ARC WELDING

ELECTRIC ARC WELDING

The welding (fusion) in which the electric arc is
produced to give heat for the purpose of
joining two surfaces is called electric arc
welding.

The joining by fusing of two or more pieces of

metal together by using the heat produced
from an electric arc .
 How an arc is formed?
• The arc is like a flame of
intense heat that is
generated as the
electrical current passes
through a highly
resistant air gap.
ELECTRIC ARC WELDING
 Arc Welding applications
• Arc welding continues to be used extensively in the
construction of steel structures and in industrial
fabrication.
• The process is used primarily to weld iron and steels
(including stainless steel ) but aluminium, nickel and
copper alloys can also be welded with this method.
• It dominates other welding processes in the
maintenance and repair industry, and though flux-cored
arc welding is growing in popularity
• Is popular because it can be used in the field without
complicated equipment and gases
Arc Welding
 Principle of Arc
• A suitable gap is kept between the work and
electrode
• A high current is passed through the circuit.
• The electric energy is converted into heat
energy, producing a temperature of 3000°C to
4000°C.
• This heat melts the edges to be welded and
molten pool is formed.
• On solidification the welding joint is obtained
 Types of Electrodes
1. Bare electrodes
2. Coated electrodes
 Arc Welding Electrodes
• The choice of electrode depends on a number
of factors, including
1. The weld material
2. Welding position and
3. The desired weld properties.
 Welding Electrodes
• The composition of the electrode core is generally similar and
sometimes identical to that of the base material.
• But even though a number of feasible options exist, a slight
difference in alloy composition can strongly impact the properties of
the resulting weld.
• Likewise, electrodes of compositions similar to those of the base
materials are often used for welding nonferrous materials like
aluminium and copper.
• However, sometimes it is desirable to use electrodes with core
materials significantly different from the base material. For example,
stainless steel electrodes are sometimes used to weld two pieces of
carbon steel, and are often utilized to weld stainless steel
workpieces with carbon steel workpieces.
 Coated Electrodes
• The electrode is coated in a metal mixture
called flux, which gives off gases as it
decomposes to prevent
1. Weld contamination
2. Introduces deoxidizers to purify the weld
3. Causes weld-protecting slag to form
4. Improves the arc stability, and
5. Provides alloying elements to improve the weld
quality.
 Electrode Coating
• Electrode coatings can consist of a number of different compounds, including
rutile, calcium fluoride, cellulose, and iron powder.
• Rutile electrodes, coated with 25%–45% TiO 2, are characterized by ease of
use and good appearance of the resulting weld. However, they create welds
with high hydrogen content, encouraging embrittlement and cracking.
• Electrodes containing calcium fluoride (CaF 2), sometimes known as basic or
low-hydrogen electrodes, are hygroscopic and must be stored in dry
conditions. They produce strong welds, but with a coarse and convex-shaped
joint surface.
• Electrodes coated with cellulose, especially when combined with rutile,
provide deep weld penetration, but because of their high moisture content,
special procedures must be used to prevent excessive risk of cracking.
• Finally, iron powder is a common coating additive, as it improves the
productivity of the electrode, sometimes as much as doubling the yield.
 Functions of electrode (flux) covering
• Provides the gaseous shield to protect the
molten metal from air.
– Cellulose-type electrode (C6H10O5)x , providing
gas mixture of H2, CO, H2O and CO2.
– Limestone-type electrode (CaCO3) – low in
hydrogen and it is used for welding metals that are
susceptible to hydrogen cracking such as high-
strength steels.
 Functions of electrode (flux) covering
• Deoxidation - Provide deoxidizers and fluxing agent
to deoxidize and cleanse the weld metal. The solid
slag also protects the weld metal from oxidation.
• Arc stabilization - Provide arc stabilizers which are
compounds such as potassium oxalate and lithium
carbonate. They readily decompose into ions in an
arc, which increase electrical conductivity.
• Metal addition - Provide alloying elements (for
composition control) and metal powder (increase
deposition rate) to the weld pool.
 Types of Electrodes
Electrodes can be divided into three groups—
1. Fast-fill electrodes,
Fast-fill electrodes are designed to melt quickly so that
the welding speed can be maximized
2. Fast-freeze electrodes,
fast-freeze electrodes supply filler metal that solidifies
quickly, making welding in a variety of positions
possible by preventing the weld pool from shifting
significantly before solidifying. and
3. Intermediate electrodes go by the name "fill-freeze" or
"fast-follow" electrodes.
 Arc Welding Power Supplies
• The current for arc welder can be supplied by
line current or by an alternator/generator.
– The amount of heat is determined by the current flow (amps)
– The ease of starting and harshness of the arc is determined by the electrical
potential (volts).

• Welding current adjustments can include:

– Amperage
– Voltage
– Polarity
 Amperage Output
• The maximum output of the power supply
determines the thickness of metal that can be
welded before joint beveling is required.
• 185 to 225 amps is a common size.
• For an individual weld, the optimum output
amperage is determined by
– thickness of the metal
– type of joint and
– type of electrode
 Alternating Current
• Alternating current: The type of current where
the flow of electrons reverses direction
(polarity) at regular intervals.
• Recommended for general purpose electrodes
and flat position.
 Direct Current
• Direct current: The type of current where the flow of electrons
(polarity) is in one direction.
• Controlling the polarity allows the welder to influence the
location of the heat.
• When the electrode is positive (+) DCRP, it will be slightly hotter
than the base metal.
• When the base metal is positive (+), DCSP, the base metal will be
slightly hotter than the electrode.
• DC is required for GMAW
• It is frequently used for SMAW
 A.C/D.C CURRENT COMPARISON
1. A.C. welding machine is cheaper, small in size, light in weight and simple to
operate.
2. Maintenance of A.C. welding machine is easier and more economical, because
there is no moving parts in it.
3. Heat generated is equal at both the poles, so it does not require changing of
polarity.
4. A.C. welding machine is not suitable for welding all metals particularly non-ferrous
metals and alloys.
5. Bare electrode cannot be used. Only specially designed coated electrodes can be
used.
6. A.C. welding machine is not suitable for welding of sheet metals due to difficulty in
starting the arc.
8. Voltage drop in A.C. is less, hence, can be used at a large distances from the power
supply.
9. It can only be used when A.C. power supply is available.
10. Less electric energy consumption per kg of metal deposited (3 to 4 kWh.).
1. A.C. Welding machine has high efficiency (0.8 to 0.85).
12. A.C. Welding machine has lower operating cost.
13. A.C. Welding machine has an disadvantage of using low power factor at the
welding station, (0.3 to 0.4).
1. D.C. welding machine is two to three times costlier, larger in size, heavier in weight
and is more complicated.
2. Maintenance cost is higher because of many moving parts in it.
3. Heat generated is different at the work and the electrode by changing the polarity.
4. D.C. welding machine is suitable for welding all types of metals by changing the
polarity.
5. Both coated and bare electrode can be used in D.C. welding machine.
6. It is used for all sorts of work as starting of the arc is easier comparatively.
7. Arc-blow is severe and difficulty to control.
8. Voltage drop is relatively higher, it can be used only at a short distance from the
power supply.
9. It can be used anywhere with engine driven D.C. generator or by rectified A.C.
supply.
10. Higher electric energy consumption per kg of metal deposited (6 to 10 kWh).
11. Efficiency of D.C. Welding machine is low only 0.3 to 0.6.
12. It has higher operating cost.
13. The motor in a D.C. Welding has an advantage of high power factor of 0.6 to 0.7.
POLARITY
Arc welding is one type of fusion welding process where base metals are fused by
applying heat in order to form coalescence. Required heat is supplied by an electric arc
constituted between positive and negative terminals of an electric circuit inbuilt with a
power source. For welding purpose work metal is made one terminal and the electrode is
made another, and thus arc constitutes in between them in the external circuit. Since
electrons always flow from negative terminal to positive terminal of any external circuit,
so based on the connection made, two cases are possible:
1. Electrode is connected with negative terminal of the power source; whereas, base
metals are connected with positive terminal- STRAIGHT POLARITY
2. Base metals are connected with the negative terminal of the power source; whereas,
electrode is connected with positive terminal- REVERSE POLARITY
However, if the power source provides alternating current (AC) then both conditions occur
one after another in every cycle. Basically arc welding power sources can provide either
DC or AC type current. Some modern power sources also contain facility to convert one
from another (integrated with AC-DC converter), so these sources can supply both AC and
Therefore, arc welding can be carried out in any of the following three polarities.
Direct Current Straight Polarity—occurs when electrode is made negative and base
plates are made positive. Thus electrons flow from electrode tip to base plates.
Direct Current Reverse Polarity—occurs when electrode is made positive and base
plates are made negative. Thus electrons flow from base plates to electrode.
Alternating Current Polarity—if power source provides AC current then above two
cases will occur one after another in every cycle. In one half of the cycle, electrode will
be negative (so base plates will be positive) and in the next half, electrode will be
positive (so base plate will be negative). Number of cycles per second depends on
frequency of supply. For example, with a 60Hz supply, 60 cycles occur in every second.
Advantages of DCEP polarity in arc welding
Better arc cleaning action so less chance of inclusion defects.
High volume deposition rate for consumable electrode, so faster welding.
Better performance for welding thin plates. It reduces distortion level, residual
stress, complete cutting, etc.
Suitable for joining metals with low melting points, such as copper and aluminum.
Disadvantages of DCEP polarity in arc welding
Shorter electrode life for non-consumable electrodes.
Higher level of reinforcement if speed is not adjusted properly. (electrode content
in weld joint high)
Insufficient melting and incomplete penetration.
Cannot fuse properly thick plates or metals having high melting point.
Advantages of DCEN polarity in arc welding
Sufficient fusion of base metals and thus proper penetration can be
achieved.
Less chance of tungsten inclusion (with TIG welding) and also low
reinforcement.
Better choice for welding metals with high melting point, such as titanium,
stainless steel, etc.
Thick plates can also be joined properly.
Disadvantages of DCEN polarity in arc welding
No arc cleaning action so chances of inclusion defects.
High distortion level.
High residual stress generation at welded components.
Broader heat affected zone (HAZ).
Lower productivity due to lower deposition rate.
Not suitable for welding thin plates.
Alternating Current (AC) polarity in arc welding

AC polarity offers advantages of both DCEN and DCEP; however, to some extent only.

With AC power source, in half of the cycle electrode becomes negative and in next

half of the cycle, electrode becomes positive. This cycle repeats 50 or 60 times in a

second depending on frequency of supply (50Hz or 60Hz).

Advantages of AC polarity in arc welding

Moderate arc cleaning action.

Compatible with most of the electrode types (but not all).

Better fusion and weld metal penetration.

Suitable for a wide range of plate thickness.

 Selecting the correct polarity
If your base metal is aluminum or magnesium then DCEP is better option because it can
rupture the oxide layer (alumina—Al2O3) present on the plate surface. Also melting
point of aluminum is quite small (660ºC), so high heat generation near base plate does
not require.
If you are welding titanium or stainless steel, then AC is better option as it will give you
all the desired advantages. Here DCEN can increase HAZ zone.
If work material has poor electron emissivity or need high voltage for electron emission
then DCEP is wrong choice as it may result in instable arc.
If base plate thickness is more (>6mm) then DCEN is preferable choice. Edge
preparation is also required. Similarly, for thin plates, DCEP should be selected.
In TIG welding, use of DCEP polarity may result in ball formation at electrode tip leading
to lower electrode life. It can also result in tungsten inclusion defect.
 Arc Welding Defects
The most common quality problems associated with SMAW include

• 1. Weld spatter

Weld spatter, while not affecting the integrity of the weld, damages its appearance and

increases cleaning costs. It can be caused by excessively high current, a long arc, or arcblow, a

condition associated with direct current characterized by the electric arc being deflected

away from the weld pool by magnetic forces. Arc blow can also cause porosity in the weld, as

can joint contamination, high welding speed, and a long welding arc, especially when low-

hydrogen electrodes are used.

• 2. Porosity

Porosity, often not visible without the use of advanced NDT methods, is a serious concern

because it can potentially weaken the weld.

 Arc Welding Defects
• 3. Poor fusion

Another defect affecting the strength of the weld is poor fusion, though it is often easily
visible. It is caused by low current, contaminated joint surfaces, or the use of an improper
electrode.
• 4. Shallow penetration

Shallow penetration, another detriment to weld strength, can be addressed by decreasing

welding speed, increasing the current or using a smaller electrode.
• 5. Cracking.

Any of these weld-strength-related defects can make the weld prone to cracking, but other
factors are involved as well. High carbon, alloy or sulfur content in the base material can
lead to cracking, especially if low-hydrogen electrodes and preheating are not employed.
Furthermore, the workpieces should not be excessively restrained, as this introduces
residual stresses into the weld and can cause cracking as the weld cools and contracts.