Constant Voltage Volt/Amp Characteristic* OCV Changes in arc length* The self adjusting arc.

Volts
Small change in voltage = large change in amperage*

Amps

External wire feed unit Internal wire feed system Power control panel 15kg wire spool Power return cable*

Transformer/ Rectifier

Power cable & hose assembly Liner for wire Welding gun assembly

Internal wire drive system*

Plain top roller

Half grooved bottom roller

Wire guide*

Torch body Torch head assembly (Less nozzle)*

On/Off switch

Hose port

Nozzles or shrouds Gas diffuser

Spot welding spacer Contact tips

Types of metal transfer:

Dip transfer: < 24 Welding volts. Low amps. & C02 Gas.
All positional. Low heat input. Low deposition rate

Spray transfer: > 24 Welding volts High amps Ar/C02 Mix

Down-hand only. (steels) High heat input. High deposition rate

Pulse transfer: Variable pulses of high current

All positional. Controlled heat input. High deposition rate* Globular transfer occurs between dip & spray, but is unstable*

1) 2) 3) 4) 5) 6) 7) 8)

A Transformer/Rectifier (Constant voltage type) A power and power return cable An Inert, active, or mixed shielding gas (Argon or CO) Gas hose, flow-meter, & gas regulator MIG torch with hose, liner, diffuser, contact tip & nozzle Wire feed unit with correct drive rolls (Push or Pull) Electrode wire to correct specification and diameter Correct visor & glass, all safety clothing and good extraction*

1) 3) 5) 7) 9) 11)

WFS/Amperage Wire type & Tip size/condition Liner size Insulation/extraction Duty cycle

2) 4) 6) 8) 10) 12)

OCV & Arc Voltage Gas type & flow rate Roller size & pressure Inductance settings Connections Angles & travel speed*

1) 2) 3)

Silica inclusions (Poor inter-run cleaning) Lack of side wall fusion (Primarily with dip transfer) Porosity (From loss of gas shield on site etc)*

Most welding imperfections in MIG/MAG are caused by lack of welder skill, or incorrect settings of the equipment The use of low quality wires will cause wire feed problems Worn contact tips will cause poor power pick up, or transfer Bad power connections will cause a loss of voltage in the arc*

Advantages:
1) 2) 3) 4) 5) Lower skill required Easily automated All positional (Dip/Pulse) Thick/thin materials High productivity (O/F) 1) 2) 3) 4) 5)

Disadvantages:
Lack of sidewall fusion Range of consumables Loss of gas shield/site Complex equipment High ozone levels*

Power return cable Power control panel Transformer/ Rectifier Granulated flux*

Welding carriage control unit Carriage assembly with flux hopper

Reel of wire

1. Wire 2. Flux 3. Dilution

SAW with low arc voltage

Typical SAW preparation*

Short arc length

1 2

Possible weld metal % composition*

Effect of increased arc voltage Long arc length

1. Wire 2. Flux 3. Dilution

1 2

Change in weld metal composition*

1) 2) 3) 4) 5) 6) 7) 8)

A Transformer/Rectifier (Constant voltage type) A power and power return cable A torch head assembly A granulated flux A flux delivery system A flux recovery system Electrode wire to correct specification and diameter Correct safety clothing and good extraction*

1) 3) 5) 7) 9) 11)

WFS/Amperage Flux type & mesh size Wire & condition Flux delivery/recovery Insulation/duty cycle Tip size & condition

2) 4) 6) 8) 10) 12)

OCV & Arc Voltage Flux condition Wire Specification Electrode stick-out Connections Speed of travel*

1) 2) 3) 4)

Lack of fusion (Caused by high levels of arc blow) Solidification cracks (From S pick up from high dilution) Shrinkage cavities (From high depth:width ratio) 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*

Advantages:
1) 2) 3) 4) 5) Low weld metal costs Easily mechanized Low Ozone production High productivity (O/F) No visible arc light (U/V) 1) 2) 3) 4) 5)

Disadvantages:
Restricted in position Arc blow with DC Shrinkage cavities (d:w) Penetration control Variable compositions*

Videos ESAB MIG/MAG Welding Steels

Or equivalent (30 minutes)*

Videos Millar Submerged Arc Welding

Or equivalent (20 minutes)*

All those things used up in the production of a weld Though generally, we refer to those elements that are used in a specific welding process i.e:

Electrodes, Wires, Fluxes and Gases*

In MMA/SMAW the only consumables used are short electrodes, which are covered in a flux coating This flux coating has many functions and there are many different types These functions are not limited too, but include: 1) To aid arc striking 2) To stabilize the arc 3) Form a shielding gas 4) To add de-oxidants 5) To add alloying elements 6) To form a protective slag 7) To refine solidifying metal 8) To control hydrogen content *

:Classification

Main Shielding :General Uses :Constituent :gas Titania TiO2 CO2 CO2 General Purpose High quality work

Rutile: E6013

Basic: E7018 Calcium compounds

Pipe root Ground cocoanut is of The core wire for most MMA electrodesshells a low quality steel, as this is a cheap *runs method of manufacture and the steel will be refined during the process of welding
by the refining agents and elements contained in the flux coating*

Cellulosic: E6010 Cellulose Hydrogen

Electrical parameters Electrode efficiency Toughness 28 & 47 Joules Electrode

E 5133B
Tensile & yield strength Flux coating type Positional capabilities Low hydrogen potential baking)

(After

Strength Toughness Coating Shown on all electrodes*

Positional capabilities Flux coating type Toughness 47 Joules Electrode

E 46 3 1Ni B
Tensile & yield strength Any light alloying composition Electrical parameters & efficiency Low hydrogen content achievable* Strength Toughness Coating Shown on all electrodes*

Positional capabilities Electrode E 80 18 Tensile strength (PSI x 1000) Flux coating & characteristics*

electrical

1: Electrode size

Diameter & length*

2: Electrode condition

Cracks, chips & concentricity*

3: Electrode specification Correct specification/code*

E 51 33 B

Gases used for TIG: Argon or Helium or a mixture of these gases* Helium gas has higher ionization potential than argon and gives deeper penetration, whilst argon is denser than air and gives good coverage of the weld area in the down hand position. We would need 2-3 times the flow rate of helium to get the same coverage as helium is less dense than air. In the overhead position the reverse is true. We often mix these gases to get both benefits* We sometimes use additions of nitrogen when welding some stainless steels, or copper*

Gases used for MIG: Argon or Helium Gases used for MAG: CO2 or mixtures of CO2 and Argon* CO2 : Very good penetration, cannot support spray transfer produces an unstable arc, with lots of spatter Argon: Shallow penetration. Very stable arc, with low spatter We mix both gases in mixture of between 5 20% CO2 in argon to get the benefits of both gases* For stainless steels we use argon with a 2% oxygen, this gives more fluidity to the weld and an improved toe blend*

Wires must be drawn as deposited and are therefore of very high quality. Electrode wires for MIG are the same as rods for TIG* The quality of temper and copper coating is also very important. The copper coating on MIG wires maximises the current pick up* Specifications for wires are as per their chemical compositions*

Grades:
Composition + Single, double, and triple de-oxidised wires*

Quality of winding:
Random wound. Layer wound. & Precision layer wound

Wires diameters:
0.6 - >2.4 mm supplied on 1 kg (fine wire) & 15 kg spools*

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*

The 2 methods of flux manufacture are: 1) Fused 2) 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* 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*

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 absorbant* 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*

Fused SAW Fluxes

*

Agglomerated Fluxes
*

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*

Pipe Visual Inspection Form

Page 1 of 3 CSWIP VISUAL INSPECTION PIPE REPORT Name [Block capitals]____________ Signature_________Pipe Ident#________ Code/Specification used_________Welding Process_______ Joint type______ Welding position__________ Outside & Thickness_____ Date ________

D Complete as per plate report form *

Practice observing & reporting using the pipes and forms provided. Use your nominated pipe code for all your visual inspections as this will help you become conversant with the specification. Practice this up and till the end of the day, or as directed by your course lecturer*