Welding Principles and Practices

PowerPoint to accompany
Welding
Principles and Practices
4th edition
Edward R. Bohnart
Flux Cored Arc Welding
Practice (Plate),
Submerged Arc Welding,
and Related Processes:
FCAW-G Jobs 23-J1-J11,
FCAW-S Jobs 23-J1-J12;
SAW Job 23-J1
Chapter 23
© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

2
Objectives
1. Describe the flux cored arc welding
process.
WELDING: Principles and Practices, 4e
2. Describe the welding variables for flux

cored arc welding.
3. Demonstrate the ability to make various
fillet and groove welds with the flux cored
arc welding process.
4. Define the operational differences between
the two main types of flux cored
electrodes.
3
Objectives
5. Explain and demonstrate an understanding
of the submerged arc welding process.
6. Describe the electroslag and electro gas

welding processes.

4
Flux Cored Wire Welding

• Biggest use in fabrication of medium-to-heavy
weldments of carbon and alloy steel
• Increases welding speeds and deposition rates

• Major producers
– Hobart: self-shielded flux cored wire – Fabshield®,
gas shielded flux cored wire – FabCO®
– ESAB: self-shielded flux cored wire – Coreshield®,
gas shielded flux cored wire – Dual Shield®
– Lincoln: self-shielded flux cored wire – Innershield®,
gas shielded flux cored wire – Outershield®

Two Basic Types of Flux Cored 5
Wire Welding
• Gas shielded, flux cored arc welding
– FCAW-G
• Self-shielded, flux cored arc welding

– FCAW-S
• Both produce welds of highest quality

Two Types Combine All the 6
Advantages of GMAW
• High deposition rates
• Good performance on fillet and groove welds
• Scavengers and deoxidizers for less-than-

clean metal
• Slag that retards cooling rate and supports
molten weld pool
• Ability to weld in all positions with correct
electrode

Flux Cored Electrode Cross 7
Section
FCAW-G is a process using a
continuous consumable
electrode to do gas shielded,

flux cored arc welding. Its core
is filled with flux and alloying
agents. These types of
electrodes require an external
shielding gas source. The
solid metal portion of the
electrode comprises about 80
to
85% of its weight.
Hobart Brothers Co.
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

Typical Composite Flux Cored Arc 8
Welding Gun Cable Construction

Note wire liner

and lack of
shielding gas
hose. This gun
cable designed
for self-shielded
flux cored wire.
Hobart Brothers Co.


9
FCAW-G
• Process using continuous consumable
electrode to do gas shielded, flux cored arc
welding
• Core filled with flux and alloying agents
• Require external shielding gas source
• Solid metal portion of electrode comprises 80 to
85% of weight

10
Process Schematic for Flux Cored Arc
Welding with a Gas Shielded Electrode
American Welding Society (AWS) Welding Handbook

11
Core Material Functions

• Acts as deoxidizer and cleans weld metal
• Forms protective slag to cover deposited weld
metal until solidified

• Stabilizes arc so smooth and reduces spatter
• Adds alloying elements to weld metal to
increase strength and provide other desirable
weld properties
• Provides shielding gas in addition to that
supplied externally

12
FCAW-S
• Process employing continuous consumable
electrode that has core filled with flux, gasifier,
and alloying agents

• Flux cored wires made from continuous tube
– Steel strip formed into U-shape to hold core flux
powders; flux loaded, U closed, wire drawn to required
size
– Basically, an inside-out covered electrode

13
Process Schematic for Flux Cored Arc
Welding with a Self-shielded Electrode
American Welding Society (AWS) Welding Handbook

14
Flux Cored Electrodes

• FCAW-G electrodes deposition efficiencies up to
90%; FCAW-S up to 87% and deposition rates
from 25–40 lbs per hour.
– Generally these high deposition rates achievable with

automatic/mechanized applications
• Metal of cored wire transferred through intense
heat (~12,000ºF) of arc column to work
• Used with semiautomatic, mechanized, automatic
or robotic equipment
• First developed about 1954 and introduced in
present form in 1957

Flux Cored Filler Metals Produced on 15
Basis of Three General Groupings
1. Single-pass filler metals

– Operate in carbon dioxide shielding gas
– Intended for welding rusted or mill-scaled plate

2. Multipass filler metals
– Operate in carbon dioxide shielding gas
– Provide ductile weld metal with high impact strength
at both low and high tensile strengths
3. Self-shielding filler metals
– Used without auxiliary shielding gas

Desirable Characteristics of 16
Flux Cored Arc Welding Process

• High deposition rates with little electrode loss
• Can be applied semiautomatic, mechanized,
automatic, or robotically
• Welds of high quality can pass radiographic
tests (suitable for code work)
• Shielding gas, carbon dioxide, low in cost
• Deep penetration reduces weld size

Desirable Characteristics of 17
Flux Cored Arc Welding Process
• Highly stable arc reduces spatter loss

• Slag removed with minimum of labor
• Weld appearance highly desirable

• Small wires of specific composition used in
all positions
• All mild and low alloy steels can be welded
• Cost lower than other processes

The Major FCAW Equipment 18
Components
• Shielding gas and control unit if carbon
dioxide used (FCAW-G)
• Power source
• Wire-feeding mechanism and controls
• Electrode wire
• Welding gun and cable assembly (gun
different for FCAW-G and FCAW-S)

Equipment Needed for 19
Flux Cored Arc Welding


20
Power Source
• Constant voltage with DCEP generally
used with continuous-feed electrode
process
• Can be d.c. rectifier or inverter
• Generator generally engine driven
• Direct current, electrode negative used for
most FCAW-S electrodes
• Variety of gun styles: air or water cooled

21

• Shielding gas used with FCAW-G wires
gives ductility, penetration, and toughness
of weld metal improved

– Carbon dioxide or argon plus carbon dioxide
• Also superior on dirty or corroded base
metal
• Require currents in range of 90 to 960
amperes
• Best welds in flat and horizontal positions

22

• Intended for large single- or multiple-pass
fillet welds in either flat or horizontal position
with DCEP
• Suitable for long groove welds in heavy
plate
• Flux cored wire weld deposit fully covered
by dense, easily removed slag
• Chemical composition of weld constant
because alloying elements built into cored
electrode
23
Internal Construction of a Typical
Self-shielded Flux Cored Arc Welding Gun
American Welding Society (AWS) Welding Handbook Committee, 1991 Welding Processes,
Volume 2 of Welding Handbook, 8th ed., Miami: American Welding Society, Fig. 5.5, p. 163

Gun for Heavy-duty, Solid, Metal 24
Cored or Flux Cored Welding

Miller Electric Mfg. Co.

25
Wire Classifications
• Covered in AWS A5.20-Carbon Steel, A5.22-
Stainless Steel, and A5.29-Low Alloy Steel
Documents
• Wires used with gas shielding:

– E70T-1, E70T-1M, E71T-1, E71T-1M, E70T-2, E70T-2M,
E71T-2, E71T-2M, E70T-5, E70T-5M, E71T-5, E71T-5M,
E70T-9, E70T-9M, E71T-9, E71T-9M, E70T-12, E70T-
12M, E71T-12, and E71T-12M
• Wires requiring no shielding gas:
– E70T-3, E70T-4, E70T-6, E70T-7, E71T-7, E70T-8, E71T-
8, E70T-10, E70T-11, E71T-11, E61T-13, E71T-13, and
E71T-14

FCAW Tubular Flux Cored 26
Electrode

27
AWS Classification Numbers

• Does not mean you can switch between
various manufacturers indiscriminately
– May require different operation parameters

• Always consult manufacturer for optimum
operating conditions
• Tables 23-4 and 23-5 compare various
manufacturers by name with AWS
classification number

Hydrogen Control of Flux 28
Cored Electrodes
• AWS Specification 5.20: flux cored process referred
to as “low hydrogen welding process”
– Makes available optional and supplementary designators
for maximum diffusible hydrogen levels of 4, 8, and 16 ml

per 100 gr of weld metal
• H added to classification if manufactured to meet
stringent hydrogen requirements
• Supplied in hermetically sealed packages if used in
critical applications where hydrogen must be
controlled at 8 milliliters per 100 grams of weld metal
– Once opened, do not expose to conditions > 80% relative
humidity for period > 16 hours

29
Joint Design
• Butt joint
– Volume of weld metal reduced by reducing root
opening, increasing root face and using smaller

groove angles
• Welding on thicknesses greater than 1/8 inch up
to 1/2 inch weldable with no edge preparation
• Fillet welds
– Reduced in exterior size
– Retain comparable or greater strength because of
deep penetration of arc

30
Fillet Weld Made with SMAW
31
Square Groove
Butt joints with backing up to 3/8 inch thick do not require

beveling. Thickness up to 1/4 inch can be welded with
one pass.

32
Square Groove
Butt joints with backing in plate more than 3/8 inch thick require
beveling. Plates 1/4 to 1/2" thick are welded with two passes.

Double Bevel Groove Weld- 33
Butt Joint
Butt joints without backing in plate up to 3/4 inch thick

require 30º double bevel groove welds.

Double Bevel Groove Weld- 34
Butt Joint
¾ Min.
Butt joints without backing in plate over 3/4 inch thick

require 45º double bevel groove welds.

35
Single Bevel Butt

Butt joints with backing

in plate up to 1 inch
thick require 30º single
bevel groove weld and
no root face.

Double V Groove- 36
Butt Joint
Butt joint with double V-groove

welds on plates, 1" and thicker,
may have heavy root face with
no root opening and a 22.5º
bevel on each plate.

37
Shielding Gas
• Limited variety for flux cored wire welding
• When using carbon dioxide, a gas flow rate of 30 to
45 cubic feet per minute must be maintained
• M-type electrodes require 75 to 80% argon/balance

CO2
• Argon-rich mixtures offer more stable controllable
arcs over 100% CO2
• A pressure-reducing regulator and flowmeter are
needed for controlling the shielding gas in the weld
zone
– Inadequate gas flow results in weld porosity
– Excessive gas flow causes porosity, weld spatter, and
irregular beads

38
Travel and Work Gun Angles

• Travel push gun angle causes gas shield
to be directed over molten pool
– Portion of arc insulated from base metal by

molten pool (less penetration, slag forced
forward)
• Travel drag angle of 2º to 15º
recommended
– Better view of arc action and weld deposition
• Push angle used only for 3F or 3G position
vertical-up
39
Drag Travel Gun Angle


40
Push Travel Gun Angle


Work Angle and Wire 41
Location
• Much like MCAW and GMAW
• It must be appropriate for bead placement
and assuring proper penetration and

fusion
• Undercut can also be affected

42
Electrode Extension
• Length of electrode wire extending from tip
of contact tube
– Subject to resistance heating called electrode preheat

– Has effect on weld quality, penetration, arc stability, and
deposition rate
• FCAW-G electrodes
– Minimum 1/4"; maximum 1-1/2"
• FCAW-S
– Minimum 1/8"; maximum 4-1/2"

43
Electrode Extensions
• FCAW-S electrodes require long extension to
preheat electrode before reaching welding arc
– Eliminates hydrogen contamination and porosity

– Activates the vaporizing and slag forming materials
• FCAW-G electrodes require medium extension

when preheating
– Helps burn off any residual drawing compounds from
sheath
– When using long extension, contact tube tip recessed
1/2 to 3/4 inch from end of gas nozzle
• Reduces spatter buildup and possibility of overheating
contact tube

Electrode Extension for the Gas 44
Shielded Electrodes

Electrode Extension for the 45
Self-shielded Electrodes

Flux Cored Arc Welding Electrode 46
Position on T-joint in 2F Position


Flux Cored Arc Welding – Gas 47
Shielded Practice Jobs

• Complete practice jobs according to
specification given in Job Outline
• Review steps for setting up equipment and

welding recommendations
• Consult Tables 23-6 through 23-8
– Troubleshooting information
– Flux indicators

48
Welding Technique
• Welding current DCEP
• Extension about 1/2 to 1 inch
• Work angle of gun

– About 60º from lower plate when welding lap joint
– About 45º from lower plate when welding T-joint
– Backing material strip required when groove
welding butt joint
• Groove angle for butt joints about 30º

49
Welding Technique
• Check extension distance
– Excessive reduces gas shield and overheats wire
• Shield arc and welding area from drafts

• Do not let weld metal overheat
• Remove all flux from underneath passes
• Proper wire-speed feed and voltage settings
give smooth, steady and spatter-free arc
– Normal voltage 29 to 35 volts
• Penetration directly related to travel speed
– Deeper with drag angle than with push angle technique

50
Groove Welding
• Bead should be equally proportioned and
fused to root face and to bevel face of
each beveled workpiece

• Bead formation should not be more than
1/16" on each side beyond width of bevel
• Face of weld should not be more than 1/8"
higher than plate surface

51
Fillet Welding
• Angle of electrode most important in
making fillet weld
– Wire pointed at bottom plate, close to corner of joint

• Weld metal will wash up on vertical plate and form weld
that does not have undercut along top edge
• Speed of travel important in bead
formation
– Too fast forms undersized bead; poor penetration
– Too slow causes excessive weld metal pile up and
porosity

52
Fillet and Groove Welding Combination Project
with FCAW-G: Job Qualification Test 1
• Demonstrate ability to:

– Read drawings
– Develop bill of materials

– Thermally cut
– Fit components together
– Tack
– Weld carbon steel project
• Follow instructions found in Table 23-10

53
Inspection and Testing

• Visual inspection only
– No cracks or incomplete fusion
– No incomplete joint penetration in groove welds except as

permitted for partial joint penetration groove welds
– Undercut shall not exceed lesser of 10% of base metal
thickness or 1/32 inch
– Frequency of porosity shall not exceed one in each 4
inches of weld length and maximum diameter shall not
exceed 3/32 inch
– Welds shall be free from overlap
– Only minimal weld spatter shall be accepted, as viewed
prior to cleaning

54
Square butt joint in 3/8" mild

steel plate with backup strip, in
St. Louis Car. Co.

flat position.
Lap joint in 3/8" mild steel plate

welded in flat position.
Horizontal fillet weld make in
single pass. St. Louis Car. Co.
T-joint in 3/8" mild steel plate.

The horizontal fillet weld made
in single pass with flux cored
St. Louis Car. Co.
filler wire 3/32" in diameter.

Flux Cored Arc Welding – 55
Self-shielded (FCAW-S)
• Semiautomatic, mechanized, automatic or
robotic application welding process
• One form, Innershield®, introduced by Lincoln

Electric Company
– Vapor produced by special electrode shields molten weld metal
during welding operation
– Flux cored electrode is continuous wire that serves as filler wire
• Tubular steel filler wire contains all necessary

ingredients for shielding, deoxidizing, and
fluxing
• Electrodes available for welding in all positions

Self-shielded Flux Cored Arc 56
Welding Process
Current Carrying
Contact Tube
Insulated Extension Tip Powdered Metal, Vapor or
Gas Forming Materials,

Deoxidizers and Scavengers
Arc shield composed of
Molten Slag
Arc vaporized and slag forming
Solidified Slag compounds protects metal
transfer through arc.
Molten
Weld Metal droplets covered with thin
SolidifiedWeld Metal Metal slag coating forming molten pool.

Process Advantages 57
(FCAW-S)
• Offers much of the simplicity, adaptability, and
uniform weld quality that accounts for continuing
popularity of manual stick electrode welding

• Visible arc process allows welder to place weld
metal accurately and to control pool visually for
maximum weld quality
• Operates in all positions including vertical-up,
vertical-down, and overhead
• Welding can be done outdoors and in drafty
locations without wind screens because
shielding does not blow away
(FCAW-S)
• Simple wire-feeding equipment not encumbered
by flux-feeding systems or gas bottles
– Installation quicker and more flexible

– Welding rigs are more portable
• Welder fatigue minimized during sustained
welding operations because guns lightweight,
flexible, and easy to handle
• Compact guns fit into places where others cannot
go
• Arc starts quick and positive without sticking,
skipping, or excessive spatter

(FCAW-S)
• Uninterrupted wire feeding results from special
electrode lubrication, freedom from spatter-clogged
guns, and ability to resist crushing of tubular
electrode by high drive roll pressure

• Welding costs cut because higher practical welding
currents provide increased deposition rates and
travel speeds
• Job-proven on many applications including repair
welding, machinery fabrication, assembly welding,
ship and barge building, field welding of storage
tanks, and erection of structural steel for buildings

Flux Cored Arc Welding – 60
Self-shielded Practice Jobs

• Practice job specifications given in Job Outline,
Table 23-11
• Set up for welding as you did when practicing

FCAW-G process
• Direct Current Electrode Negative (DCEN) is
common check welding procedure or the
electrode manufacturer for correct polarity
• After completing these jobs, practice with other
forms of joints, various thicknesses of material
and different wire sizes

61
Power Sources
• Constant voltage (c.v.) used for FCAW-S
process and electrodes
• Machines
– Transformer rectifier
– Inverter
– Engine-driven generator
• Many self-shielded electrodes very voltage
sensitive (± 0.5 volt)

62
Wire Feeders
• Generally of push type
• Operates off output voltage from power source
and does not require separate power and cord

• Does not require gas solenoid valve
• May be equipped with weld contactor to turn
power to arc on and off
• Drive rolls should be V knurled type for hard
sheath wires; V or U cogged-type for soft
sheathed wires

63
Guns
• Light and maneuverable to facilitate high speed
work
• Equipped with small guide tip for reaching into

deep grooves
• Light-, medium-, and heavy-duty models to provide
for different current ranges and electrode diameters
• Electrode in gun cold until trigger pressed
• If voltage sensing feeder used, then weld contactor
required
• Medium- and heavy-duty guns have shield to
protect welder’s hand from excessive heat

64
Electrode Extension
• Range from 1/2 to 4-1/2" from contact tip
• Visible extension is length of electrode
extending from end of the nozzle on gun

• Specified electrode extensions obtained by
using proper guide tip and visible stickout on
welding gun
• Long guide tip used to provide 4-1/2" electrode
extension, both voltage and amperage must be
increased
• Guide tip not used when extension 1/2 to 1"

65
Welding Technique
• Check all welding controls
• Check all equipment for correctness for wire
size and electrode extension

• Starting the arc
– Set proper electrode extension
– Tip of electrode positioned just above work
– Trigger pressed
– Mechanical feed advances electrode
– Welding stopped by releasing trigger or pulling gun

66
Travel or Work Gun Angles

• Drag angle same angle as stick electrode
welding
• Electrode-to-joint (work) angle varies with

type of joint and thickness of material
– 45º at bottom plate for horizontal fillets 5/16"
– 40º into joint corner for fillets 1/4 inch and smaller
• Out-of-position welding with E71T-G wire,
drag angle is in direction of travel

67
Operating Variables
• Four major variables affect welding
performance with self-shielded electrodes
– Arc voltage
– Current (WFS)
– Travel speed
– Electrode extension
• All interdependent
• Study Table 23-7 for corrections

68

• Same inspection and testing procedures in
previous welding practice
• Examine welds for bead formation

• Good fusion along edges
• Normal convexity
• Free of undercut and surface defects
• Fine, smooth ripples

Fillet and Groove Welding Combination 69
Project with FCAW-S: Job Qualification

Test 2
• Combination test project allows

demonstration of ability to
– Read a drawings
– Develop a bill of materials
– Thermally cut
– Fit components together
– Tack and weld carbon steel project
• Using FCAW-S process and electrodes

Fillet and Groove Welding Combination 70
Project with FCAW-S: Job Qualification

Test 2
• Inspection and testing
• Only visual inspection used
– No cracks or incomplete fusion

– No incomplete joint penetration
– Undercut shall not exceed lesser of 10% of base
metal thickness or 1/32 inch
– Frequency of porosity shall not exceed one in each 4
inches of weld length and max diameter not exceed
3/32 inch
– Welds shall be free from overlap
– Large spatter shall be unacceptable (as viewed prior
to cleaning)

Automatic vs. Mechanized 71
Applications
• In mechanized applications an operator

must guide the electrode in the joint
• In automatic applications sensors are used

to guide the electrode in the joint or the
joint in regard to the electrode

Automatic/Mechanized 72
Applications of Welding Processes
• Replaced many other joining methods such

as rivets, bolts, resistance welding, and
castings
• Characteristics desirable for manufacturing
– Repeatability – Desirable weld appearance
– High quality – Continuous output
– High production – Ability to conform to various
– Low welding costs welding conditions
– Almost 100% duty cycle
– Uniform welds

73
Submerged Arc Welding (SAW)
• Welding takes place beneath blanket of

granular, fusible flux
– Bare filler wire electrode fed continuously into

arc and completely hidden by mound of flux
• Equipment
– Power source, automatic wire-feeding device,
flux-feed system, gun in semiautomatic
welding, and flux pickup

74
Submerged Arc Welding (SAW)
• May be robotic, automatic, mechanized, or

semiautomatic
• Filler wire not in actual contact with workpiece

– Current carried across arc gap through flux
– Weld pool completely covered at all times
– Welding operation without sparks, spatter, smoke,
or flash
• Welds
– Good ductility, impact strength, uniformity, density,
corrosion resistance, and low hydrogen content

Automatic Submerged Arc 75
Welding Equipment
Wire Feeder
Set up with
welding
Flux-feed System
positioner to
provide for
Welding flexibility of use
Power Positioner
Source
Rexarc

76
Cutaway View of Welding Zone

Single V-groove welded with

submerged arc welding
process

77
Submerged-arc Welding
• Used extensively in welding of carbon steel,
chromium-molybdenum alloy steel, and
stainless-steel piping
• Welding performed in flat position
– Bed of flux must be supported
• Welds made in one or two passes
– Any thickness of steel: 16 gauge to 3+ inches
• Backing rings often used for groove welds

Various Types of Flux Supports for 78
Submerged-arc Welding

79
Power Source
• d.c. rectifier or a.c. transformer
• DCEP
– Best control of bead shape and maximum penetration

• DCEN
– Highest deposition rates and minimum penetration
• Alternating current
– Minimizes arc blow at high amperage
– Preferred for single-electrode welding with high
currents and for multiple-wire, multiple-power welding

80
Power Source
• Cost of producing current with
transformers less than generators
• Both constant current and constant voltage

power supplies used for submerged arc
welding
• Constant voltage welding machine used
with constant speed wire-feed control
system

81
Wire and Flux Classifications

• Specifications for submerged arc welding
covered in AWS A5.17 for carbon steel and
AWS A5.23 for low alloy steel

• Wires divided into three groups according to
manganese content
– Low: EL8, EL8K and EL12
– Medium: EM11K, EM12, EM12K, EM13, EM15K
– High: EH10K, EH11K, EH12K, EH14

82
Wire Classification
Example: EL8K
• Prefix E designates an electrode
• Letter L indicates low manganese content

– 0.60% maximum
– M for medium (1.5% max), H for high (2.2% max)
• Number indicates nominal carbon content
• Letter K indicates made from heat of steel
that has silicon killed

83
Flux Classification
• Companion fluxes for wires designated
with F
– F only means virgin flux without crushed slag

– FS indicates made solely from crushed slag or
blend of crushed slag with virgin flux
• Number following F or FS indicates
mechanical properties achievable
• See Table 23-8

84
Three General Types of Fluxes
• Active fluxes
– Contain controlled amounts of manganese and/or
silicon
– Used for making single-pass welds with fewest

defects and high quality
• Neutral fluxes
– Not produce any change in all-weld metal composition
– Used for multiple-pass welding on plate > 1" thickness
• Alloy fluxes
– Used with plain carbon steel electrode to make alloy
weld deposits
– Used on low alloy steel and for hard-facing

85
Example: Flux Classification
F6A0-EH14
• Prefix F designates a flux
• Number designates mechanical properties

• Letter A indicates “as welded”
– P would have indicated postweld heat treatment
• Digit after letter designates required minimum
impact strength temperature
• Suffix after hyphen gives electrode classification
with which flux will meet specified mechanical
property requirements
86
Results Provided by Fluxes

• Produce results like those provided by
other fluxes
• Protect weld pool from surrounding air in

envelope of molten flux
• Act as cleaning agent for base metal
• Satisfy special metallurgical or chemical
needs
• Provide minerals or alloys to the weld
metal

87
Results Provided by Fluxes

• Guard against porosity caused by rusty
plate
• Provide maximum resistance to weld

cracking
• Specific fluxes designed to work best with
certain electrodes, materials, and welding
conditions
• Improve weld appearance

88
Wire Sizes
• Furnished in continuous lengths wound into
coils or drums or on liners
• Stiff wire decreases flexibility of cable and large

pool of molten metal hard to handle
• Large sizes require high current and provide
high deposition rates
– Can bridge gaps when fitup poor
• Arc starting more difficult as wire size increases
• Standard sizes: 1/16, 5/64, 3/32, 1/8, 5/32, 3/16,
7/32, and 1/4 inch

89
Polarity
• DCEP recommended for most applications
– Smoother welds, better bead shape, greater
penetration, and better resistance to porosity

• DCEN applications
– Conventional fillets in clean and rust-free plate
– Hard-surfacing
– Hard to weld steels
– Prevention of cracking due to deep penetration
• Increase voltage 4 volts to maintain similar bead
shape when changing from DCEP to DCEN at
same current

90
Alternating Current
• Recommended for two specific
applications
– Tandem arc welding for increased speed

– Single-arc applications where arc blow cannot be
overcome and travel slowed
• Higher current density needed to maintain
good arc stability

91
Joint Design
• Basic joints common to all welding
• Plates either butted tightly together or
backing bar used

– To avoid excess melt-through due to deep,
penetrating process

92
Cleaning
• Rust, scale and moisture cause porosity
• Cleaned joint gives best results
• All substances must be removed

• Use clean, rust-free wire and screened flux
to remove large particles and foreign
matter

93
Position of Welding
• All welding done with work level or in flat
position
• Some sheet metal may be welded slightly

downhill
• Heavy, deep-groove welding sometimes
done with plate at uphill angle of 2º to 5º
– Helps keep molten metal from running ahead of arc

94
Fitup
• Should be uniform and accurate
• Seams should be butted tightly unless root
gap specified
– Gap may be required to secure penetration or to
prevent weld cracking or distortion of plates
• Gaps greater than 1/16 inch may be filled
with SMAW, GMAW, or FCAW processes
– Use appropriate electrode for base metal and weld
quality required

95
Starting and Stopping Tabs

• Tack-welded pieces of steel at each end of long
seam
• Possibility of cracking and weld craters

eliminated by starting and ending in tabs
• Enable welding condition to stabilize and
maintain uniformity at beginning and end of joint
• Tabs should be similar in material and design to
weld joint
– Large enough to support flux and molten metal
– Welded in manner that prevents molten metal from
dropping through any gaps

96
Flux Coverage
• Insufficient flux coverage
– Permits arc to flash-through and does not provide
proper shielding
• Excessive flux
– Produces narrow hump bead
• For application like roundabout, edge, and
horizontal welds, support may be needed
to hold flux around arc while welding

97
Flux Depth
• Suitable depth gives fast, quiet welding
action
– Too deep: gases generated during welding cannot

escape giving rough, uneven, porous weld
– Too shallow: arc flashing and porous weld
• Good indication of proper flux depth
– Smoke rising out of flux layer
• Important to keep flux clean and dry

98
Flux Recovery
• Unfused flux can be recovered during
welding
• Systems available that use air power and

others use electrical power
• Great savings
• Fused flux recrushed and reprocessed
– Done off-site by company specializing in reprocessing
fused flux
– Mixed with new flux in certain ratios

99
Flux Recovery

100
Weld Backing
• Support for highly fluid weld pool so it will not
fall through joint
• Most common forms: steel backing bars, weld

metal backing copper, or flux
– Steel backing bars usually remain as part of weldment
– Copper best material to use
• Nonfusible and good conductor of heat
• Copper backing bar often liquid cooled
– Flux may be place at bottom of groove as support for
molten weld pool

101
Operating Variables
• Voltage
• Current
• Wire-feed speed
• Travel speed
• Electrode extension
– Normal for most applications
– Nozzle attachments available to increase extension to
2-1/4 or 3-1/4 inches (current preheats wire so melts
more quickly)
• Nozzle angle

102
Normal Electrode Extensions

Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. The Lincoln Electric Co.

Use of Nozzle Extension for 103
Long Electrode Extension

Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. The Lincoln Electric Co.

104
Electrode Size
• At fixed current setting, electrode size affects
depth of penetration
– Penetration decreases as size of electrode increases

• Automatic/mechanized submerged arc welding
filler wires large for higher currents and higher
deposition rates
• All other conditions (other than WFS) held
constant, increase in wire size reduces
deposition rate and penetration
– Also increase current then increase deposition rate
and penetration

105
Multiple-wire Techniques
• Multiple arcs increase meltoff rates and
direct arc blow to provide increase in
welding speed
• Two electrodes fed through same jaws
from one power source increase
deposition rate by 50% on work
– Pull together, causing back blow at front arc and
forward blow at trailing arc
– Twin electrode SAW process

106
Multiple-wire Techniques
• Multiple-wire, multiple-power arcs
– Two or more electrodes (each have separate
power source) provide high speed on fill-in

and square groove welds
– Difficult to set up
– Justified only on long welding runs or on
production work
– At least one arc should be a.c.

107
Multiple-Wire Techniques
• Two-wire series
– High deposition rate with minimum penetration
into base material

– Used for hard-surfacing materials
– Each filler wire operates independently in series
• Welding current travels from one electrode to
other through weld pool and surrounding material
– Two electrodes mounted at 45º to each other

108
Submerged Arc Surfacing

• Surfacing – used to describe application of
welding layer of metal on surface
• Often used to surface carbon steel with stainless

steel
– Economical way to obtain corrosion-resistant vessel
• Typical round electrode or strip used
– Strip produces wider weld with less penetration
• Arc moves back and forth across edge of strip
• Single pass
• Special welding head and drive system
• Widths: 9/16 to over 9 inches, 0.024 in. thick

Semiautomatic Submerged Arc 109
Welding
• Being replaced by solid wire, metal cored
wire, and flux cored wire welding
• Two examples
– Squirt Welding®, a Lincoln process
– Union Melt®, a ESAB process
• Equipment
– Welding machine, conical flux container, welding
nozzle, wire reel, wire-feeding mechanism, and
control unit for control of wire feed and arc voltage

Schematic Diagram of Component Units Needed 110
for Automatic/Mechanized or Semiautomatic
Submerged Arc Welding
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. Hobart Brothers Co.

Characteristics of the 111
Semiautomatic Process
• Can follow irregular shapes
• Welding can be done without fixtures or with
only simple fixtures

• Equipment easily portable, and process highly
versatile
• Cost of equipment lower than for
automatic/mechanized applications
• Lower deposition rates can drive labor cost per
weld up

Semiautomatic Process 112
Applications
• When gun can be dragged along joint, providing
accurate guiding
• When work can be rotated and gun held in

position by hand
• When work can be rotated and gun held in a
simple locating fixture
• When both gun and work can be moved by
special fixtures

Submerged Arc Welding 113
Semiautomatic Practice Job

• Complete practice job according to
specifications given in Job Outline
• Set up as when practicing with FCAW-S

process
• When done, practice with other forms of
joints and various thicknesses of material
– Wide range of current (WFS) and voltage
should be employed


• Power source
– Constant voltage d.c. power sources
• Transformer, rectifier type, inverter type, or

engine driven
• Wire feeder
– Same as FCAW with as large diameter as
possible
– 1/16 inch best
• Gun
– Same gun as GMAW or FCAW-G practice


• Electrode extension
– Set before welding starts: range from 1–2
inches
• Welding technique
– Check welding control settings, drive rolls,
wire size and type
– Gun, cable, and nozzle contact tip correct for
wire size and electrode extension used


• Starting the arc
– Establish proper electrode extension
– Pour layer of flux into joint

– Rest electrode tip in root of joint ~1" from edge
– Press trigger to start arc
• Mechanical feed advances electrode
• Welding stopped by releasing trigger

Semiautomatic Application of 117
Submerged Arc Welding Process
Nozzle
Contact Tube
Flux Depth
Electrode Wire
Approximately 1 in.
Note Extension
of Approximately Steel Plate
1-1/2 in. 3/8 in. thick

118
SAW Process
• Work or travel gun angle
– Travel drag angle about same as stick electrode welding
– Work angle varies with type of joint and thickness of
material
– Drag nozzle along joint to deposit single stringer bead of
approximately 1/2-inch leg size
• Operating variables
– Arc voltage, current (WFS), travel speed, and electrode
extension
• Inspection and testing
– Weld shows good fusion along edges, normal convexity,
free from undercut and surface defects, and fine, smooth
ripples

119
Electroslag Welding (ESW)

• Developed for welding of vertical plates
– Ranging in thickness from 1-1/4 to 14", single pass
– Plate edges require no preparation

• Automatic/mechanized application process
• Equipment
– Carriage assembly which moves along joint
– Multiple set of feed-wire assemblies
– Copper shoes positioned against joint to act as dam
– Nozzle in vertically down feed holding filler wire

120

• Fusion of base metal and continuously fed filler
wires takes place under heavy layer of high
temperature, electrically conductive molten flux

– Filler wires may be either solid, metal cored, or flux
cored
– Voltage ranges from 42 to 52; and amperage, from
500 to 640, depending on thickness of metal
– Power is alternating current
• Plates in vertical plane with square edges
spaced from 1 to 1-5/16 inches, according to
thickness of plate

121

• Water-cooled copper shoes form mold around joint
gap
• Prepared block placed under plate edges to close
joint cavity
• Granular flux poured into cavity, and weld pool
established with filler wires
– At first only flux fused into molten slag
• Extreme heat produced by resistance heating in weld
pool, molten flux, and electrode cause base metal to
melt
• Weld formed by water-cooled plates
– Homogeneous and good penetration into base metal
and smooth, clean weld faces

Basic Components of an 122
Electroslag Welding Operation

Flux Hopper
Horizontal
Wire Feed Drive
Wire
Molten Slag
Vertical Drive
Molten Weld Metal
Copper Shoe Power Source
Water System Power
Leads
Work

123
Square Groove Butt Joint
Made with electroslag

process in steel plate 3

inches thick. It had a 1" root
opening and was welded in
1 pass. The completed weld
is 1-3/4" wide with 1/8" face
reinforcement. Welding was
done in vertical position,
travel up.

Electroslag Welding with a 124
Consumable Guide
• Consumable guide welding (CG)
– Method used to weld vertical beam joints
• Tube, coated with slag-forming and alloying

elements, guides filler wire from wire-feeding
unit into bath formed by two sides of joint being
welded and two water-cooled copper shoes
– Bath contains molten weld metal and slag
• Tube connected to positive side of rectifier
power source DCEP
• Guide tube and filler wire melt at rate that
determines welding speed
Electroslag Welding with a 125
Consumable Guide
• Not true submerged arc welding process
– Uses arc only at start of process to generate heat for
melting of slag
– Once bath of molten slag established, slag causes arc
to be extinguished
• Length of tube limited to 40 inches
– Can be extended if movable current contact used
• Operates equally well on direct current or
alternating current
– Constant voltage power source recommended

Essentials of Consumable 126
Guide Welding
Electrode
Electrode Feed Roll
Consumable Guide
Base Material
Water-cooled Copper Dam
Slag Bath
Weld
Water ESAB

127
Consumable Guide Process Advantages
Over Conventional Electroslag Welding
• Welding machine portable, lightweight, and

easy to operate
• Welding of thinner metals possible

• Increase in welding speed increases
productivity and improves mechanical
properties of weld metal and heat-affected
zones
– Weld free from porosity and slag inclusions
– Fewer problems with residual stresses and plate
deformation

128
Electrogas Welding (EGW)

• Done with solid metal cored or flux cored
electrodes
• Arc welding process using approximately

vertical welding progression with backing
provided by molten weld metal
– Used with or without externally supplied shielding
gas (determined by type of electrode)

129

• Automatic/mechanized methods for
welding of butt, corner, and T-joints in
vertical position
• Similar to electroslag welding
• Uses direct current, electrode positive
• Uses shielding gas fed into weld pool
• Possible to weld metal sections of 1/2 inch
to over 2 inches in thickness with single
pass and without edge preparation

130

• Water-cooled copper shoes span joint
cavity and form dam to contain molten weld
metal
• Flux cored, metal cored, or solid filler wire
fed into cavity by curved guide
• Electric arc established and maintained
between filler wire and weld pool
• Helium, argon, carbon dioxide, or mixtures
of these gases may be fed continuously into
cavity
131

• Flux core of filler wire provides deoxidizers and
slagging materials for cleaning weld metal
• Base metal melted and fused as result of high

temperature from arc and molten slag
• Edges square cut and spaced from 11/16 to 7/8
inch or more
• Minimum spacing large enough to admit wire
guide and permit it to oscillate without arcing on
plate surfaces
• Welding within range of 500 to 700 amperes

Electrogas Welding
Basic Components for
132
133

• Lincoln Electric company has variation of
EGW known as Verti-Shield
– Mechanized vertical-up welding process designed to

maximize productivity when joining steel plates
– Welding done vertically in single pass on either butt
joints or T-joints
• Two different methods
– Consumable guide tube process
– Movable dam process (butt joint-groove welds only)

134
Manual Welding Applications

• Out-of-position welding in which a large, highly fluid
weld pool would spill
• Relatively short welds

• Light and heavy gauge metals
• Nonrepetitive jobs
• Jobs that are costly or difficult to fixture
• Jobs in which fitup cannot be controlled
• Jobs in which it would be difficult to retain flux
because of the shape of the work
• Jobs where obstructions of one kind or another
make it impossible to make an uninterrupted weld
135
Manual Welding Advantages

• Can be done indoors or outdoors
• Can be done in any position and in
inaccessible locations
• Can weld a wide range of alloys and
dissimilar metals
• Low cost, portable equipment

136
Semiautomatic Application
• Jobs in which you can take advantage of
the additional meltoff provided by currents
higher than those possible with manual

processes
• Jobs that are repetitive enough so that a
high degree of skill can be acquired
• Medium and heavy metals
• When continuous wire feed increases
welding time (duty cycle)

137
Semiautomatic Application
• When complicated shapes or extremely
large weldments make fixturing for
automatic/mechanized process too difficult

• When penetration, which deeper than that
produced by other manual processes, is
an advantage
• When contour of the work irregular and
fitup is not accurate enough for
automatic/mechanized guiding

138
Semiautomatic Advantages
• Produces welds of desirable appearance
and high quality weld metal characteristics
• Higher welding speeds than hand welding

• Less slag and weld spatter
• Reduces cost

Mechanized and Automatic 139
Welding Application
• Highly repetitive jobs that can be fixtured

Advantages
• Pushbutton arc striking
• High rate of weld metal deposition
• Welds have smooth, even appearance

• Heavier construction than manual and
semiautomatic equipment
• Higher current capacity than manual or
semi-automatic equipment
• Increased welding speeds

Advantages
• Self-contained travel mechanism
• Reduced electrode loss
• Machine precision
• Minimum slag removal
• Reduced problem of heat distortion
• Accurate, continuous control and fewer
weld rejects due to mechanization or
automation
• High mechanical properties of welds

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PowerPoint to accompany

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

2. Describe the welding variables for flux

6. Describe the electroslag and electro gas

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Flux Cored Wire Welding

• Increases welding speeds and deposition rates

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

• Self-shielded, flux cored arc welding

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

• Scavengers and deoxidizers for less-than-

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

electrode to do gas shielded,

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Welding Gun Cable Construction

Note wire liner

Hobart Brothers Co.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

American Welding Society (AWS) Welding Handbook

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Core Material Functions

metal until solidified

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

and alloying agents

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

American Welding Society (AWS) Welding Handbook

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Flux Cored Electrodes

– Generally these high deposition rates achievable with

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Basis of Three General Groupings

1. Single-pass filler metals

– Intended for welding rusted or mill-scaled plate

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Flux Cored Arc Welding Process

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Flux Cored Arc Welding Process

• Highly stable arc reduces spatter loss

• Weld appearance highly desirable

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Flux Cored Arc Welding

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Flux Cored Electrodes

of weld metal improved

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Flux Cored Electrodes

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Cored or Flux Cored Welding

Miller Electric Mfg. Co.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

• Wires used with gas shielding:

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© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

AWS Classification Numbers

– May require different operation parameters

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for maximum diffusible hydrogen levels of 4, 8, and 16 ml