Power control Power source.

panel Transformer/
Rectifier
Electrode oven
Heated quiver

Electrodes
Inverter power
Power return source
cable
Electrode holder
Safety visor Power cable
(With dark lens) *
Copyright 2002 TWI Ltd 1
ELECTRODE HOLDER METERS
WELDING (OPTIONAL)
LEAD
ARC

THE POWER I V
SOURCE INPUT
OUTPUT 80 VOLTS
CONSTANT
OCV MAX
CURRENT
CHARACTERISTIC

RETURN VARIABLE
EARTH* LEAD
CURRENT
CONTROLLER
Copyright 2002 TWI Ltd 2
When an arc is struck between the consumable metal rod
(electrode) and the workpiece, both the rod and workpiece surface
melt to form a weld pool. The electrode is manipulated by the
welder who controls the arc length.

Simultaneous melting of the flux coating on the rod will form gas
and slag which protects the weld pool from the surrounding
atmosphere.

The slag will solidify and cool and must be chipped off the weld
bead once the weld run is complete (or before the next weld pass
is deposited).
Copyright 2002 TWI Ltd 3
Copyright 2002 TWI Ltd 4
 SIZE:- TYPICALLY 1.6mm THRU TO 6.3mm
TYPE:- BASIC, RUTILE AND CELLULOSIC.
CONDITION:- of Electrode including Heat Treatment
BASIC = LOW HYDROGEN POTENTIAL
THEREFORE BAKING REQUIRED.
RUTILE = GENERAL PURPOSE MEDIUM IN
HYDROGEN, THEREFORE NO BAKING (DRYING
O.K.).
CELLULOSIC = HIGH IN HYDROGEN, THEREFORE
NO BAKING AND RARELY DRIED.

Copyright 2002 TWI Ltd 5

 BASIC = HIGH INTEGRITY WELD WHEN
HYDROGEN CRACKING IS A RISK.

RUTILE = MILD STEELS (LOW CARBON).

WELDER FRIENDLY GIVING ASTHETICS.

CELLULOSIC = FOR STOVEPIPE WELDING

TECHNIQUE (PIPELINE WELDING).

Copyright 2002 TWI Ltd 6

 MAINLY STEELS, INCLUDING STAINLESS STEEL
AND NICKEL ALLOYS.

IN THICKNESSES RANGING TYPICALLY FROM

6mm TO ?

MATERIALS NEED TO BE CLEAN, BUT BECAUSE

OF THE FLUX/SLAG, SOME MINOR
CONTAMINATION O.K.

Copyright 2002 TWI Ltd 7

1). A Transformer (AC) or Transformer/Rectifier (AC/DC)

2). A power and power return cable

3). Electrode holder

4). Electrode (To correct specification)

5). Correct visor & glass, all safety clothing and extraction

Copyright 2002 TWI Ltd 8

Power source can be AC or DC or Both

AC = Transformers
DC = Rectifiers or generators

Therefore:-

AC = Shop welding

DC = Shop and Site welding

DC is safer than AC due to having a lower O.C.V.

Copyright 2002 TWI Ltd 9

1) Amperage 2) Arc Voltage

3) Polarity 4) Speed of Travel

5) Electrode type & 6) Duty Cycles

7) Electrode condition 8) Connections

9) Insulation / extraction 10) Electrode treatments*

Copyright 2002 TWI Ltd 10

1) Slag inclusions

2) Arc strikes

3) Porosity

4) Undercut

5) Shape defects

Most welding imperfections in MMA are caused by a lack of

welder skill (not an easily controlled process), the incorrect
settings of the equipment, or the incorrect use, and treatment of
electrodes*
Copyright 2002 TWI Ltd 11
 Advantages: Disadvantages:

1) Field or shop use 1) High skill factor

2) Range of consumables 2) Slag inclusions

3) All positional 3) Low operating factor

4) Very portable 4) High level of fume

5) Simple equipment 5) Hydrogen control

Copyright 2002 TWI Ltd 12

 ELECTRICAL RISK

FUMES

ARC RADIATION

HEAT

FIRE AND EXPLOSION

TRAINING ESSENTIAL!!!

Copyright 2002 TWI Ltd 13