basics of welding eduction

7/28/2019 Basics of Welding Eduction.

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WELDING EDUCATION

By

R.SRINIVASANCONTECH ENGINEERS.


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Welding education

At the outset we would like to thank forgiving us an opportunity to recommend

and educate about the variousdocumentation for carrying out thewelding operations as required by yourcompany.

We are happy to recommend thefollowing for your kind considerations

and its implementations.


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Topics covered

WELDING PROCESSES.

WELDING CONSUMABLES

WELDING EQUIPMENTS WELDING PROCEDURE

WELDING PROCEDURE SPECIFICATIONS(WPS)

PROCEDURE QUALIFICATIONS (PQR)

WELDER PERFORMANCE QUALIFICATIONS(WPQ)

WELDING DEFECTS ITS CAUSES AND REMIDIES

SAFETY


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SESSION-1

WELDING PROCESS


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WELDING PROCESS

The present process of welding used tomanufacture various components

generally are as follows MMAW- Manual Metal Arc Welding

Process

GMAW- Gas Metal Arc Welding process

GTAW Gas Tungsten Arc Welding


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Types Of Welding

Welding

Gas Welding Arc Welding


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Normal practiced process

Manual Metal Arc Welding MMAW

Gas Tungsten Arc Welding GTAW

Gas Metal Arc Welding GMAW

Flux cored Metal Arc Welding FCAW

Sub Merged Arc Welding SAW


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Advanced process

Narrow Gap Welding

Laser Beam Welding

Electron Beam Welding Diffusion Bonding

Friction Stir Welding

Plasma Welding Plasma Transfer Arc Technique (PTA)


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Selection of Welding process

The Type of Weld Joint

The Joint Design

The place of welding Welding Position

Type of consumables availability

The skill availability of personnel The types of equipment availability.


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WELDING CONSUMABLES

&

WELDING EQUIPMENTS.


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WELDING CONSUMABLES

The Welding consumables such as thewelding electrodes and filler wires thatare required and are recommended areas follows.

E-6013 Welding Electrodes for Weldingin MMAW process for Carbon steel,Mild steel, For the general purpose

welding applications up to thickness 18mm or 3/4th inch and does not requireany Mechanical testing or radiographyof the weld .


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For thickness over the above mentionedmust be welded with Low Hydrogen

electrodes as per AWS E 7018 or E7018-1Type of welding consumables irrespectiveof the requirement regarding the

mechanical properties..


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Welding consumables for varioussteels.

General Mild steel Up to 18mm

AWS 6013 class ER 70 SG & ER 70 S-6

General Mild steel Above 18mm

AWS 7018 class ER 70 S2 & ER 70 S-6 orER 71 T-1 Flux cored wires.


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Selection contd.

For Radiography joints

The following grades consumables are

mandatory.AWS 6013 & 7018 classified Electrodes

ER 70 S2, ER 70 S-3TIG welding filler

wires ER 70 S-6 Mig Welding continuous filler

wires.


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Consumables- gases

ER70 S-6 Solid wire for welding theGMAW (MAG) welding process

ER 70-S-2 Tig filler applications incase ofcarbon steel welding .

The use of 100 % Co2 gas for Mig welding

and 100 % pure Argon gas for TIGwelding applications are the main criteria.


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Consumables-contd

In the case of use of Low alloy steels

where C, Mo, Cr and other alloys areinvolved the creep properties areimportant and hence the matching

composition of the weld metals aremandatory


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RECOMENDATIONS

The selection of the correct weldingconsumables depends on the followingparameters

Selection of the base materials

The weldability of the steel

Selection of the welding consumables as perASME section-II- C

Welding materials that meet the standards ofASME to be used.

Acceptance of AWS or any other standardsdepends on the clients requirements.


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Consumables contd.

Welding of Stainless steels like commonlyused steels such as 304, 304L, 308L, 309,

316. and other categories such as 310,321, 347, Super Duplex Steels, therespective grade of Electrodes and the

Filler wires to be used with propershielding gases.


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Stainless steel

301,304,308 Class

AWS E 308 & 308 L grades Electrodes

and ER 308 L TIG/ MIG welding wires.

316 and 316 L

AWS E- 316 & 316 L ER 316 L TIG and MIG fillers


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SS Contd.

For 309 Grade steels

AWS E 309 Electrodes and ER 309 L Wires

Dissimilar metals of SS and SS-MSAWS 309 L and 309 MoL

ER 309 L & ER 309 MoL


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SS Contd.

Stabilized steels of 321, 347

Namely Niobium, Columbium stabilized

steels the use ofAWS E- 347 electrodes and wires of

ER 347 grade is recommended.

For other grades like 310,312, 317 therespective grades of consumables beused.


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Alloy steels

AWS class of low alloy electrodes & wires


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Other metals

Cast Iron and Steel, Monel etc

Machinable cast iron

Non Machinable


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WELDING EQUIPMENT


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TYPES OF EQUIPMENTS

Standard Type of welding Equipments

Arc Welding Transformers

D.C. Rectifiers Thyristor controlled Welding Rectifiers

Welding Invertors

TIG Welding Equipments Mig/Mag Welding machines

Sub Merged Arc Welding machines


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Advanced Welding Machines.

Electron Beam Welding machines,

Narrow Gap welding machines

Laser cutting and welding

Plasma Welding

Girth Welding Equipments.


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Under Tig Welding category we can have

DC Pulsed welding machines

AC/ Dc Tig welding machines,

AC Square wave pulsing machines


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In the category of MIG Welding we have

Pulsed Mig Welding Machines,

Inverter based Mig Welding Machines

Synergic Pulsed MIG Welding Machines

Surface Tension Transfer Machines (STT)


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Selection of the correct equipment

Selection of the right type of equipment isimportant to get the desired welding properties.

The selection decides the feasibility of the use ofthe process.

The selection should be based on the availabilityof the equipment,

The acceptance of the process

The convenience of the operation.

basics of welding eduction

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