2014.02.17.

COLLEGE OF DUNAJVROS
INSTITUTE OF TECHNOLOGY

WELDING

FUSION WELDING
PROCESSES HEAT SOURCES
Prof. Dr. Bla Palots
palotasb@mail.duf.hu

Identification of welding
procedures

For example the numerical sign for manual arc

welding is 111, TIG (GTAW) procedure is 141 and
shielded metal active gas arc welding received the
identification number of 135, shielded metal
natural gas welding is 131 and submerged arc
welding has the number 12.
Standard naming of the processes usually differ
from the terminology used in practice, but it is
useful to be aware of the official terms (MSZ ISO
4063-2000).

Welding lectures

dr. Bla Palots

2014.02.17.

Heating sources 1.

Gas heating
Gas Welding (Oxyfuel Gas Welding)
Pressure Gas Welding
Thermal Spraying Methods
Powder Spraying
High Speed Spraying
Explosion Spraying
Flame Wire Spraying.

Welding lectures

dr. Bla Palots

Heating sources 2.

Arc Heating

Arc Welding Procedures

Stud Arc Welding Procedures
Magnetically Impelled Arc Welding

Resistance heating

Welding lectures

Electroslag Welding
Resistance Welding
Diffusion Welding
dr. Bla Palots

2014.02.17.

Heating sources 3.

Friction Heating
Friction Welding
Friction Stir Welding

Electron Beam Heating

Electron Beam Welding

Light Beam Heating

Light Beam Welding
Thermit Reaction Heating
Thermit Welding

Laser Beam Heating

Laser Welding and Laser Cutting

Dielectric Heating
Plasma Beam Heating
Dielectric Welding
Plasma Welding and Cutting
Welding lectures

dr. Bla Palots

Gas Welding
Gas Sign

Volume/ O2/gas Flame

mass,
temp.
m3/kg
C**

Acetylene C2H2 0,906 0,91

Combustion
heat, MJ/m3
I.

II.

2,5

3087

19

36

55

Propane

C3H8 1,52

0,54

5,0

2526

10

94

104

Metyl
acetylene
propadin

C3H4 1,48

0,55

4,0

2927

21

70

91

Propilene C3H6 1,48

0,55

4,5

2900

16

73

89

2,0

2538

0,4

37

37

0,5

2660

12

Metan

CH4

Hydrogen

H2

0,62 1,44
0,07 11,77
* Relative to air

Welding lectures

**For natural flame

dr. Bla Palots

2014.02.17.

The most commonly used

gas

Acetylene (C2H2), because its combustion

heat is relatively high.
Used for welding, cutting and also for
preheating.
It often provides excessive heat, particularly
in cases of cutting and preheating.
Gases providing less combustion heat are
rather used in cutting (hydrogen) and
preheating (propane-butane).
Welding lectures

dr. Bla Palots

The burning of Acetylene

Primary reaction:
(oxygen from a battle)
C2 H 2 O2 2CO H 2 Q

Secondary reaction (now

oxygen is coming from the
air):
3
2CO H 2 O2 2CO2 H 2O Q
2
Welding lectures

dr. Bla Palots

2014.02.17.

Acetylene is suitable for

Unalloyed and low alloyed steel

welding and cutting
Cast iron welding
Non-ferrous and light metals
welding
High alloyed steels

Welding lectures

dr. Bla Palots

Oxyfuel-Gas Welding
Equipment

Dissous gas pressure bottle

Oxygen pressure bottle

Dissoous gas: Acetylene is dissolved in acetone, to enable

acetylene pressure to increase to 30 bars (15 bar). The
pressure bottle is filled with porous material (cement
asbestos - carbon), so the gas cannot get concentrated in a
few cm3-s. The porous material soaks up the gas-fluid
mixture. In a few cm3 volume (approx. 15x15x25 mm)
acetylene is dissociating explosively.
Welding lectures

dr. Bla Palots

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Welding Torch and Reductor

Gas blowing through
the little diameter hole
arrives into a bigger
chamber, this way its
pressure decreases.
Burning gas and oxygen mixes
based on the injector-effect.

Welding lectures

dr. Bla Palots

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Welding Technique
Welding
direction
Hegeszts
irnya

Backward
welding
Balra hegeszts

Welding
direction
Hegeszts
irnya

Forward
welding
Jobbra hegeszts

Backward welding is applied to thin metal sheets (s 3

mm), forward welding is used for thicker metal sheets
and tubes. In case of forward welding the weld bead is
heated, so bigger penetration is archived.
Welding lectures

dr. Bla Palots

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2014.02.17.

Applied flame types

Natural flame (for welding

steels and copper)
Oxidizing flame
(for welding brass)
Carburizing flame
(aluminum and its alloys)
Natural Oxidizing Carburizing
Welding lectures

dr. Bla Palots

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Application of oxyfuel-gas
welding
Welding parameters:
On-site Welding,
applying to gas and
df = 1....10 mm
(filler material diameter) water pipe welding.

pC2H2 = 0,1....0,6 bar

pO2 = 2....5 bar

Repairs (for example car

chassis).

For building assemblies

vweld = 10....100 mm/min
central heating, water,
VC2H2 = 1.....50 l/min
gas piping other
procedures are very
VO2 = 1.....55 l/min.
difficult apply.
Welding lectures

dr. Bla Palots

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2014.02.17.

Thermal Spraying Processes

High Speed Spraying

Powder Spraying

Flame Wire Spraying

Welding lectures

Explosion Spraying
dr. Bla Palots

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Oxyfuel-Gas Cutting
The process:

Preheating for flashingpoint temperature

Burning with oxygen
Blowing out combustion
products from the gap

Welding lectures

dr. Bla Palots

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2014.02.17.

Oxyfuel-Gas Cutting
conditions
T, C

The material must be capable

to burn in oxygen
2,1

The Flash Point Temperature

must be lower than the
Melting Point Temperature.

Limit
of well
cuttabilityhatra
A knny
lngvghatsg

C, %
0,8

4,3

The Melting Point of the oxide

must be lower than the
Well cuttable materials:
Melting Point of the metal
Weldable unalloyed and low
itself.
alloyed steels. Alloying
The combustion result must
be fluid, so it can be flown out materials usually decrease
sweldability.
from the gap.
Welding lectures

dr. Bla Palots

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Oxyfuel Gas Cutting

application

Welding lectures

Oxyfuel gas cutting is

a very economical
thermic manufacturing
process, primarily for
cutting and preparing
raw materials of
welded constructions.

dr. Bla Palots

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2014.02.17.

Characteristics of the Arc

The electric arc is a long

lasting electric discharge
between solid or liquid
state electrodes.
It is followed by strong
light and thermal effects.
The electric arc is
practically capable to melt
any kinds of materials (of
course other conditions
must exist).
Welding lectures

DC/AC

Arc needs particles to carry

electric charge.
Electrons are the result of
thermal emission.
Ions are originating from
thermal ionization, collision
ionization and electromagnetic
vibrations.

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dr. Bla Palots

Arc Static Characteristics

U
U0
U2

L2

Lapos
vzszintes
Flat or vagy
horizontal

M2 U
2

L1
U1

U1
M1
Es
Dropping

I 2 I 1 I Rz

Welding lectures

I
I2

I1

Increase in arc
length brings an
increase in voltage.
If the arc length
increases, the
current must
decrease. This is
the condition of arc
stability.

dr. Bla Palots

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2014.02.17.

The condition of stable

working point

U U

0
I v I f
arc

machine

Gradient of the arc characteristic curve must be higher

then the gradient of machine characteristic curve.
As the length of the arc increases, the current of the arc
also decreases, this causes less electrode material to
melt, so the length of the arc consequently decreases.
Welding lectures

dr. Bla Palots

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Possibilities of arc ignition

Short circuit
Short circuit:
High frequency spark
ignition

Spark ignition:

IG

Welding lectures

DC/AC

dr. Bla Palots

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2014.02.17.

The dynamic characteristics

Dinamikusan
"rossz"
gp
Dynamically
bad
machine
U

Dinamikusan good
"j" gp machine
Dynamically
U

Rvidzrlat
resjrat

resjrat

resjrat

I
max

Rz

t
U

Rz

U
0

Dynamical requirement:

Rvidzrlat
resjrat

50 V must be available
in 0.05 sec, so the
speed of voltage
increase is:
1000 V/s.

I
I Rz

Welding lectures

Imax

I Rz

dr. Bla Palots

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The Alternating Current Arc

Welding lectures

Less stable, it ignites and

goes out 100 times a
second.
Inductive circle voltage
has advance compared to
current. A break time can
be sensable between
ignitions.
AC is not good dynamically
the current can be a max.
of 1.8 times more
compared to nominal value.

dr. Bla Palots

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2014.02.17.

The Internal Control

ve = constant

L v

L v
L

When the legth of the arc

increases, the current
decreases. When the
current decreases, the
speed of electrode melting
also decreases. The
original balance loosens,
the wire forwarding speed
exceeds the melting speed,
this way the length of the
arc decreases (flat
characteristics needed).

v1

Changing arc length is a consequence of weld bad swing.

A fmfrd lengsnek kvetkezmnye az vhossz vltozsa

Larc2 < L arc < L arc1

L v

L v

L v

arc

veltols
vwire = const.

L v
1

U
Forwarding
Eltol
motor
motor

L v
L

v2

+
L

=
v

I
I1

Balance: vvwire==vvmelt
Egyensly:
el.
leolv.
vmelt = f (I)

In. I
I nvl.
2

Arc length increases:

v leolv. = f ( I )

vhossz n: I

Arc length decreases:

vhossz cskken: I

nvl.

nvl.

I1 < Inominal

I2> Inominal

v
v
vmelt <leolv.
vwire el.

vleolv. v el.
vmelt > vwire

Welding lectures

dr. Bla Palots

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The External Control

U

vel. const.

L2
Gerjeszt tekercs

U2

L1

U1

=/

f ( U )

Az vhosszsg vltozstl fggen: U ha pozitv ( vhossz n )

U ha negatv ( vhossz cskken )

n
cskken

vel. n ( vhossz cskken )

vel. cskken ( vhossz n )

In case of external control we can regulate the wires

forwarding speed above the self control of the arc. Increase in
arc length results in an increase of voltage. By amplifying
voltage increase the motor rpm can be increased, this way
the length of arc can be decreased (dropping characteristic
needed). Welding lectures
dr. Bla Palots
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2014.02.17.

The Magnetic Blowing Effect

As the Lorentz force law

says, in a magnetic field
force is directed to a
moving charge. (Magnetic
Blowing Effect)
Starting from the side of
the work-piece, the arc is
bending forward, at the
end of the part, the arc is
bending backwards.
Welding lectures

Can be decreasd by:

- simm. Current drive in
- decrease of arc length
- decrease of current
- no effect when using AC.

dr. Bla Palots

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