Welding Processes

1.

General

An arc is created when an electrical discharge occurs across the gap between an

electrode and parent metal

The discharge causes a spark, causes the surrounding gas to ionize.
The ionized gas enables a current to flow
The arc generates heat for fusion
Heat input to the fusion zone depends on the voltage, arc current and welding/travel
speed.

2.

Heat Input

energy is the amount of heat generated in the welding arc per unit length of weld.
Heat Input = Arc Energy x Thermal Efficiency Factor

Welding position and the process have a major influence on the travel speed that can
be used.
For manual and semi-automatic welding the following are general principles:

Vertical-up progression tends to give the highest heat input because there is a

need to weave
Vertical-down welding tends to give the lowest heat input
Horizontal-vertical welding is a relatively low heat input welding position because

the welder cannot weave in this position.

Overhead welding tends to give low heat input because of the need to
use low current
Welding in the flat position (down-hand) can be a low or high heat input
Of the arc welding processes, SAW has potential to give the highest heat input
and the highest deposition rates and TIG and MIG/MAG can produce very low

heat input.
Typical heat input values in the range ~1.0 to ~3.5kJ/mm.

3.

Welding General Parameter

3.1 Arc Voltage

potential or pressure required for current to flow

Arc voltage is related to the arc length
voltage setting will affect the profile of the weld.

3.2 Welding Current

major influence on the depth of fusion/penetration

Amperage controls burn off rate
Welding current level is determined by the size of electrode
the higher the current the greater the depth of penetration

Amperage too low: Poor fusion or penetration, irregular weld bead shape,
slag inclusion unstable arc, arc stumble, porosity, potential arc strikes.
Amperage too high: Excessive penetration, burn through, undercut, spatter.

3.3 Polarity

Determines whether most of the arc energy (the heat) is concentrated at the
electrode surface or at the surface of the parent material.

DCEP, Electron flow direction is from the workpiece to the electrode.

DCEP, two thirds of the available heat energy at the tip of the electrode, with the
remaining one third being generated in the parent material, result in an increase

in the depth of the weld penetration.

DCEN, Electron flow direction is from the electrode to the workpiece
DCEN, causes heat to build up on the electrode, increasing the electrode melting
rate and decreasing the depth of the weld penetration

4.

Power Source Characteristics

An open circuit voltage (OCV) to initiate the arc, between 50 and 90v.
Welding voltage to maintain the arc during welding, between 20 and 30v
There is a relationship between the arc voltage and the current flowing through
the welding circuit that depends on the electrical characteristics

4.1 Constant Current Power Source

This is the preferred type of power source for manual welding (MMA and manual

TIG).
Arc voltage is controlled by the arc length
too long the arc will extinguish

too short the electrode may stub into the weld pool
Large changes in arc voltage give only small change in current, 10v = 5 amps

The power source must provide:

An open circuit voltage (OCV) to initiate the arc, between 50 and 90v.
A suitable current range, typically 30-350 amps
A constant welding current. The arc length may change during welding

4.2 Constant Voltage Power Source

Preferred type of power source for welding processes that have a wire feeder

(MIG/MAG, FCAW and SAW).

Wire feed speed and current are directly related
Current is increased, the feed speed increases and there is a corresponding

increase in the burn-off rate to maintain the arc length/ voltage

If the arc length is decreased, momentary increase in welding current, gives a
higher burn-off rate and this brings the arc length (and arc voltage) back to the

pre-set value.
Small changes in arc voltage give only large change in current