It 349

In stable. crc eneaHonpoint:

tosses,is.Hinm
More hecit is produced.
re lenath uoltge charachoishie e quen b
++4La
Va=24+4 La.
. v-L choracteeisric of Pooe
pore.
Soce is dssumed a's St: Line wih open
iYcwt Uoltage is 8oV and Is
deteemine opHmum lenát for ñax obe
V 24 + Co
Vo=8D
Is6oo AmP
V
Vo
V
(-)v =
Is
P= V
=(24+e La)I
HLa 4r
(
-NasVt
P= VtIt
Vt= Vo It: o =(24+4la) (425-Sol
= 80 - t 0 df -lopt 4mm,
for const Go|
oIe:
Vt=Va Prmax =|2kw
It
Q4+uLa = 80-| 80
It.= s20-3o La
Qy V-I chnr cteishcs oP powee Soce 1s
givn yby It2= - 60o (-Goo). rc chrrac
Uen by La 20 (v l6) Deteemine Pow
OF Stable ee.
It = La
-6on (V-60) = yo (v-l6)
 -606vt36000.=Y oD V256-32v]
i600vt 36T=yuo.v +256Xyeo-32xy 00V.
Va 23709.

Ve ( V=709):
VE23t
Ia=20(v-6)

-'. Pe VI= 3 463 kus

Arc lengh voltoe chracheshie is gon
by Va = 20 +s La. rc length in
procer is ch¡ngea blw 4ymm to 6 mm
and corTes pond rg cUrnt PLom
chane r
4sO A SsO Ai assming ineat powoe
Cureine 's st: ne.

Va 36 Vo'=ss
For sta ble Te
+ Và
Va
Vay =36v
36
Va

Is.
Ntz Vo

Vo= 8D
Is
 13

with. Lcneas. Pousr Sonree

uy- A De wl'nig me oit
ehaxqeustcs prpdeg iopen ciruitcumment
{80v mg Ls-goo A. Dming weldung
Changeo fron soo to y6o ÀA and corespon
rc lerath is chanics iom Smm to 7 mm
whar is theinea ottoge charatedsc
wding Vo=8O,
VE Lt Va=Vt
Vo
Is

A+Ba =
A+S =30
8o0
A+$B =34
A 2o

Va= 20+2Lq
happen in Dc not În.Ac.
tt ARC BLOW : (slesS due to defHecta
FeectiedA
of elechornegnetfe flux
ster
bot

erta metu splashin

Tab Tabout
yweld spatte (deFecH)
 Due t d e Fle chion oP electro magneic Hux
iné Towae+he wP elee i e cuill
be deflecHng to wrd the wP is knowr
ds c blow Etec c an Blou).
Due to re blou heat Concentaion. onP
t a aiuen point will be reduced dnd wed
Spa Hee wil be Forin.
....

)
Remedy:
prouide Some exteo mateau at the beg
and endoe mareiau Kno u¡n as tabin,'
and Tab-Our

Reduce the intensity ot the weldig cumnt

aa the begining and end of.olp
poide Smal ero lenaths:
) PrOUide fux CogHng .Ón +he elechods
Þhey uill be haoing fonisaion compound
dnd
ed uce +he magneic fux ine ekrec
and rc blow En tve ele cto d -Ve coahirg
B@ iS Po U0ded. gnd Vice-veeSa?.e Redyce. Crrent inteasy
Cument on c to:Ac So mag nenc Fux nu
E FuncHion Þp Fux Coatina :

-Elechee

Pie
rslay

materiu is as de- oxidis

D By forming the Slag it uill pTo tect the liq- meky
fiom the atm asea.
It wiu contro the heat tms fee ate of dip
poo.
 :

15
4- I t i l l contro the UscOsity of .
meta.
inereasethe.strengrh o Joint by.
adding uWoyn lement.
6 By contotling H"T
the H.t Losses omhe eorth,
heat. ConcA on the. up çitH beineredsed:
t moteiu for Fur Coaing:
) De-oxidising elem ent
Grophite, Auming AlL03), F e oSilico and
fevyo- mgnese.
) SLaz formaton compound.
fron ox ide, sijcondi-oxide,Tetaniu Delde,
Silica Four, and caliumn Firide (CaF)
3) Arc Stablisei
Sodium oxide, CaUuum oxide 4 potosium
Silicaue
4) Woying elemens:
Chromum, Nickel cobaJt ard Venedium.
s) jase formin compound
celu kose and Calcium caebonae.
5 Weling Technique (Posiion)
L FLat
weldingi- (F):
Easiest mehocd to perferm yeld

HoriZontal welding: (H):

 base matewal
Elecrode mateal is shenL ton

Vextica (u;D) : ‘

4)-Dverhead: (o)

Designahion (B[S);Beüro,otIS
tt Electsode
E I 2 1 323 P rmanuFacturure
Lysped Heaton, wil!
proide speer ay ntormhioe
Strenahof Hhe elode
3:Tenelle shengtb,£yield srngh,
3:.ge of elongatjen cUmet
polqritY ( 1’ D' Dcrode tve)
2 Dtvgo (open Chcurt votyeof geN)
PosiHon of Ehe elechod
F,H, U, D, o.LEH,U,D :

2’ F;H only
Type oEPux cocaing (High Te, High Celulese)
LyRytle coatm
Type oE electrode manu facturing
(E= Exrusi on)
Re &usion-unth Raunforcement
S Solicl type
2 2 1 413

Eletnde
Flux
poilion Tenle
Yeitel
menufectshent
2elorgetrn
 2H20ZH2+02 maue
elecocinclusibn Trusten ihour
st
produced. proteed
domped and oide eletD thickness m
yo5 ’Ve
elechod
UH enLed less Suppyed A,
wding
EGas DCRP
tungsten
:)
- -ve
maeal
At
useform
eC.c
Consumable
in
oF
be
mateiau
be excep
in wling
For smmCan
used Can iS
Date: GKAW)
|ofD8]16 DCSP hen js cal atm.
motua
heat reneated
base bect matoÚau
1) P.S Toint poo
Oxide
Non- is than
(1IG, mm :-[shyde a wp tas usd
the weld
:shielded^Avc
Welding
: t>SAl rermoNe iun
pt b|w au
nert,Gas meF foyis mn. more the
innut
Pos zZincon of mateù Fue be
i
ofheat elecrod
geneated
and
wP.
(nereaoe the u
used thickness
For.wldingoF can
t<büse
rust
Smm: tcathodíC
clean
Secono
in
y'de inproujding
mateua, oF
Tungsten, not and Fuer
Dcsp
Gas it,Dot wldng
etau
2/9rd To
s shidd
Inect JonF
iS ís AsG.is
Thoríun
electDd
DCRP mmusing mn ay
He, TÊG bcz Tp y. by
5 For
[ES- 2
 +hickneo a y MIG,GmAW)ovLOmTIG
To
technqa
etade’omaicaly
|-2s
mmg opeae
pouw more
poLaiy
St oFelectons takinSigle
Aom
arc
ha oxide Rom knon
wptoele trode
al by c02 co,He
so of a0
mtacUeldi
brz
Acst
halF its chemicau
processoxideLaye^clean
and
mm
mechanism
cosy
and dueto wt. ealled
Al,
ma.aoy, btCan we
sed
c02
next
polaviy is S ix
uhich
wSP han iS
ma gnd is
used. lengt. moe
m also
this used
elechod
’ S OAr use
In.the more
WELDING isqeive
Al, Aenspqce. &
in the Revers Face
less
of
He
’
DDropfrarefer
So ’ I t
’B
t
usec fom. for Ts
Genecay
use P
e usill
be.on Sucarhodic
cleanin:
rocess wlding
düeto GAS
For
wding
of worK
be hear
uil
be be
.mouin atomobile,
De wate
sppy. INERT.
cyce
can APPLICATION
wil
USll thehe" of
Cost
the for
cycie .matei
a. +ve
thhe teyos
Suppy industuy.
purifom Euse
METAL mechanism
Ve
the Secvo
6f
in
He Ar
t
 so7
usiN DCRP SO no oxide fos m on Srfacet
increases
tp1
dto mak t lehod sld prol
DephO penehaion is less So used hiah current.
(I=)so-uA) (becz rd t hedt envated atotr)
high thickness upUse Ac beze So Hme.
For
Op is st póLay ond peneion is more
usel for Al, m

eneted bfuädonsumable elechode

and p. Electode is.in the form öFSpoo
0Fwire and t is onHnüoss peed fothe
BPhrougAhhe mouement of the RolleS.
Rotlers mouemnent can Be contol by poTdin|
Sunvo- mechanism.
qeneay used fo more ttan Smm thicker
of wP matiau.
DCRP (Diret curent ReverSe pOlaiy) oR
Ac Powe Suppy can be used uithhigh
IRare of Cnrent.
t APPLICATION
Genay used for wedig oF Al, mcu
and s aloy in Automobile & aeOspace
ndustries
334 PLASMA ARC WELDING:- (PAW)
manm ||000°, 20-15o A)
plasma
Cerami Tungsten
noztle
Eletnoele
Inext s P-s

Plasma
 4o2
Costy ploceo
Inet&AsseS . is proUided to proide oxde farmatHon
.

more hickness, can bewld,

St.
pokity: used, except Foy A, Ac is used
Ave ie 2neated bËw Don- Consumable
Tungustehn elechoc and wlp.
Thnrouah the noz\e high
eneASPICSmg o
artc ana"produeeLasma
PLasma ac .3hich S
|hauinghigh k:E
Ehe wp on +he ard it will be focused on
hear Conda on given point due to +his
the sp is UeH high
HiahthicKness
Can be Wded,
and high mpoint. mteal
Depth Penehahion and wdig sPeeg
's more.
d bead & Hea afected Zone is les.

cooling
+he ceramic noz& elehoe.
Cost :of: the.pQcesg (s nre..
DesP OR Ac POwUe Suppy can be uscd.
FAPPLICATION_:
Wedina of +itani um, nfcKel a cobal t,
molede num A æs aloy in auo spgce, Je
engine trbine blacded ete.
t# Nimonte dwoy -’ Nickea & cobaut base alloy
4tt SUBMERGED ARC WELOING: Soid fux
(caD, caF)
lt’s-somm (pow. (
I=200--2000ASuppy
deposition Rate = 2o alr
u= Sn min
nnat ld tng r
Désible, mO r
 2
+hickness io more +han MIG.
ele consumabje (DCRP)
: wld jn oPen am hen hear s.lógs insr
and less amount of hear ar oP So wtp So coaiy ag
Tc is Complftelay submerZed info plux So catec
Subme rc.
rc weldi ,HAZ T, Shreo ‘, So anneallng

tAsc is enerateal b<uw a Consumdble elechd

|end wp by suppuing sold Form oF Fhe
Flux toughtheuweldingtorrch.rc oiU
beSubmgcd in the tux due to this
hecr tiansfe losses Pom c can be Recuco
by inceasing her conc
Deph of Penthaion will be morc.
SpLashina of the liq- meal,
SLoa inclusion can be less.
wedina speed and wld deposition Rre
IE can beused in mass prod.
Heat Ffected. zone(HAZ) 0Simore an
heat weld distorsion wiil be takes
>It can
pLace.
be.usedinELarp0si
-’ DCRP wJh high Rare
Hon
of Cmen Can bc used.
APPLICATION:
uyeldina.oF high thickness pate in ship
building
h-Fabxieahon of press. vessels and domesic
LPG Cylinders.
Mettng cff:- (n):
Lh= Are heat tgnsfe eff:
Hm = Heat Reqwred to met(T nm)
Hs = Heat supplied
(3|mm3) P=vi
 Ab= bt h 30-4/.
Soheat loss ismarm
V= mm)sec
Hm mcAT+m: V= vo;tg
9= Ueoity mm]sec
Hs=VI*n
VXAb s]mm
HsnJmm
Hm Hm
Hs
Ab9

QLyp-6S.13! V= 2SV, = 300 A

9= Bmm|see
VÊ Hs?
Hs =Vmh=
796:31S

E= t0|mm. P= 2 Kw

Hm
VI 2K000,
A SXV

V= |4 mmse c

28) Hs= 200 J]m,

Hns |S rlmm
|S

Ab

Ab 36 mm
 L92S mm }See, 23
38) V=60V,
SO,

Hs=VI

9 s mmmn
L= qo0mn,. 1= |SO A, V=20V,
H=? J|mm.

Hs=
VI 20x1SO U80Jmm
. 30

o-6
6o. duuhy cyce
Consr Dry yue
D2 D, O234
6- 234 Go91.

I200 A, V29,-V= 60
d=|2 mm, wire Feed = 4 mmin
=06S H= kg |mm
H=

= |08 y|mm.
weld begd
Aw Fw =

Ab =25 |3 mm
 Vo8Ov, Is=(oUD A Li’u-pm
*.

LE
Vo
(Ve=VaSnea
Lt
It:sw

30) Vo,= 80V; I=60oA

Ve Vo
P= VI
600
80 88 x t

VE8030O

Pe yOX 30 l2 k
A FoY ma m POJL
Vt Vo
2

It =
 S-95 O2.-
Sound ")_Crbrizing
No
fLame:
SoundRparig Flame
)Oxidisiah
|215°c
Hame 3200°C
FLame: Neutal 1.
Sound. Hissing
Types-oFFLame:. t}
hz>ah Ha0 2c02+ C2Hat02
Ah -t
Ahe H20+ 2Co2
t+ 02 t+ H22Co+
Reduce ReacHon Seconday H
|osion
OFAcceton +Ah
in
famfunFstoríng +02 Ha Cz
gas other Reaction FrimamY
han Rarher
t
edy used So
toRequire
is 1
morehand
o mpa) (S
reuuaccelene ylinder CaH,
NDz2le
mpa) (cylindo
1S DXYQen
Torch
PiPeHose
lene) Acety Gasurelding
oxy- ( 1
Reachon: chemical E
25
413
 supp
O2 is suppy as faster Rae so atn not
io amount. (dueto whtc a y For O2]
Fusion sejding Techntque
AUor mateia SUPpy etenay
Borae is;used asfur matvuay (Nitogen laromt
Due to heceneraioinniyone ts prode&
Ahh
etoSecondamy RK ouoe Hgme s Porlue
Yegitra
&- fesstemp
I mole accetelyne Require 2smole 02
hinn whitçt Blaht Inne or
Bue
Oues temps same in au 3 cased lenghaso
Intuemeciate Home Red colour:
lengh of Hame Represent unbrnt carbon
In+he Hame
tengh is same iw au flome
Louw cebon, mill, mediums cI is NF.

By: Buning the accerelene tn the presence,

oF OxgAn due toeKohemic RkA hearea
be produced. this is used For
Of diPFeent maeial.
By contolina he uo|m Rate oF OxYfen
and acctehe diffeent Fame can be
produce. 7hey uiu be üsed for liPPeent
applicaions.
E|Appllcoton of the flame &
L Neuhay. plam:
rt is eneial pr pose flame used for wadin
OF louS corbon, mdium crrbon ano mid
Cast fn, aluminium and its a l y
 415

2oxidisina flome:
fwsuaing of, Cu, zinc, brass ce.
3. Cacbwçsina Ftame;
High' cacbon steei, Nick basec aloy
tSas cuting
-kid
zrli
..:O

Wedig Cutin3.:

H C2H2 Geneator: bloum

Cacz
CackHoo ’CHyt Ca(OH),
.

fempism¢nm temp ar woh ich matoa

kendiing
( oxidrze.
Cur.
kerf: widh of
ser-up which is used for weldin9
t| SarYe
an be used for weldiy cuting ercept in
he form of nozzle tip. [n case of as Cuting
tmugh the ircumfoeent au holes, Neunaçflome
1S Com ming using +his base metau can be
pre-heated upro Kendling temp. Itregdily
is+heto
minm temp at,which maeiau is
OX 0díse, By Releasing higb preo o n J
mere amomt vapor Coun be eveporates by
mutnRemnig com be blwm,
 hroplek.
n the form op Hne' A-ete d e to oXUYN

Gas weding Techique

Sck han
FßYehand.
upl
9d thickneo, of

outee fame is usec) for pre-heaiy 4 poshen

conse raw shrutre ’ DUCHIe:
Crack is reduce due to pre- heci
is brld
boel
most.easily sediy
by f s e
by using pre-hecirg
X
s
tIn fore handrldig' techique "inne
meltina the base mateiau and
is preheating the base mateial. Due to
Hhis by edçcGng the tenmp: difFa sow
Tate op cooling eam be takesi place due
to this by forming +he ducHle strucure
CacK
Cygck formeeion can be minimi zed.
..

Ln Backhanwlding technique innu

Core 1S mehinathe maia otPfame.
is re-heain +the al veady wldedipostion
dttetothis--intenay tessed can berealeave
(Anneaing).
- > Ln Case of cast Iron due to Free Por m
Of +he cabon i the cobling Rate /s
Vey bigh t wiU be Conve nto carb icBe (

md wiu ferm brit

britt}e strucure To oveLoe
Hhis CI can be wel ed by a9s ueln
with pre-heatig
 SÍmpte setUp, sihin
easily 29)
t Themit Welding -
Cusiblk 3FeaD4 +8A4Fe +4Al,0s
Thocmit mbturei+Ah

Feg04: AL( 8:1) By nass!

Gmetaic
Cuoz Al
pLates C03! AL. procuee

Repaur uSor k, Crack a meal break cr time G casht

du to, coldshur (2 casing) Joined by Jhoemit geiy
-X
Jheit mixture can be heaed into a crUsible
upto (200*c by using magnesium Rod and cra cke
ar this temp. due to
+heemit RK 0ron will
be Separate and more hear uuì) be Produceq
Jhis heat wil be used
FoY.mlHng of on.
ig Form of iron can be ènter into the wlP
|and t wil) altow to Solidify.
Auminium oxide usill be acing a Stof
tApplicaion:
Repaur workshoP, Rilway Rail,usedigof Lr
Size pLate and broken casting
Dele tcU sheets roe uulded by
8L SoFt acc llene. Butr
Neuhau Plame using
w l was found to
be defecHue It will
Re-weded
fLame wha is con sumption oF
usi oxdis
Sol9 OXYjen.
For Neuha fLame

=||S-S

9.2 - l2 L
’02 = l1S*8 -:S
 >Rsis alven to
Amic Hychrogen welding: welding tourchey
P.s H+HsHetaha
(4000'c) Ha +H-Ah

Non-consumable
electode

’Ac Power suppiy is use

beez uniform heat suppy
is obtuned
tE E iS a
Combinaion of ele cic arc
as wel ding principay. Are is fenoaed
bBw w:non- consumable
ony.. umable tungusten eechad
Hyhrogen gas uill be Suppytothe qrc
a hiah temp. Hyhegen mote
be dissoaed into ue wit)
ndiUidiau H-aom
Dy eons yming Some heat Pom +he ne
ushen hey çi u be strin King on cold f
SusFace oP the wP due to
hey wi e- om
unstabily
binedsNTS Hycrogen
molecwei
Exo+themic RKA due to thrs
hear
hect wtu be produce and thís wi||
wiII
be used for mehn op bqse
matedal.
(0S to pote qmery Fomam shieadi
|ARPlicahion: ’
wldin of tool Stee) ang Die stee.
.) Repav uwrRShop, cutting tool and dies
 Date: nlo8||6
tResista nce elding:-(3 tyPes).
a)SPoT WELDING :- For 2 mmthíckncss

Cu elech t

|he 2(t-indentáion)*
Ps R2

Rocker
rm
-|ndental
-ion

Nuggt R3 >>Ry4R2

S= Squeeze Hme) Presse

W= wu
Current
H = Hold yde appy
Teme
V=S-|oV
t _ I : |0,000 So,000 A
Wal H
’ Time
Heat zenehon is due to more ContatResisance
Cu, eechode ís ud. due to Low Resistance 4
high conductiuy.
Joint formaion takes pLace below +he elecod
leak proof weldir is not H=12Rt
possible becz ngaer for m
ar Some clistance not form
Caninou_y
electbd is in +he foY m o Cylindcal shape
So Form srcuaae nugEe:
Irentoion is approx (o0f Ehickness
To Kept to plate -toge hr by appyiny ele chode p
caled Sqyeee time
 40-S0Y
Meing8 eERCiency :
-*m, Vol* Temp Hrn
Hm=.mct + mL'. Lm= Hs
Hs == I²Rt
LTee
pTOUded bluw two cu
TurO shets me
ele chode by suppyn highate, ofcue
Ehough the coppo electreale ts he wlP
heat wiu be genáted arhe conta ct
Of tuO wP s due to. contac Resistance
Aftee ¿ting Sufficient amount of. heat by
Suitch OFF the pouJt Suppy exteena
Presg Can be,'aPpy to produce sint.
By application ot the pTe SS. asses an
|be auow te escapec to produce
Joint withow any a4s defect.
leak prOOFJint can be no Possjble.
ii hee wil be possi blies of indentaa
a he conta of eje cro
wp
Appicaion
"Eap, Joining of Wo shees n duonobile
bodies ond RePrioators body.
b. SEAM WELDENG : Cuelectode

Psc()
V= ADN.
60
=5m mìn,
 e in +he form Rolioc
Elechhode continousypp
Powet in:this case is PlaceSo lak
Dyeslapping of nuager can take
Pvof w¯ding is procuce.
!
more Speec ie fost Rate oF PMOc
woShees cne psoded blus two CoPp
elechods ohich e in thc form oF ROllee
Shed. By Suppying high Rate oFmen F
OR
-igOUgh +he ueiode to tthewlp heat
.
GiU be geneated to+he, contat af
due fo max
Contac Resistance:
By appyina the Roina pres. Jen
be foN m blus s due to
the tuo Shes
Coninous Rotation of the ROll,N e
UiU be oUee lap.
becz of +hts teak
Proof Toint can be possib|e
wlding sped is
High Rote oP POd can, be posible
without indentation producina oF Joint
is difHcwt
EAPpLication :
|Fabyicaion oF Fue tanks, Rdiators bodies
an mufflee Used in exhaust pipe
HPROTECTION WELDENG :
Culelectsode.
 Indentaion selding ts done
uho
not possibie.
eakpoOf Soint Net
SCTeUS
wiYeS
Grsilles
to þt
On one oP the Sheet hich (s wdd
Produce proreHon by embossin techni
Tuo, shes Te poUided.b|w two
Lag
high rate
siee cu vethod.by suPpyi
of CUret ar a proeion
mareça ui be melted Ater
At r qehiA
SuFH den t armount of hear by eitch
OFE the Powet Suppy extena -press
Can be appyed to rbcuce the nyjget
the proeHon.
+moYe no of nu3tet can be prouced
fn snale cycte:
hee i no indentaion blw ejeod
and wtp
LedkProof uint is not Possib le.
IE Cän be-usedtn--ASSProgu ion:
t APpicain
threade Screw and
Joinin of teaded nus to
the Shee mateal
9 Fbri caion op the gils and usres mehy
** Al above 3 methOd Ss for op toint:
 423
3S
FLASH 8UTT WELDING
Ekctude
holdue

4
..busidhoP:wld
t FLash wding:
Elechod holdoe mwted from both
ends o F the obrect
Hs=I 2Rt
Hm= mcT +ML

Hrm
PS Hs
;Boh e used for Toint en to end e but

melcu is meued di to elec c

t FLash but uelding:

In this technique two wlps uill be prout
,
blw tuo"elechode holde. By Suppyiy high
ate of cumrent a the Conta of to
Sufaces initialy tuo flosh will be
produae Becz oE the reslstan ce of theav
be gen aed
eneaed t a Contocrsnfa
heat wiu
Afto eeting suPHent
sUFHUnt amount 66 hear
the Pow Supp y ctora
| Cow be apPpy to poduee tthe