanism of self-regulation
by schematic drawing.

5. Explain the principle of inverter welding machines and give two advantages of
inverter welding machine when it is compared with the conventional SCR-type.
Inverter welding machines is a type of welding power supply capable of providing a high
current for welding. It uses a series of rectifiers and solid-state switches to convert AC
input power into DC output power.
Advantages:

Light, give it possibility to operate mobile.

Compact, simple and easy to operate.

6. Explain the definition of duty cycle in the electric welding machine, and provide
the formulas or equation for estimating the performance of welding machine.
A duty cycle is the percentage of one period in which a signal is active, the formula of duty
cycle is given below:

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Where:

T = Rated duty cycle (%)

Ta = Required duty cycle (%)

Ia = Maximum current at required duty cycle (A)

= Rated current at rated duty cycle (A)

B. Calculate: What is the maximum allowable current when welding machines

operated continuously for welding machine by using the capacity of welding power
source of 450A at 60% duty cycle?
Using duty cycle formula above:
Ia

= I x (T/Ta)1/2

Ia

= 450A x (60/100)1/2

Ia

= 450 x 0.775

Ia

= 348.75 Amps

So, the maximum allowable current if the welding machines operated continuously without
idle for welding machine by using the capacity of welding power source of 450A at 60%
duty cycle is 348.75 Amps.
7. A. Explain the function of voltage reducing device in AC welding power source.
The device reduces, when the arc is halted, the voltage between the electrode holder and
base metal to be 25V or less.
B. Explain the meaning of the electrode code of E6010, E7018, E7028-B3, ER70T-6
and F72-EM12K.
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Electrode codes:

E6010
E = Electrode
60 = Minimum tensile strength of 60

= All position

= Cellulosic

E7018
E = Electrode
70 = Minimum tensile strength of 70

= All position

= Iron powder, low hydrogen, AC or DCEP

E7028-B3
E = Electrode
70 = Minimum tensile strength of 70
2

= Flats and horizontal position

= Iron powder, low hydrogen, AC or DCEP

B3 = Composition assumption from weld deposit 2.25% Cr and 1% Mo

ER70T-6
ER = Electrode or rod
70 = Minimum tensile strength of 70
T = Tubular
6

= Contains shielding without gas

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8. Why are some types of electrodes for SMAW needed to be dried before use. What
factors should be considered and what happens when the electrodes were not dried in
welding for HSLA steel.
Because the re-drying process is useful for enhancing and optimizing the performance level
of welding process.
9. What is the effect of electrode polarity (+ and -) on the weld penetration for (a)
consumable electrode (SMAW & GMAW) and (b) a non-consumable electrode
(GTAW & PAW). Give schematic drawing for them.

SMAW & GMAW

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GTAW & PAW

10. Explain the advantages and disadvantages when using a gas mixture of AR + CO 2
compared with fully CO2.
Advantages:

High deposition rates

The sputtering is less

The fumes is less

Disadvantages:

More expensive

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