Applying welding process to TIG , SMAW , FCAW Teknologi Las Kapal Applying welding process to TIG , SMAW , FCAW

Tig Welding Teknologi dan Rekayasa

TIG Welding Torch Back Cap Tungsten Rod Ceramic Tip Teknologi dan Rekayasa

TIG Machines Foot Control torch Ground Regulator Argon 100% Teknologi dan Rekayasa

Foot Control Practice controlling the heat with the foot pedal to see the weld puddle increase and decrease. Ideally, you want your weld puddle to be about 1/4 inch wide. Keep your puddle size consistent so it doesn't grow, shrink, spread or narrow while you are welding. Teknologi dan Rekayasa

TIG Welding Specifics Plasma consisting of ionized gases and metal vapors Commonly used to weld thin sections of stainless steel, nickel and copper alloys, as well as light metals such as aluminum, magnesium, titanium Teknologi dan Rekayasa

TIG Welding Operation Teknologi dan Rekayasa

How do I set up the Tig Welder? 1. Connect Torch 2. Connect Gas Hose and Regulator to Argon Cylinder 3. Connect Amperage Foot Pedal 4. Connect Work Clamp to the Work Piece 5. Prepare the Tungsten 6. Assemble the Torch 7. Install the Tungsten Teknologi dan Rekayasa

Lets Get Started Get dressed Get a welding helmet and meet me at the set up station I will demonstrate proper arc length, torch angle, and filler rod feeding After shop-work, a quiz will be given over the parts of the welder Teknologi dan Rekayasa

How to do TIG welding 1. Align your torch at the correct angle 2. Set the foot pedal to the correct amperage, so that you create a ¼” wide weld pool 3 Align your filler metal to the correct 3. angle 4. Heat an area of the joint’s surface 5. Dab the filler metal quickly 6. Push the torch forward enough to heat a new weld pool and cool the previous weld pool Teknologi dan Rekayasa

Torch and Filler Positioning Teknologi dan Rekayasa

Torch and Filler Positioning Teknologi dan Rekayasa

Torch and Filler Positioning Teknologi dan Rekayasa

Torch and Filler Positioning Teknologi dan Rekayasa

Show Aluminium TIG welding Teknologi dan Rekayasa

SMAW Welding Teknologi dan Rekayasa

Electrode The SMAW process uses a consumable electrode. Electrode must be compatible with base metal. Electrodes are available for different metals. Carbon steels Low alloy steels Corrosion resisting steels Cast irons Aluminum and alloys Copper and alloys Nickel and alloys Teknologi dan Rekayasa

Equipment Teknologi dan Rekayasa

Direct Current straight polarity The direction of the current flow determines the DC polarity. DC- or direct current electrode negative is the arrangement of direct current arc welding cables/leads in which the electrode is the negative pole and the workpiece is the positive pole of the welding arc. When using DC- polarity, the majority of the heat is directed at the electrode. The electrodes designed for DC- polarity produce weld deposits with shallow penetration. Primary applications are fast travel speeds on sheet metal. Teknologi dan Rekayasa

Direct Current Reverse polarity DC+ or direct current electrode positive is the opposite of DC- or direct current electrode negative. In this case, the electrode is the positive pole and the workpiece is the negative pole. When using DC+ polarity, the majority of the heat is directed at the work piece. The electrodes designed for DC+ polarity produce weld deposits with deep penetration. Teknologi dan Rekayasa

Starting The Arc Before you start to weld, ensure that you have all the required equipment and accessories. Listed below are some additional welding rules that should be followed. Clear the welding area of all debris and clutter. Do not use gloves or clothing that contains oil or grease. Check that all wiring and cables are installed properly. Ensure that the machine is grounded and dry. Follow all manufacturer’s directions on operating the welding machine. Have on hand a protective screen to protect others in the welding area from FLASH bums. Always keep fire-fighting equipment on hand. Clean rust, scale, paint, or dirt from the joints that are to be welded. Teknologi dan Rekayasa

Striking The Arc Select the best electrode Set the welder (Fig 26-8) Turn on welder Warn bystanders Lower helmet Start arc (two methods) Brushing Tapping Teknologi dan Rekayasa

Brushing Method Hold end of electrode about 1/4 - 1/2 inch above the surface. Lower helmet Gently brush surface of the metal with the end of the electrode. When arc starts, lift electrode 1/8 inch. If electrode sticks, twist it back and forth. If it does not break loose, release electrode from electrode holder. Do not shut off the welder with the electrode stuck to the metal. Teknologi dan Rekayasa

Tapping Method Set up welder Hold the electrode at the travel angle and 1/4 - 1/2 inch above the metal. Quickly lower the electrode until it touches the metal and then lift it 1/8 inch. Teknologi dan Rekayasa

Electrode Angle The electrode angle influences the placement of the heat. Two angles are important : Travel Work Teknologi dan Rekayasa

Arc Length The arc length is the distance from the metal part of the electrode to the weld puddle. The best arc length is not a fixed distance, but should be approximately equal to the diameter of the electrode. Arc length can be adjusted slightly to change the welding process. Excessive length Excessive spatter Reduced penetration Poor quality weld Insufficient length Electrode sticks Narrow weld Teknologi dan Rekayasa

Speed of Travel The speed of travel (inches per minute) is an important factor when arc welding. The best speed of travel (welding speed) is determined by several factors: The size of the joint, The type of electrode The size of the electrode The amperage setting on the machine Deposition rate of the electrode (cubic inches per minute) The deposition rate of an electrode will change with the welding amperage. Teknologi dan Rekayasa

Speed of Travel The correct welding speed is indicated by the shape of the ripples. Too slow = excessive width, excessive penetration Too fast = narrower width, elongated ripple pattern, shallow penetration. Recommended = width 2-3 times diameter of electrode, uniform ripple pattern, full penetration. Teknologi dan Rekayasa

Current and Speed normal weld current too low current too high speed too fast too low Arc too long Teknologi dan Rekayasa

Weaving Motions You may use one of the weaving motions shown, depending upon the type of joint and size of electrode. Teknologi dan Rekayasa

FCAW Welding Teknologi dan Rekayasa

FCAW Welding A flux-cored wire is optimised to obtain performance not possible with a solid wire. A flux-cored wire can do it better and faster for many welding applications like : vertical-up welding flat welding welding over galvanized welding hard-to-weld steels Teknologi dan Rekayasa

American Welding Society Specification Electrode E70 T - 1 Electrode Minimum UTS 70,000 psi Position Flux Cored /Tubular Type Gas, Usability and Performance American Welding Society Specification AWS A5.20 and AWS A5.29. Teknologi dan Rekayasa

Electrode Classification E71T-1 (FCAW-G): Highest deposition rates out-ofposition. E71T-8 (FCAW-S): Highest deposition rates out-ofposition without a shielding gas. E70T-4 (FCAW-S): Highest deposition rates in the flat position. E70T-1 (FCAW-G): Highest deposition rates in the flat position with Charpy properties. E71T-14 (FCAW-S): Fastest travel speed on galvanized and coated steels. E70T-5 (FCAW-G): Fastest way to weld hard-toweld steels. Teknologi dan Rekayasa

FCAW Process Teknologi dan Rekayasa

FCAW Process Hold gun and control gun trigger Workpiece Work clamp Electrode extension Cradle gun and rest hand on workpiece End view of work angle Side view of gun angle Teknologi dan Rekayasa

Gun Movement Stringer bead – Steady movement along seam Weave bead – Side to side movement along seam Weave pattrens 1 2 3 Teknologi dan Rekayasa

Gun Movement Teknologi dan Rekayasa

Knowledge is the key to success Teknologi dan Rekayasa