WELDING PROCESS

Simple to operate, portable, versatile, cheap and easy  SAW (Submerged Arc Welding) also known
MMA (MANUAL METAL ARC) maintenance, suitable for restricted access, low H2  Sub-arc is an arc welding process uses an
 Also known as SMAW (Shielded Metal possible, not require gas for shielding. 2. Spray Transfer: arc between a melting of ‘bare wire’ to the base metal.
Arc Welding) Flat and HV, Al, mg, high dilution, solidification crack, The arc is shielded by fused or agglomerated fluxes.
 MMA is an Arc Welding Process uses an Disadvantages: Ar 85%
arc between a Low productivity, low operating factors, high skill - + Type of power sources:
melting tip of covered electrode to the base metal required, required oven to bake the electrode, not Constant voltage < 1000 V, Constant Current > 1000 A
 he type of Power Source characteristic suitable for reactive materials
is constant Type of Flux:
current or drooping arc Safety: 3. Globular transfer:  in between dip and spray 1. Fused: flaky or shiny appearance, good
Figure: V Arc rays, electric shock, burn skin, fumes, fire, recycling, smooth profile, limited composition, high
explosion (ledakan) resistance to moisture absorbtion
2. Aglomerated: granular appearance, good
TIG (TUNGSTEN INERT GAS) properties, addition od additive, good recycling, very
I  Also known as GTAW (Gas Tungsten Arc hugroscopic.
Variable:
Type of welding machine: Transformer, DC Rectifier, Welding) Current, voltage, T. Speed, electrode extension, 4. Pulsed Transfer:
Engine Driver, Inverter  TIG as an arc welding process uses an polarity, gas flow rate Low Heat input, low distortion, better fusion (Co2 for Function of flux: to provide shielding to avoid atmospheric
arc between a non consumable electrode to the deep penetration but make many spatter) contamination, to stabilize the arc, to add deoxidant, to
Type of polarity: DC + (Reverse Polarity)  Deepest base metal Materials: improve the properties of weld metal
Penetration,  Filler metal may or may not be added to S: Min 1.0 mm ~ max 15.0 mm
DC – (Straight Polarity)  the hair deposit high, AC the molten pool (autogenously) T: Suitable for most materials including the reactive Current controls the depth of penetration
 The type of power source is constant or materials such as titanium
Type of Flux Covering: Rutile (Co2)  General drooping C: Must be very cleaned Voltage controls the weld bead shape:
purpose High voltage = flatter bead shape
Cellulose (H2)  Deepest penetration, Basic (Low H2) Arc Characteristic: Consumable: Current control; the depth of penetration (WFS) – wire Low voltage = change properties, high flux melting
Figure: V S: Min 0.8 mm ~ Max 4.0 mm feed speed combined with current
Function of Flux Covering: T: As Per parent metal Voltage controls; the weld bead profile, high voltage = Welding head arrangement: single head single wire, single
 To provide shielding to avoid C: Store at clean and dry area flatter weld bead shape head twin wire, tandem wire
atmospheric contamination
I Type of torch: Variables: current (H. Current – H. deep penetration),
 To provide deoxidant to avoid surface Gases:
contamination Type of welding machine: Ar, He, Ar+He, Ar + H2 (Austenitic Stainless Steel) Air cooled, water cooled – Al, mg Voltage, T. Speed (L. T. speed – H. deepest and weld
 To improve smoothness of weld metal Transformer / rectifier, inverter bead), wire size (Small wire – H. deepest penetration),
and to produce slow cooling by slag layer Typical Defects: Type of roller: V’ Groove, U’ Groove, Knurled (FCAW) electrode extension, flux depth (not depth will be result
 To improve the properties of weld metal Type of polarity: Tungsten Inclusion, Silica inclusion (ferritic steel), porosity).
 To aid arc ignition DC+, DC-  Steel, AC  Al, mg nothing spatter and slag inclusion Equipment Set-up:
 To stabilize the arc Materials:
Table: Advantages: S: min 6.0 mm ~ Max 150.0 mm
MMA is a manual welding process, welder control: Effect of DC - DC + AC Very high quality welding process, very smooth and T: C. Steel, S. Steel, Alloy
Arc length, Travel speed, Electrode angle polarity clean, easily automated, suitable for thin mat’l, suitable C: Moderated Cleaning
Electrical for any welding positions, versatile, low H2 welding - +
Equipment set-up MMA: characteristic process (<3 ml / 100 gr) Consumable:
Figure S: min 2.4 mm ~ max 6.0 mm
Electron Disadvantages: T: as per parent metal
Flow or heat Low productivity, expensive, need gas for shielding, not C: store at clean and dry area
distribution suitable for thick mat’l, ozone levels, high frequency
start will interfere the usage of electronic devices, Fluxes:
complex welding machine Variables: current (WFS), Voltage, T. Speed, Stick out  fused (high resistance to moisture)
Penetration
- + length, nozzle to work distance, contract tube to work  Agglomerated = need to bake prior to their
Safety: distance used, 500° C ~ 1H or as per manufactuter instructions
Cleaning No Yes Yes,
action every Arc rays, electric shock, burn skin
Materials: Typical defects: solidification crack, slag inclusion, burn
half S: Min 1.0 mm ~ max 50.0 mm
cycle MIG (Metal Inert Gas)  Ar, He, Ar + He through, porosity
MAG (Metal Active Gas)  Co2, Ar + Co2 T: C. Steel, Stainless steel, Al, Alloy, copper
Variables: C: Moderate cleaning  for avoid porosity it’s cover at
(2% - Austenitic stainless steel) Advantages: high quality, smooth profile, easily automated,
Current, arc voltage (arc length), travel speed, Type of shielding gas: antideoxidant suitable for thick mat’l, no visible arc
electrode angle, O.C.V (Open Circuit Voltage), polarity  Argon: easy to initiate the arc, stable arc
 Helium: hotter arc, high heat input, deeper  Also known as GMAW (Gas Metal Arc Welding)
 MIG/MAG is an arc welding process uses an arc Consumable: Disadvantages: bulky (besar sekali), not so portable,
Materials: penetration S: Min 0.8 mm ~ Max 1.6 mm
between a melting tip of ‘solid wire’ to the base difficult control the depth of penetration, H. heat Input,
S: Min 3.0 mm ~ max 25 mm  Ar + He, Ar + He ~ (2%) : austenitic stainless steel T: As per parent metal
metal limited welding position, expensive
T: Carbon Steel, Stainless Steel, Copper, Alloy C: Store at clean and dry area
C: Some tolerance on the surface preparation Type of tungsten:  The type of power source is constant voltage or flat
Safety: electric shock
 Thoriated ~ 1% or 2% - Steel Gases: Ar, He, Ar +he, O2, Ar + O2, Co2
Consumable:  Zirconiated – Al, mg Characteristic:
Figure: Note: Ar can not for steel, stainless steel and alloy
S: Min 2.4 mm ~ max 6.0 mm  Ceriated – AC and DC
T: Basic, Rutile and Cellulose  Lanthanum - AC and DC Typical Defects:
C: Chip, Crack, Concentricity Spatter, lack of sidewall fusion (DIP), solidification crack,
Technique to initiate the arc: silica inclusion (ferritic Steel), Copper inclusion (15 dent
Treatment: Scratch start, high freq start, pulsed arc start metallic)
Basic (low H2): Bake at 350° C ~ 1H or as per
manufactures instruction, holding oven at 150° C, Type of welding torch: Advantages:
Quiver at 70° C ~ 80° C Air cooled, water cooled  al, mg, and thick materials High productivity, easily mechanized, low H2 welding
Rutile: My be oried at max 120°C ~ 1H Type of welding machine:
Transformer rectifier, inverter process (<3 ml/100 gr), suitable for all welding positions
Cellulose: Never Bake or what so ever Equipment set-up:
Figure: Type of polarity normally: DC + (Reverse polarity)
Disadvantages: complex set-up, expensive, need gas for
Typical defects: shielding, high ‘ozone’ level, not suitable for restricted
Slag inclusion, porosity, lack of side wall fusion, lack of Type of metal modes of transfer:
1. Short circuiting or dip transfer : access, need proper protection when use on site
root penetration
I < 200 A, V < 20 V, all welding positions, lack of
sidewall fusion, spatter Safety: arc rays, electric shock, fumes, fire, burn skin
Advantages:
SUB – ARC