1. Applying welding process to TIG , SMAW , FCAW
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Applying welding process to
TIG , SMAW , FCAW

2. Tig Welding
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3. TIG Welding Torch Back Cap Tungsten Rod Ceramic Tip
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4. TIG Machines Foot Control torch Ground Regulator Argon 100%
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5. 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.
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6. 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
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7. TIG Welding Operation
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8. 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
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9. 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
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10. 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
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11. Torch and Filler Positioning
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12. Torch and Filler Positioning
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13. Torch and Filler Positioning
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14. Torch and Filler Positioning
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15. Show Aluminium TIG welding
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16. SMAW Welding
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17. 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
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18. Equipment
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19. 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.
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20. 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.
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21. 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.
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22. 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
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23. 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.
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24. 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.
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25. Electrode Angle
The electrode angle influences the placement of the heat.
Two angles are important :
Travel
Work
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26. 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
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27. 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.
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28. 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.
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29. Current and Speed normal weld current too low current too high speed
too fast
too low
Arc
too long
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30. Weaving Motions
You may use one of the weaving motions shown, depending upon the type of joint and size of electrode.
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31. FCAW Welding
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32. 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
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33. 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.
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34. 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.
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35. FCAW Process
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36. 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
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37. Gun Movement Stringer bead – Steady movement along seam
Weave bead – Side to side movement along seam
Weave pattrens 1 2 3
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38. Gun Movement
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39. Knowledge is the key to success
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