Professional Documents
Culture Documents
Welding
Principles and Practices
Third Edition
Sacks and Bohnart
Shielded
Metal Arc
Welding
Principles
Chapter 11
1
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Objectives
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11 - 4
SMAW
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11 - 5
Process Capability
11 - 6
SMAW Advantages
11 - 7
SMAW Operating Principles
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11 - 8
Welding Process
11 - 9
SMAW Operating Principle
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11 - 10
Welding Power Sources
11 - 11
Welding Power Sources
11 - 12
Type of Output Slope
11 - 13
Output Slope
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11 - 14
Output Slope
11 - 15
Typical Output Slopes
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11 - 16
Four Types of Power Source
• Engine-driven generators
– Powered by gas or diesel combustion engine
– Can be found with a.c. or d.c. electric motor
• No longer being manufactured and rarely found
• Transformer-rectifiers
– Use basic electrical transformer to step down a.c. line
power voltage to a.c. welding voltage
– Welding voltage then passed through rectifier to
convert a.c. output to d.c. welding current
– May be either d.c. or a.c.-d.c. machines
11 - 17
Four Types of Power Source
• A.C. transformers
– Used to step down a.c. line power voltage to a.c.
welding voltage
• Inverters
– Increases frequency of incoming primary power
– Constant current, constant voltage, or both
– Produce a.c. or d.c. welding current
11 - 18
Power Sources
11 - 19
Constant Current
Welding Machines
• Used for shielded metal arc welding and gas
tungsten arc welding
– Current remains fairly constant regardless of
changes in arc length
– Called drooping voltage, variable voltage, or
droopers
• Load voltage decreases as welding current increases
11 - 20
Constant Current Output Slope
11 - 21
Constant Current
Output Slope
Some jobs require steep volt-ampere curve
Other jobs use less steep
volt-ampere curve
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11 - 22
Open Circuit Voltage
• Voltage generated by welding machine when no
welding being done
– Machine running idle
• Arc voltage
– Voltage generated between electrode and work
during welding
• Load voltage
– Voltage at output terminals of welding machine
when arc is going
– Combination of arc voltage plus voltage drop in
welding circuit
11 - 23
Open Circuit and Arc Voltage
11 - 24
Open Circuit and Arc Voltage
11 - 25
Motor Generator Welding
Machines
• Usually supply only direct current
– Can be made to supply a.c.
• Most constant current type
• Used chiefly for shielded metal arc welding
and gas tungsten arc welding
11 - 26
Motor-Generator
Welding Machine
Sturdy steel lifting eye
Large voltmeter
Calibrated dial for easy,
fine adjustment of heat
and relation between
voltage and current
Outer wheel and dial
for selecting desired
welding range
Stop button
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11 - 27
Motor-Generator
Welding Machine
Ground cable
connector
Optional steel guard
Pressed steel bearing cap
Heavy-duty ball
bearings
Arc welded copper
squirrel cage rotor
Motor stator
Heavy steel fan
Hobart Brothers Co.
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11 - 28
Motor-Generator
Welding Machine
Steel frame
Fourpole "Multi-Range"
generator
Heavy-duty metallic
graphite brushes
Large commutator
Heavy-duty ball
bearings
Pressed steel bearing cap
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11 - 29
Motor-Generator
Welding Machine
Removable steel covers
Heavy-duty single unit
steel shaft
Welding cable connector
Polarity switch
Large ammeter
Steel turret top with
removable cover
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11 - 30
Motor Generator Welding
Machine for SMAW
Instruction on the
Variable Name-plate
voltage
control
Polarity switch
Constant
voltage
The Lincoln Co.
Toggle switch
Current control
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11 - 31
External Construction of d.c. Motor
Generator Welding Machine
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11 - 32
Internal Construction of a D.C.
Motor Generator Welding Machine
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11 - 33
Motor Generator Desirable
Characteristics
• Have forceful penetrating arc
• Versatile
– Can be used to weld all metals that are weldable by
arc process
• Flexible
– With proper electrode, can be used in all positions
• Durable and have long machine life
11 - 34
Generators
Generators used
in the field
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11 - 35
Sizes
11 - 36
Maintenance
11 - 37
Start and Stop Buttons
11 - 38
Polarity Switch
• Electrode negative and electrode positive used
in d.c. welding
• DCEN (d.c. electrode negative)
– Electrode connected to negative terminal of power
source and work connected to positive terminal
• DCEP (d.c. electrode positive)
– Electrode connected to positive terminal of power
source and work connected to negative terminal
• Switch changes to either electrode positive or
electrode negative
11 - 39
Volt-Ampere Meters
11 - 41
Dual Tapped-Current Control
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11 - 44
Remote Control
11 - 45
Air Filters
11 - 46
D.C. Transformer-Rectifier
Welding Machines
• Have many designs and purposes
• Flexibility one reason for wide acceptance
– Deliver either DCEN or DCEP
• May be used for:
– Stick electrode welding
– Gas tungsten arc welding
– Submerged arc welding
– Multi-operator systems
– Stud welding
Miller Electric Mfg. Co.
The Lincoln Electric Co.
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11 - 47
Transformer-Rectifier Machines
11 - 48
A.C.-D.C. Transformer-Rectifier
Welding Machines
• Permit welder to select either a.c. or d.c. and
electrode negative or electrode positive
• Switch
– Permits welder to use only transformer part of
machine for a.c. welding
– Flipping switch then output current directed
through rectifier which converts it to d.c. welding
• High frequency arc-starting devices, water/gas
flow controls, balance controls for a.c.
operation, remote control often built into
machine
11 - 49
A.C.-D.C. Transformer-Rectifier
Welding Machines
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11 - 50
A.C. Transformer Welding
Machines
• Most popular a.c. welding machine
• Function of transformer
– Step down high voltage of input current to high
amperage, low voltage current required for welding
• Especially suited
for heavy work
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11 - 51
Advantages of a.c. Power
Sources
• Reduces tendency to arc blow
• Can use larger electrodes
– Resulting in faster speeds on heavy materials
• Lower cost
• Decreased power consumption
• High overall electrical efficiency
• Noiseless operation
• Reduced maintenance
11 - 52
D.C. and A.C.-D.C. Inverter
Welding Machines
• Portable, lightweight, and versatile
• May be either constant current, constant
voltage or both
• Can perform several different processes
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11 - 53
Cost Comparisons:
Arc Power Sources
• Three main areas
– Cost of purchasing equipment (nearly equal)
– Operating efficiency
• Motor generator machine: 52-65%
• Transformer-rectifiers: 64-72%
• Inverters: 85% See Table 11-2
– Maintenance for more comparisons
• Motor generator machine: replacing parts, lubrication
• Transformer-rectifiers and inverters have no moving parts
11 - 54
Multiple-Operator Systems
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11 - 55
Power Supply Ratings
• Standards set
– The National Electrical manufacturers Association
– Occupational Safety and Health Administration
• Provide guidelines for manufacture and
performance of power sources
• Rated by
– Current output – Efficiency of output
– Open circuit voltage – Power factor
– Duty cycle
11 - 56
Current Output
11 - 57
Open Circuit Voltage
11 - 58
Duty Cycle
11 - 59
Efficiency
11 - 60
Power Factor
11 - 62
Electrode and Work Cable
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11 - 63
Cable Core Construction
• Woven of thousands of very fine copper wire
– Greater the number of strands the more flexible
• Components
A. Wires stranded for extra flexibility
B. Paper wrapping around wires
allows conductor to slip within
robber covering when bent
C. Extra strength from open-braided
reinforcement of extra cotton cords
D. Special composition and curing of
heavy rubber covering
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11 - 64
Work Cable
11 - 65
Cable Lugs
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11 - 66
Work Clamps
Rotary
This clamp stops twisting and turning of
type
welding cable where work rotates. Clamp
welded to part, thus permits work clamp to be
Lenco dba NLC. Inc.
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11 - 67
Quick Connector
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11 - 68
Metal Electrode Holders
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11 - 69
Metal Electrode Holders
11 - 70
Spring Type Electrode Holder
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11 - 71
Short-stub Electrode Holder
Entirely insulated
Holds electrodes burned to very short stub.
Lifeguard insulation Twist-type locking device permits electrode-
gripping power in excess of 2,000 pounds.
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11 - 72
Angle-head Electrode Holder
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11 - 73
Other Electric Arc processes
11 - 74
Carbon Arc Welding
11 - 75
Twin Carbon Electrode Holder
Metal shield to protect welder's
Two leads are hand from intense heat.
required because
the arc is created
between the two
electrodes.
Larger than the The Lincoln Electric Co.
metal electrode
holder
Holder is water cooled
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11 - 76
Atomic-Hydrogen Arc
Welding
• Process in which electric arc surrounded by
atmosphere of hydrogen
– Gas shields molten metal from oxidation and
contamination from the air
– Transfers heat from electrode to work
– Arc formed between two electrodes
• Temperature produced by arc: 7,500ºF
• Current supplied by a.c. welding transformer
• Hydrogen supplied in cylinders
11 - 77
Atomic-Hydrogen Electrode
Holder
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11 - 78
Atomic-Hydrogen Arc
Welding
• Metal of same analysis as being welded can be
deposited
• Welds may be heat treated
– Unusually smooth, ductile, nonporous and free
from impurities
– Surface free from scale
• May weld hard-to-weld metals
• Advantages: increased production, low
operating cost, and low maintenance cost
11 - 79
Hand and Head Shields
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11 - 80
Hand and Head Shields
protection
Fibre-Metal Products Co.
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11 - 81
Hand and Head Shields
• Constructed of heat-resisting, pressed-fiber
insulating material
• Shields fully molded at top and bottom to
protect head and neck
• Usually black to reduce reflection with
window frame to hole protective lens Fibre-Metal Products Co.
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11 - 82
Head Shield Lens
• Sizes: 2 x 4.5 or 4.5 x 5.25
• Colored to screen out ultraviolet, infrared rays,
and most of visible rays
• Variety of shades of color
– Density depends on brilliance of arc
– Varies with size of electrode and volume of current
• Side exposed to weld pool protected by clear
polycarbonate plastic cover lens
– Protect costly filter lens from molten metal spatter
and breakage (replaced when pitted and clouded)
11 - 83
Auto-darkening Electronic
Filter Helmet
• Useful when working close
quarters,
. doing high production
work, or avoiding inadvertent arc
strikes
• Single shade or variable shades
• Filter can switch from light to
dark in less than 1/10,000 of a
second
Jackson Products Co. • Battery powered
– May have solar battery booster
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11 - 84
Safety Glasses
• Should be worn
– Also behind hood to prevent severe arc
flash reaching eyes
• Can Absorb more than 99.9%
harmful ultraviolet rays
• Worn by others who work with
welders
• Light in weight, well ventilated, and
comfortable
• Lenses have light tint (Not dark!)
and tented side shields
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11 - 85
Protective Clothing
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11 - 86
Protective Clothing
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11 - 87
Protective Clothing
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11 - 88
Further Protection
• Ear Protection
– Full ear muffs that cover entire ear or ear plugs
– Dangers
• Noise
• Hot weld spatter or slag entering ear canal
• Flume Protection
– Always use proper ventilation to keep head out of
fume plume
11 - 89