Professional Documents
Culture Documents
1. POLARITY
A welder should understand the meaning of polarity, and recognize what effect it has on the welding process. For proper penetration, uniform bead appearance and good welding result, the correct polarity must be used when welding with any wire or electrode. Incorrect polarity will cause: poor penetration, Irregular bead shape, excessive spatter, difficult to control the arc, overheating, and rapid burning of wire or electrode. ARC BLOW Occurs when the arc refuses to go where it is supposed to, blows wildly forward or back, and produces spatters badly. Most frequently encountered at the start and finish of joints, and in corners and deep grooves, particularly when high amperages are being used in welding thick. Makes welding very difficult, reduce speed and lowers weld quality When the arc blow opposite to the direction of travel it is called back blow. When the arc blows with the direction of travel, it is called forward blow. Is caused by magnetic force acting on the arc, making the arc blow from its normal path. TO REDUCE ARC BLOW: Reduce current Weld toward a heavy tack or toward a weld already made Use back stepping on long welds Place ground connection as for from joint to be welded as is possible
If back blow is in the problem, place ground connection at start of weld and weld towards a heavy tack If forward blow causes trouble, place ground connection at the end of weld Wrap ground cable around the work piece and pass ground current through it in such a direction that magnetic field will be set-up to neutralize the magnetic field causing the blow Hold as short and arc possible to help the arc force counteract the arc blow If the machine bring used is of type producing both AC&DC, switch to AC.
Use of jigs and fixtures such as clamps, jigs, strong backs to hold the work in a rigid position during welding.
Legends: Contraction in the weld & HAZ along the length. Bowing due to the greater volume of metal at the top of the weld Peaking due to the V angle Ripple (in sheet) away from the weld Contraction in the weld metal and HAZ transverse to the weld
a.Too long arc length Increase of spatter Poor penetration Sound of arc will be more of a hiss than a crackle Metal will melt off the electrode in large drops Slag removal will be difficult b.Travel speed too fast Bead will be thin & stringy Poor penetration c. Travel speed too slow Weld metal will pile up and roll over Excessive overlap d.Amperage too high Bead will be flat Excessive spatter Excessive porosity Electrode becomes overheated
e.Amperage too low Difficult in striking the arc Difficult in maintaining correct arc length Weld metal pile up Excessive overlap Poor penetration
LEGENDS: Made by a correct procedure Amperage too low Spatter and undercut caused by excessively high amperage Voltage too low Excessively high voltage or long arc Travel speed too slow Travel speed too fast
To restart a continuous bead: Strike the arc Move the electrode to the crown of the crater Resume forward travel
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The weave should not be wider than three times the diameter of electrode. And the purpose accomplished by both these motions is substantially the same and their usage is largely a matter of preference.
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