Formation of haz in Weld Columnar grains

Coarse grains (a)

Fine grains
Temp °C Partially refined grains
Peak Liquid
Temp c Composite Region 1600
FsonBoundary 1400 Liquid
Coarse-Grained Austenite
Supercritical 1200 SS316
| Austenite HAZ @ 100X
Fine-Grained 1000
Supercritical Liquid
Intercritical 800 Fe Carbide

Subcritical
600
Ferrite+
4004 | Fe Carbide
Unaffected
weid Base Metal 2004
E SS316
E WELC@ 1OX
Distance o.15 1.0 wt %C
True HAZ
Isothermal Transformation (or TTT) Diagrams
Summary of austenite transformations
(Temperature, Time, and % Transformation) Austenite
100

Transformation Transtormation
temperature 675°C ends
50 Slow Rapid
Transformation cooling quench
begins
Moderate
10 104 l05
Time (s) cooling

Austenite (stable) Eutectoid temperature Pearlite (a+ Fe,C) + Bainite Martensite

Austenite
(c) 700
Temperature (unstable) a proeutectoid phase (Ca + Fe,C) (BCT ph ase)
Pearlite
Reheat
600
50% Completion curve

500 Completion curve

(-100% pearlite) Tempered martensite
Begin curve (a+ Fe.C)
400
(~0% pearlite)

10 102 103 104 105

Time (s)
Solid lines are diffusional transformations, dashed is
diffusionless m artensitic transform ation
 |Tungsten
Fixed
Electrode

P Electrode

D Inert Gas Filler wire

Supply
Contact Tube Gas shielding
N Gas Nozle Arc
Molten pool
Arc Weld
Hand-hetd shietding Gas
T Welding Rod
Molten Weld Pool
Weld Metal

Base Metal
C
H Ground Cable Area to be welded
Metaldroplet
Power Source

Major Components
1. Power Source

2. Welding gun and cable assembly

N 3. Shielding gas apparatus and accessories
4. Cooling system
 1. Power So LON
SHORTARC
Power Source
º AC/DC (Voltage and Current)
Generating Power AV
>Arc Characteristics
Power Source Characteristics
conditions)
Control (staticand dynamic
> Weld Quality DROOPING TYPE
> ArcEfficiency POWER SOURCE

Peak Cathode 20 000 c

18 O00 'c
temperatures drop zone -15 000c
18,000 K 12 000 c
R
Anode I0000 C

E drop zone
TEMPERATURE DISTRIBUTION
 Dynamic con
Weld Quality Control(Static and
Downslope
Upslope Welding Current
Postflow
Preflow Crater Fill Current
Initial Current

Pulse Frequency
Downslope
Upslope

Posttlow
Preflow Welding Current
(Base Current) Crater-Fill
InitialCurrent Pulse Current Current

Basic Operation of GTAW Process

P
L. Weld Quality Control (Static and Dynamicconditions)
D:
Upslope Downslope
N Welding Current

Preflow Postflow
Initial Current Crater FillCurrent

Pulse Frequency
Upslope Downslope

Preflow Postflow
Welding Current
R (Base Current)
E Crater-Fill
Initial Current Pulse Current Current
N
BasicOperation of GTAW Process
 Arc Efficiency piece.
transferred to the work
of arc energy that is
The proportion

00

H AD.,6141

Eficiency.
Figure 4. Factors affecting the Arc
C
R
E reducing Arc efficiency.
Increasing current and Arc Length is arc efficiency.
H2 in argon gas shielding will enhance
N Use of
2. Welding Guns and Cable Assembly
 Gas Lens
D

N - These lens save up to

40% of argon usage
They provide a much
improved gas coverage
Reduces turbulence
and gives laminar flow
Enable the tungsten to
be extended further
from the torch.
They ovide ue

nar iew
Bended furibe
fem h e toreh
 Electrode preparation
Use a 200 grit or finer grinding wheel. Do not use the wheel for other jobs or tungsten can become
contaminated causing lower weld quality.

2-1/2 Times
Electrode Diameter

CORRECT Straight Ground INCORRECT Radial Ground

Stable Arc Arc Wander

Point
R Flat
Grincang
Wheel
E
Grinang
Wheel
N
 Effect of polarity in AC

Electrode negative

Electrode positive
 GMAW process
Basic Layout of
Regulatcr/
P
Flowmeter
L. Gas Hose Power Source nozle of
welding torch
D Wire spool Wire fccder Shie'ding
Gas
filer
N Power sourcc Fecder / / Contactor
Control Cord wire
welding
Brc
Wite Feeder
Electrode
T
Cable
Gas weld
Torch cylinder Torch
Work Cable bead

H Work
Work
Clamp

H
E Major Components
1. Power Source

Welding gun and cable assembly

R
2.
E Wire feed drive and accessories
E 3.
4 Shielding gas apparatus and accessories
5 Cooling system
1. P w e r Source 50

40 - Ara length
AC/DCPower Source
30
Generating Power (Voltage and Current) b
20
Arc Characteristics Power source output
10
Power Source Characteristics
Weld Quality Control(static and dynamic conditions) 100 200 300
Curront (A)
400 500 600

Synergic Mode of Operation (Wire Feeding, Gas and torch) Short aro D Normal 0L Long arc
Metal Transfer Behaviour Self-adjustmont with a constant-voltago powor source.
> Arc Efficiency

3/4"
1/2 (19.omm)
(12.7mmn)
1/4"
(6.4mm)
 50 r
Arc length
P 1. Power Source (V)
Voltage
40 Et
D: > AC/DC Power Source 2 30 C

and Current)
> Generating Power (Voltage
Power source output
20
N º Arc Characteristics 10

> Power Source Characteristics 300 400 500 600

100 200
T dynamic conditions) Current (A)
Weld Quality Control (static and b Normal C Long arc
Gas and torch) Short arc
Synergic Mode of Operation (Wire Feeding, power source.
Self-adjustment with a constant-voltage
C
> MetalTransfer Behaviour
H
> Arc Efficiency
T min)
H
(m 12
E E 10
speed

feed
C
Wire 4
3/4"
2
(19.Omm)
100 200 300 400 1/2"
Current (A) (12.7mm)
1/4"
Wire diameter (6.4mm)
1.2 mm 10.8 mm 1.6 mm

Burn-off characteristics for plain carbon steol filler wire.

 Metal Transfer Behaviour

gravitationa!
acceleration
wire electrode
electronagnetic force
(pincheffect) viscositY
contracting droplet
surface tension
reaction forces of
H inertial forces
E
evaporating material
S electrostatic forces suction effect by
C plasma beam
R work piece
E
E

Detaching Forces : gravitational, electromagnetic and plasma drag forces.

Retention Forces : surface tension and the vaporization forces
 3. Wire Feed Drive and Accessories
D

U-Groove, V-Groove and Knurled Rolls

Two-roll Drive systemn

Wire Straightener
Four.roll Drive system
 GMAVW
Welding]
TGas Metal Arc
P
L.
D:

C MAG
MIG
H
Metal Active Gas Welding
T Metal Inert Gas Welding
H

Argon, Helium. CO2 orArgon+CO2 mixed gas

Non-Ferrous metals - Ferrous metals -
N Alltypes of steels
Aluminum, Copper
Shlelding gas and Gao FlowCottnge
"Are Gharaeteriatles
"Mode of metal tranefer
Penetratlon and weld bead proflle
Underouting tendeney ARGON-HELIUM HELUM

Weld metalmeohanleal properties

ARGON

Exeesalve Gas at Hlgher WER

xeeselve Ga0 at lower WFR and and MIgher SOD
Higher 8OD

WR
P
Contact Tube
Travel
D

Molten Slag
Solidifed Slag

Weld Pool
C Parent Metal

Figure 4.66-An Excessive Push Angle Can

T Figure 4.64-Proper Drag Angle Prevents Slag Reduce Penetration and Increase Spatter
H
from Roling in Front of the Weld Pool for FCAW

S
C Corroct
Angle
R Angle Too AnglLow
4045 Too High
E
E
N
Figure 4.67--Transverse Angle of Welding Gun