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FCAW Electrode Identification System
Electrode
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FCAW Electrode Identification System
Strength
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FCAW Electrode Identification System
Position
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FCAW Electrode Identification System
Tubular
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FCAW Electrode Identification System
Chemical Composition
Operating Characteristics
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E308T-X - Welding 304
E308LT-X - Welding 304L
E316T-X - Welding 316
E316LT-X - Welding 316L
E309T-X - Welding sst to cst
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High productivity
Deep penetration
Tolerates contamination
Suitable for field work
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Slag removal.
Smoky process.
Electrode costly.
Equipment complexity.
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Slag inclusions
Porosity
Incomplete fusion
Incomplete joint penetration
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The TIG welding process was first developed in the USA
during the 2nd world war for the welding of aluminum alloys
The process:
• uses a non-consumable Tungsten electrode.
• requires a high level of welder skill.
• produces very high quality welds.
• considered as a slow process compared to other arc welding processes.
The arc may be initiated by a high frequency to avoid scratch
starting, which could cause contamination of the tungsten electrode and
weld metal.
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Power control Transformer/
panel Rectifier
Power return Inverter power
cable source
Torch Power control
assemblies panel
Power cable
Tungsten
electrodes*
Flow-meter
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Weld
Penetration
increases
Increase
2-2,5 times
electrode
diameter
Vertex
angle
Decrease
Bead width
increases
Electrode tip prepared Electrode tip prepared for
for low current welding high current welding
DC -ve AC
Electrode tip ground Electrode tip ground and then conditioned
1) Current 2) Arc Voltage
3) AC or DC + Polarity 4) Speed of Travel
5) Tungsten type & Ø 6) Calibration Validity
7) Tungsten vertex angle 8) Current Connections
9) Gas type & flow rate 10) Insulation of wires
11) Ceramic condition 12) Gas lens fitted*
Good for thin materials
High quality welds
Good appearance
Very clean
No slag
Mechanization potential
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Relatively slow
Low tolerance for contamination
Shielding & Purging gas expensive
Filler metal is fed manually.
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Porosity
Incomplete fusion
Incomplete joint penetration
Tungsten inclusions ( shows white spots in RT film)
Contact between:
Tungsten and base metal
Tungsten and molten weld metal.
Tungsten and filler metal
Excess current
Excess tungsten extension
Improper tungsten tip grinding
Welding consumables for TIG:
• Filler
wires, Shielding gases, Tungsten electrodes (non-
consumable).
• Filler
wires of different materials composition and variable
diameters available in standard lengths, with applicable code
stamped for identification
• SteelFiller wires of very high quality, with copper coating to
resist corrosion.
• Shieldinggases mainly Argon and Helium, usually of highest
purity (99.9%).
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Welding rods:
•supplied in cardboard/plastic tubes
Courtesy of Lincoln Electric
•must be kept clean and free from oil and dust
•might require degreasing
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Pre-placed filler material
Before Welding After Welding
Other terms used include:
EB inserts (Electric Boat Company)
Consumable socket rings (CSR)
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Consumable inserts:
•used for root runs on pipes
•used in conjunction with TIG welding
•available for carbon steel, Cr-Mo steel, austenitic stainless steel, nickel
and copper-nickel alloys
•different shapes to suit application
Radius
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Application of consumable inserts
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Argon
low cost and greater availability
heavier than air - lower flow rates than Helium
low thermal conductivity - wide top bead profile
low ionisation potential - easier arc starting, better arc
stability with AC, cleaning effect
for the same arc current produce less heat than helium -
reduced penetration, wider HAZ
to obtain the same arc power, argon requires a higher
current - increased undercut
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Helium
costly and lower availability than Argon
lighter than air - requires a higher flow rate compared with argon
(2-3 times)
higher ionisation potential - poor arc stability with AC, less
forgiving for manual welding
for the same arc current produce more heat than argon - increased
penetration, welding of metals with high melting point or thermal
conductivity
to obtain the same arc power, helium requires a lower current - no
undercut
Hydrogen
not an inert gas - not used as a primary shielding gas
increase the heat input - faster travel speed and increased
penetration
better welding action - improved bead profile
produce a cleaner weld bead surface
added to argon (up to 5%) - only for austenitic stainless
steels and nickel alloys
flammable and explosive
Nitrogen
not an inert gas
high availability - cheap
added to argon (up to 5%) - only for back purge for duplex
stainless, austenitic stainless steels and copper alloys
not used for mild steels (age embritlement)
strictly prohibited in case of Ni and Ni alloys (porosity)
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Carbon Steels
ER70S-2, ER70S-3, etc.
Stainless Steels
ER308, ER308L, ER316, etc.
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Welding carriage
Power return
control unit
cable
Power control Carriage assembly
panel with flux hopper
Transformer/
Rectifier
Granulated Reel of wire
flux*
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Filler wire spool
Flux hopper
Power supply
- +
Slide rail
Wire electrode
Flux
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Submerged Arc Welding(SAW)
Submerged arc welding was developed in the Soviet
Union during the 2nd world war for the welding of thick section
steel.
• The process is normally mechanized.
• The process uses high current in the range of 100A to over 2000A,
which gives a very high current density in the wire, producing
deep penetration and high dilution welds.
• A flux is supplied separately via a flux hopper in the form of either
fused or agglomerated.
• The arc is not visible as it is submerged beneath the flux layer ,
hence no eye protection is required.
1) A Transformer/ Rectifier (Constant Voltage type)
2) A power source and power return cable
3) A torch head assembly
4) A granulated flux
5) A flux delivery and recovery system
6) Electrode wire to correct specification and diameter
1) Wire Feed Speed/ Amperage 2) OCV & Arc Voltage
3) Flux type & mesh size 4) Flux condition
5) Wire Ø & condition 6) Wire Specification
7) Flux delivery/recovery 8) Electrode stick-out
9) Insulation/duty cycle 10) Connections
11) Tip size & condition 12) Travel Speed
1) Lack of fusion (Caused by high levels of arc blow)
2) Solidification cracks (From S pick up from high dilution)
3) Shrinkage cavities (From high depth:width ratio)
4) Porosity (Using damp fluxes, or un-cleaned plates)*
Most welding imperfections in SAW are caused by incorrect setting of
the equipment, using incorrect or wrongly dried consumables, or
welding plates that have not been properly cleaned. Minor changes in
the welding parameters of SAW can have a major effect on weld
composition and weld quality.
Bad cable connections can have a serious effect on changes in arc
length, and thus effect alloying to the weld via the flux*
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Advantages: Disadvantages:
1) Low weld metal costs 1) Restricted in position
2) Easily mechanized 2) Arc blow with DC
3) Low Ozone production 3) Shrinkage cavities (d:w)
4) High productivity (O/F) 4) Penetration control
5) No visible arc light (U/V) 5) Variable compositions*
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Crack
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SAW Filler Metal Identification System
Flux
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SAW Filler Metal Identification System
Tensile Strength
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SAW Filler Metal Identification System
Heat Treatment
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SAW Filler Metal Identification System
Impact Test Temperature
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SAW Filler Metal Identification System
Electrode
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SAW Filler Metal Identification System
Electrode Classification
(Low, Medium, High - Mn%)
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SAW Filler Metal Identification System
Electrode Classification
(8 through 16 for chemistry)
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SAW Filler Metal Example
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Consumables for Submerged Arc Welding consist of a wire and a
flux*
The wire is similar to that of solid wire MIG/MAG and is chosen
from a table of chemical compositions*
Fluxes are varied and are classified by their method of
manufacture and composition*
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The 2 methods of flux manufacture are:
Fused and Agglomerated
Fused fluxes are baked at a high temperature after mixing and all
components are fused together like glass. The slab is then smashed
into very small particles and sifted into grain sizes*
Fused fluxes: cannot contain certain alloying elements such as
Ferro Manganese, and tend to be used for lower quality work.
These fluxes are non moisture absorbent*
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Agglomerated fluxes are not baked as high as the fused fluxes and
are held together as particles by binding agents. These fluxes are
also sifted into grain sizes*
Agglomerated fluxes: contain many alloying elements, but are
prone to moisture absorption. They are used for higher quality
work*
All Submerged Arc Fluxes should be separately and carefully
stored in a dry area*
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Fused SAW Fluxes
*
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Agglomerated Fluxes
*
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Fused:
Baked at high temperature, glossy,hard and black in colour, cannot
add ferro-manganese, non moisture absorbent and tends to be of
the acidic type*
Agglomerated:
Baked at a lower temperature, dull, irregularly shaped, friable, (easily
crushed) can easily add alloying elements, moisture absorbent and
tend to be of the basic type*
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