CLD 20502 Basic Engineering Workshop

Topic 3:
Metal Joining Process

Topic 3.3: Welding Processes

 Introduction

3 types of arc welding will be discussed here.

Arc welding is a type of fusion welding which used
heat to melt the base metal.
 Shielded Metal Arc Welding (SMAW)

The arc is created between the

electrode and the workpiece
due to the flow of electricity.
The arc provides heat or
energy to melt the base metal,
filler metal and electrode
coating.
The welding leaves solidified
weld metal covered by a layer
of converted flux which is
called slag.
 Shielded Metal Arc Welding (SMAW)

Electrode the primary element

Metal core wire covered with a layer of granular flux
held in some type of bonding agent.
When an arc struck the following happens:
- Shielding, Deoxidation, Alloying, Ionizing,
Insulating

SMAW Electrode identification system

EXXXX
 Shielded Metal Arc Welding (SMAW)

Advantage of SMAW
Simple and inexpensive equipment
Numerous types of electrodes
Resulting weld quality is consistently high.

Limitation
Relatively slow in speed
Need a slag removal
Some electrode need a special storage.
Arc blow.
 Gas Metal Arc Welding (GMAW)

Commonly referred as MIG

metal inert gas welding
Solid wire electrode is fed
continuously through a welding
gun.
An arc is created between this
wire and the workpiece to heat
and melt the base and filler
materials.
Once molten the wire become
deposited in the weld joint.
 Gas Metal Arc Welding (GMAW)

Shielding gas
Emitted from the welding gun from some external
source.
Gas used both inert and reactive gas.
Argon, helium, carbon dioxide.

Electrode
Solid wire which are supplied on spools or reels of
various sizes.
Code:
ERXXS-X
 Gas Metal Arc Welding (GMAW)

Advantages
Speed
Relatively clean process
Visibility of process no slag present

Limitations
The only protection is from shielding gas. No flux.
Base metal can be excessively contaminated.
 Gas Tungsten Arc welding (GTAW)
Electrode used is not intended to be
consumed during the welding
operation.
Made of pure/ alloyed tungsten, able
to withstand high temperature.
Arc is created between tungsten
electrode and the workpiece.
When filler metal is required, it must
be added externally.
Arc and metal shielding is achieve
through the use of gas which flows out
of the nozzle surrounding the
tungsten electrode.
 Gas Tungsten Arc welding (GTAW)
Electrode
The code consists a series of letters starting with E for
electrode and W for tungsten. Then followed by letters
and numbers which describe the alloy type.

Filler metal
Same designation code with GMAW filler metal.

Shielding gas
Most utilizes inert gas not combine with metal but
protect from contaminants.
Argon, Helium
 Gas Tungsten Arc welding (GTAW)

Advantages
Good for thin material.
High quality and excellent visual appearance.
No slag, very clean choice for critical application.

Limitations
Slowest process
Low tolerance in contaminants extremely clean
condition.
High skill level both hand
 Welding Discontinuities

Crack Overlap
Incomplete fusion Convexity
Incomplete joint Weld reinforcement
penetration Arc strike
Inclusion Spatter
Slag inclusion Lamination
Tungsten inclusion Lamellar tear
Porosity Seam/ lap
Undercut Dimensional
Underfill
 Crack

A long sharp ends discontinuity either in the weld

itself or in the base adjacent to the weld.
Most serious welding defect which signifies the
reduces in weld strength.
 Incomplete fusion

Weld discontinuity in which fusion did not occur

between weld metal and fusion faces or adjoining
weld beads.
 Incomplete joint penetration

Weld metal does not extend entirely through the

joint thickness when complete penetration is
required.
 Inclusion

Entrapped foreign solid material such as slag,

tungsten or oxide.
 Imperfect shape or unacceptable contour

Surface discontinuities.
Underfill occurs in weld metal of groove weld.
Undercut occurs in the base metal directly to the weld.
No sufficient filler metal deposited to adequately fill the weld
joint.
 Porosity

Cavity type discontinuities formed by a gas

entrapment during solidification.
Miscellaneous defects
 Testing
1. Visual testing (VT)

2. Destructive Testing
Tension Test
Tension-Shear Test
Bend Test
Fracture Toughness Test
Corrosion and Creep Test

3. NDT
Penetrant Test (PT)
Magnetic Particle Test (MT)
Radiographic Test (RT)
Ultrasonic Test (UT)
Eddy Current Test (ET)
 Testing

1. Visual testing (VT)

 Testing

2. Destructive Testing
Destructive testing methods in which the weld is
destroyed either during the test or to prepare the test
specimen. They include mechanical and metallurgical
tests. Figure below shows some example of mechanical
destructive testing method.
 Testing

3. NDT
Penetrant Test (PT)
Magnetic Particle Test (MT)
Radiographic Test (RT)
Ultrasonic Test (UT)
Eddy Current Test (ET)
 Testing

3. NDT
 Questions

Differs between consumable and unconsumable

electrode.
Explain on how the surface defects can occur in
welding.
List three types of testing that can be done in
detecting a welding defects.