Workshop Practice Manual-2

Department of Mechanical Engineering Galgotias University Greater Noida, UP

Contents
Electric arc welding Types of Electric arc welding Metal Inert Gas (MIG) Welding

Tungsten Inert Gas (TIG) Welding

Electric arc welding

Arc is a state of plasma. Arc is placed between the electrodes at the zone where the joint is to be made. The electric source is either AC or DC supply. The arc is developed due to high resistance encountered by the flowing current. The heat due to arc is so intense that the base metal and the electrodes melt simultaneously as it is in the range of 27000 to 55000C. The metal of the electrode drops in the form of fine globules. Also due to the force of the arc both the metals fuse into each other, thoroughly. On cooling a perfect joint is available.

Types of Electric arc welding

AC welding
It uses AC source. Its initial cost is low. It operates quietly. Since there are practically no moving parts, its maintenance cost is also low. Arc blow is not encountered but it cant be operated in those places where there is no power supply

DC welding
It uses DC power supply. The voltage range is around 45 volts. Both the current and voltage may be changed in this machine. It creates arc blow, besides, it is noisy too

Types of Electric arc welding

Figure: Arc welding setup: (1) switch box (2) secondary terminals (3) welding machine (4) current reading scale (5) current regulating hand wheel (6) leather apron (7) leather hand gloves (8) protective glasses strap (9) electrode holder (10) hand shield (11) Channel for cable protection (12) welding cable (13) chipping hammer (14) wire brush (15) earth clamp (16) welding table (metallic) and (17) job.

Metal Inert Gas (MIG) Welding

Arc is established between a continuously fed consumable metal electrode or wire and the work piece as shown in figure. Arc is shielded by inert gas like argon, helium, carbon dioxide or mixture of these gases. Electrode wire is fed from a coil rotated with a constant speed motor and the arc length is maintained constant by using (a) self adjusted arc for semi automatic plants or (b) self controlled arc in fully automatic MIG plants AC is not generally preferred because of unequal/burn off rates in positive and negative half cycle. DCRP (Direct current reverse polarity) gives deeper penetration and is used for thicker job. Argon or helium is used for welding of Aluminum, Magnesium, and Copper and Carbon dioxide for mild Steel and nitrogen for copper. Argon + CO2 are used for welding Mild steel, low alloy steel and stainless steels, whereas as a mixture of argon, helium and CO2 is used for welding austenitic stainless steel.

Figure: Setup for Metal Inert Gas (MIG) welding

Tungsten Inert Gas (TIG) Welding

Electric arc is struck between non consumable tungsten electrode and the work piece and shielding is provided by argon, helium or CO2 or mixture of any two as shown in figure.

Filler rod may or may not be used (as in close fit joints). It is an all position welding technique.
Electrode used in TIG welding are non-consumable type of tungsten electrode which varies in size from 0.13 to 9.5 mm and are of two main types: (a) Thoriated or (b) Zirconiated tungsten electrode Arc initiation by (a) torch started or by (b) high frequency AC power. Both DC and AC are used. Dc with straight polarity (DCSP) is more common for longer life of electrode. In general, AC power source is best for TIG welding of non ferrous alloys. For ferrous alloy DCSP is better for reducing volumetric loss from tungsten electrodes.

Figure: Tungsten Inert Gas (TIG) welding

Thank You