Module 3 - 1

Module 3

Metal Joining
and
Cutting
Am Processes
W
e r i c a nS e l d i n g o c i e t y
 Welding Process Module 3 - 2

Knowledge -
A Benefit to Inspectors
Helps spot problems
Leads to better inspection
Gains respect of welders
Gains cooperation

Am e r i c a n We l d i n g S o c i e t y
 WIT Coverage of Welding Module 3 - 3

Processes
Advantages
Limitations
Equipment
Filler Metals
Techniques
Problems

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 4

3 Basic Process Groups

Welding
Brazing
Cutting

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 Module 3 - 5

Weldment

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 Module 3 - 6

Common Features of
Welding Processes
Source of energy
Source of shielding
Filler metal (optional)

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 Module 3 - 7

Shielded Metal
Arc Welding
(SMAW)

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 Module 3 - 8
SMAW

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 9

EXXXX
SMAW Electrode Identification System
Electrode

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 10

EXXXX
SMAW Electrode Identification System
Strength

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 11

EXXXX
SMAW Electrode Identification System
Position

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 12

Position Description
1 - used in all positions
2 - used in flat or horizontal fillets
only
3 - not used at present time
4 - used for downhill progression

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 13

EXXXX
SMAW Electrode Identification System
Coating/Operating Characteristics

Am e r i c a n We l d i n g S o c i e t y
 Electrode Coating
Module 3 - 14
Classification
F #s - Figure 3.4, page 3-5
F1 - EXX20, EXX24, EXX27
F2 - EXXX2, EXXX3, EXXX4
F3 - EXX10, EXXX1
F4 - EXXX5, EXXX6, EXXX8

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 15

Low Hydrogen Electrodes

Types end in a 5, 6, or 8
Purchase in sealed, metal
containers
Store after opening in heated,
vented oven
Limit atmospheric exposure

Am e r i c a n We l d i n g S o c i e t y
Electrode Suffixes - 1 of Module 3 - 16

2
- A1 0.5% Mo
- B1 0.5% Mo; 0.5% Cr
- B2 0.5% Mo; 1.25% Cr
- B3 1.0% Mo; 2.25% Cr
- B4 0.5% Mo; 2.0% Cr
-W Weathering

Am e r i c a n We l d i n g S o c i e t y
Electrode Suffixes - 2 of Module 3 - 17

2
- C1 2.5% Ni
- C2 3.5% Ni
- C3 1.0% Ni
- D1 0.3% Mo; 1.5% Mn
- D2 0.3% Mo; 1.75% Mn
-G 0.2% Mo; 0.3% Cr; 0.5% Ni;
1% Mn; 0.1% V

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 18

Stainless Steel Electrodes

E308, E308L - Weld 304 and 304L
E316, E316L - Weld 316 and 316L
E309 - Weld Stainless to Carbon
Steel

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 Module 3 - 19

SMAW Equipment

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 20

Constant
Current
Power
Source

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 21

Constant Current
As arc voltage, V, drops, arc current, A, rises
Arc V related to distance from electrode to work
Electrode moved closer, Arc V falls, Arc A rises
Electrode moved away, Arc V rises, Arc A drops
Arc current directly related to heat input
Welder controls heat input to work

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 22

SMAW Advantages
Simple equipment
Inexpensive
Very portable
Welds most alloys

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 Module 3 - 23

SMAW Limitations
Relatively slow
Slag removal
Electrode storage considerations
Arc blow- solutions noted in text

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 24

Magnetic
Aspects of
Current Flow

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 Module 3 - 25

Arc Blow

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 Module 3 - 26

SMAW Discontinuities
Porosity
Slag inclusions
Spatter
Incomplete joint penetration
Incomplete fusion

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 Module 3 - 27

Gas Metal Arc Welding (GMAW)

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 Module 3 - 28

GMAW Schematic

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 Module 3 - 29

ERXXS-
X
GMAW Electrode Identification System
Electrode

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 Module 3 - 30

ERXXS-
X
GMAW Electrode Identification System
Rod
(Designation used also for GTAW filler)

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 31

ERXXS-
X
GMAW Electrode Identification System
Strength

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 32

ERXXS-
X
GMAW Electrode Identification System
Solid Wire

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 33

ERXXS-
X
GMAW Electrode Identification System
Chemical Composition

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 Module 3 - 34

GMAW
Equipment

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 35

GMAW Nomenclature

Am e r i c a n We l d i n g S o c i e t y
Constant Potential Power Module 3 - 36

Source

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 Module 3 - 37

Constant Potential Source

Is self-regulating (maintains
constant arc length)
Reduces effect of vertical
movement of gun
Less operator sensitive
Somewhat easier to learn

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 38

GMAW Modes
of Transfer - 1
of 4
Spra
y

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 Module 3 - 39

GMAW Modes
of Transfer - 2
of 4
Globul
ar

Am e r i c a n We l d i n g S o c i e t y
GMAW Modes of Transfer - Module 3 - 40

3 of 4

Pulsed Arc

The welding current is variable; it is

pulsed between high and low current
cycles set by the welder

Am e r i c a n We l d i n g S o c i e t y
GMAW Modes of Transfer - Module 3 - 41

4 of 4
Short-Circuiting Transfer

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 Module 3 - 42

Factors for Transfer Modes

Shielding gas
Current level
Voltage level
Power supply

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 Module 3 - 43

GMAW Advantages
Semiautomatic process
High productivity
No slag to remove
Clean process
Continuous filler metal feed
Welds most alloys

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 44

GMAW Limitations
Unsuitable for windy conditions
Little tolerance for contamination
Usually limited to shop welding
Equipment is more complex
Consumables - liners, contact tips

Am e r i c a n We l d i n g S o c i e t y
 Module 3 - 45

GMAW Discontinuities
Porosity
Incomplete fusion
Incomplete joint penetration

Am e r i c a n We l d i n g S o c i e t y