Scribd Logo
Upload

Welcome to Scribd!

  • 67 views

    10.introduction To Welding Processes

    Uploaded by

    finhay
    This document provides an introduction to various fusion welding processes and techniques for monitoring heat input during welding. It describes common welding processes, factors for choosing a welding process, and how to calculate heat input and arc energy values. Monitoring and controlling heat input is important for meeting requirements in welding standards.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd

    10.introduction To Welding Processes

    Uploaded by

    finhay
    67 views21 pages
    This document provides an introduction to various fusion welding processes and techniques for monitoring heat input during welding. It describes common welding processes, factors for choosing a welding process, and how to calculate heat input and arc energy values. Monitoring and controlling heat input is important for meeting requirements in welding standards.

    Original Title

    10.Introduction to Welding Processes

    Copyright

    © © All Rights Reserved

    Available Formats

    PPT, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    This document provides an introduction to various fusion welding processes and techniques for monitoring heat input during welding. It describes common welding processes, factors for choosing a welding process, and how to calculate heat input and arc energy values. Monitoring and controlling heat input is important for meeting requirements in welding standards.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    67 views21 pages

    10.introduction To Welding Processes

    Uploaded by

    finhay
    This document provides an introduction to various fusion welding processes and techniques for monitoring heat input during welding. It describes common welding processes, factors for choosing a welding process, and how to calculate heat input and arc energy values. Monitoring and controlling heat input is important for meeting requirements in welding standards.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 21

    CSWIP 3.

    1 Welding Inspection

    Introduction to Welding
    Processes
    TWI Training & Examination

    TWI Ltd 2009


    Services ©

    Copyright
    Course Reference WIS 5
    Course notes section reference 10
    Welding Processes

    Welding is regarded as a joining process in which the work


    pieces are in atomic contact

    Pressure welding Fusion welding


    • Forge welding • Oxy-acetylene
    • Friction welding • MMA (SMAW)
    • Resistance Welding • MIG/MAG (GMAW)
    • TIG (GTAW)

    TWI Ltd 2009


    • Sub-arc (SAW)
    • Electro-slag (ESW)
    ©

    Copyright
    • Laser Beam (LBW)
    • Electron-Beam (EBW)
    Welding Processes

    The four essential factors for fusion welding:


    1. Fusion is achieved by melting using a high intensity heat
    source
    2. The welding process must be capable of removing any
    oxide and contamination from the joint

    TWI Ltd 2009


    3. Atmosphere contamination must be avoided
    4. The welded joint must possess the mechanical properties
    ©

    Copyright
    required by the specification being adapted
    Welding Processes
    CHOICE OF WELDING PROCESS
    Material Type:
    • Steels all processes
    • Reactive metals TIG & MIG
    (Aluminium & Titanium)
    • Nickel-based Alloys all processes for most alloys
    • Copper-based alloys mainly TIG & MIG
    Material Thickness:

    TWI Ltd 2009


    • MMA all above ~ 3mm ©

    • TIG (low productivity) generally thin sections (<~

    Copyright
    10mm)
    • MIG/MAG/FCAW typically ~ 3 to 30mm
    • SAW typically ~ 15 to 150mm or
    above
    Welding Processes

    CHOICE OF WELDING PROCESS


    Joint Properties
    • very high quality TIG & SAW
    • very demanding properties TIG usually best
    (for toughness & corrosion
    resistance)
    Welding Position

    TWI Ltd 2009


    • MMA, TIG, MIG/MAG all positions
    ©

    • SAW mainly flat but is used for girth seams

    Copyright
    on large diameter storage tanks
    Welding Processes

    OTHER FUSION WELDING PROCESSES

    Electron Beam Welding


    • One-pass welding of thick joints (~ 400mm) in vacuum chamber
    • Precision fit-up required
    • No filler wires
    • Very low distortion - can weld near-finished machined items

    Laser Beam Welding


    • One-pass welding - very thin sections to ~ 20mm

    TWI Ltd 2009


    • Precision fit-up required
    • Can use robotics (YAG lasers) ©

    • Low distortion

    Copyright
    • Hybrid systems being developed with filler wire additions
    Welding Processes

    NON-FUSION WELDING PROCESSES

    Friction Welding
    • Because no fusion - can join wide variety of dissimilar materials
    • Sound joints produced
    • HAZ degradation minimised
    • Many variants being developed for different shapes/applications

    TWI Ltd 2009


    ©

    Copyright
    Welding Process Comparison

    Process Electrical characteristic Electrode current type

    MMA Drooping / constant current DC+ve, DC-ve, AC

    TIG Drooping / constant current DC-ve, AC

    MIG/MAG Flat / constant voltage DC+ve,

    MAG FCAW Flat / constant voltage DC+ve, DC-ve,

    TWI Ltd 2009


    Drooping / constant current >1000amp
    Sub-arc DC+ve, DC-ve, AC
    ©

    Copyright
    Flat / constant voltage <1000amp

    Electro-slag Flat / constant voltage DC+ve,


    An Introduction to Fusion Welding Processes

    TWI Ltd 2009


    ©

    Copyright
    Monitoring Heat Input

    ARC ENERGY &


    HEAT INPUT

    TWI Ltd 2009


    ©

    Copyright
    Monitoring Heat Input

    TWI Ltd 2009


    ©

    Copyright
    Monitoring Heat Input

    • ARC ENERGY;
    The amount of heat generated in the
    welding arc per unit length of weld.
    Expressed in kilo Joules per millimetre
    length of weld (kJ/mm).

    TWI Ltd 2009


    Arc energy (kJ/mm)= Volts x Amps ©

    Copyright
    welding speed(mm/s) x 1000
    Monitoring Heat Input

    HEAT INPUT
    The energy supplied by the welding arc to
    the work piece.
    Expressed in terms of;
    arc energy x thermal efficiency factor

    Thermal efficiency factor is the ratio of

    TWI Ltd 2009


    heat energy introduced into the weld to ©

    the electrical energy consumed by the arc

    Copyright
    Monitoring Heat Input

    Heat input values for various welding


    processes can be calculated from the arc
    energy by multiplying by the following
    thermal efficiency factors;

    TWI Ltd 2009


    ©

    Copyright
    Monitoring Heat Input

    Thermal efficiency factor k of welding processes


    Process No Process Factor k
    121 Submerged arc welding with wire 1.0
    111 Metal-arc welding with covered electrodes 0.8
    131 MIG welding 0.8
    135 MAG welding 0.8
    114 Flux-cored wire metal-arc welding without gas shield 0.8
    136 Flux-cored wire metal-arc welding with active gas shield 0.8

    TWI Ltd 2009


    137 Flux-cored wire metal-arc welding with inert gas shield 0.8
    138 Metal-cored wire metal-arc welding with active gas shield 0.8 ©

    Copyright
    139 Metal-cored wire metal-arc welding with inert gas shield 0.8
    141 TIG welding 0.6
    15 Plasma arc welding 0.6
    Monitoring Heat Input

    Abbreviations and symbols


    I Arc welding current (Amps)
    k Thermal efficiency Factor
    v Welding Speed (mm/min)
    Q Heat Input (kJ/mm)
    U Arc Voltage (Volts)
    Q = k v x 10-3 = kJ/mm

    TWI Ltd 2009


    ©

    Amp x volts x time

    Copyright
    or Q = k WS (mm/min) x1000
    Monitoring Heat Input

    EXAMPLE.
    A MAG weld is made and the following
    conditions were recorded;
    Arc volts = 24
    Welding amperage = 240
    Travel speed = 300mm / minute.

    TWI Ltd 2009


    ©

    Copyright
    What is the arc energy and heat input?
    Monitoring Heat Input

    AE (kJ/mm)= Volts x amps


    Travel speed(mm/ sec) x 1000
    = 24 x 240
    (300/60) x 1000
    = 5760
    5000

    TWI Ltd 2009


    AE = 1.152 or 1.2kJ/mm ©

    HI = 1.2 x 0.8 = 0.96kJ/mm

    Copyright
    Monitoring Heat Input

    TWI Ltd 2009


    ©

    Copyright
    Monitoring Heat Input

    • Monitoring Heat Input As Required by


    • BS EN ISO 15614-1:2004
    • In accordance with EN 1011-1:1998

    When impact requirements and/or hardness


    requirements are specified, impact test shall be taken
    from the weld in the highest heat input position and

    TWI Ltd 2009


    hardness tests shall be taken from the weld in the lowest ©

    heat input position in order to qualify for all positions

    Copyright
    Monitoring Heat Input

    When impact requirements apply, the upper limit of heat


    input qualified is 25% greater than that used in welding
    the test piece

    When hardness requirements apply, the lower limit of heat


    input qualified is 25% lower than that used in welding the
    test piece

    TWI Ltd 2009


    Heat input is calculated in accordance with EN1011-1
    ©

    Copyright
    If welding procedure tests have been preformed at both a
    high and low heat input level, Then all intermediate heat
    inputs are also qualified

    You might also like