Chapter 3 Flashcards

1
Q

Coalescence

A

Joining together of two or more metals

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2
Q

SMAW - Other Name?
Currents ?
pros ?
Cons?

A

Shielded Metal Arc Welding (SMAW) AKA - Stick welding

Currents (AC / DCEP / DCEN)

Flux

  • Shielding from electrode coating
  • Deoxidation, alloy properties
  • Insulation for weld metal for slower cooling
  • Globular transfered electrode

PROS: Simple / inexpensive /portable / small / lightweight / can weld underwater / weld most alloys /flexible / good for hard to reach areas

CONS: Slow speed / Arc blow / discontinuities / clean up of slag / manual only / not good for low temp welding

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3
Q

Slag

A

Floats on the outside of the melted weld material

solidifies after the molten metal does, so it slows down the cooling of the weld and also has a less likelihood that it will be trapped inside the weld resulting in slag inclusion

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4
Q

Electrode coating characteristics in SMAW

A

Shielding - some shielding decomposes to form a gaseous shield for the molten metal

DEIXIDATION - Flux action to remove impurities and oxygen and other gases

ALLOYING - Adds alloying elements to the weld

IONIZING - when flux becomes molten it improves electrical characteristics to increase arc stability

INSULATING - Slag is a insulating blanket that slows down the weld metal cooling rate - The thinkers the slag the better weld appearance you will have

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5
Q
Electrode Identification E XX X X
E
xx
x
x
A

E - Electrode
xx - Strength
x - Position (1=any pos / 2 = flat / 4 = downhill) 3 not used
x - other characteristics determined by the composition

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6
Q

SMAW - Electrode Identification of the X’s
- E XX X X
/\

A
1 = use in any Position  
2 = flat of horizontal for fillet welds 
3 = Not used anymore
4 = downhill progression
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7
Q
GMAW - Other Name?
Currents ? 
Metal transfer modes
pros ?
Cons?
A

Gas Metal Arc Welding - MIG welding
usually used in DCEP

Metal transfer modes
- Spray, globular, pulsed arc & short circuiting

PROS
Can be automated / little to no clean up during welding
no slag or flux / increased productivity /

CONS
not well suited for field welding / very sensitive to wind & drafts / more complex equipment / mechanical problem can arise / incomplete fusion happens often

  • Porosity doe to contamination of loss os shielding
  • Incomplete fusion due to use os short circuiting transfers on heavy sections
  • Worn liners can cause instability
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8
Q

GMAW - Electrode Identification ER XX S X

A
ER = Electrode & Rod 
XX = Strength
S    = Solid wire 
X   = Chemical composition
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9
Q

Flux Cored Arc Welding

A
  • Similar to GMAW
  • FCAW-G - Gas shielded
  • FCAW-S - Self shielded
  • Electrode is tubular and contains a granular flux instead of a solid wire used in GMAW
  • There may or may not be an externally-supplied shielding depending on the electrode used
  • shelf shielding
  • Gas used are - CO2 or 75%argon & 25%CO2
  • G & GS refer to multi pass or single pass
  • DCEP (1,2,3,4,6,9,12) or DCEN (7,8,10,11,13,14) or 5 =both
PROS
High (most) productivity / Deep penetrating arc / Can handle more metal contamination the GMAW / lack of maintenance can cause issues 

CONS
Has slag that must be produced / smoke during welding
/more complex than SMAW

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10
Q

FCAW - Electrode Identification ER XX T X

A

E = Electrode
X = Strength
X = Position* (0=flat or horizontal / 1=any position)
T = Tubular
X = Chemical / operating composition
(1,2,5,9,12 suffix Electrode require external shielding)

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11
Q
GTAW
Electrode type?
Filler material?
Gas?
Best used for ?
Currents? Details?
Pros? 
Cons?
A

Gas Tungsten Arc Welding

  • Electrode is not consumable (arc created between the tungsten electrode and the work
  • Filler metal must be added externally
    (same designation for filler as GMAW)
  • gas shielding (Aragon and helium
    (inert gas won’t combine with metal)
  • Used on a lot of aluminum because of the BALL TIP
    (less concentration of current unlike the pointy electrodes)
  • DCEP = more heating of electrode (common for steel)
  • DCEN = heat base metal more
  • AC - heats both - (good for aluminum)

PRO - can weld all metals because electrode is not consumed during welding

  • good for aluminum
  • can weld at extremely low currents
  • can weld the thinest of metals
  • good 4 aerospace, food & drug processing, petrochemical
  • High quality and visually appealing welds
  • NO SLAG due to no FLUX
  • don’t need filler material in all cases - cane use a small piece of base metal and feed by hand for filler
CON
- Slowest of weld processes 
- Low tolerance for contamination 
- req. high skill level 
- higher cost 
- Tungsten inclusions - caused by...
(contact of electrode tip to base metal of filler material 
spatter on the electrode tip / exceeding current limit for electrode diameter / over heating of electrode / improper gas / Defects on electrode)
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12
Q

GTAW - Electrode Identification
EWP
EWCe-2
EWLa-1

A

E = Electrode
W = stand for tungsten
the color coded based on allow chosen

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13
Q
SAW
Electrode type?
Filler material?
shielding?
Best used for ?
Currents? 
Pros? 
Cons?
A

Submerged Arc Welding SAW - “SUBMERGED ARC”

Continuously fed SOLID WIRE electrode (Like GMAW)
with an ace totally covered with GRANULAR FLUX distributed ahead of or around the wire

Seperat electrode & Flux so many combinations

  • Alloy electrode with neutral flux
  • Mild steel electrode with alloy flux

DC - constant voltage power source

Pro

  • Most efficient - High weld deposition
  • No need for protective clothing and eye shielding
  • Not a lot of smoke
  • Granular flux can be reused if not consumed already
  • Can be mechanized
  • Can be used on numerous metals
  • Deep penetration

CONS

  • Slag and clean up
  • Cant see the arc for alignment purposes
  • has to be used in flat or Horizontal position to a device will need to be used to hold flux
  • Need protection from moisture
  • Solidification cracking - extreme width to depth ratio
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14
Q

SAW - Electrode Identification

FXXX-EXXX

A
F = FLUX
X = Strength 
X = A (as welded) or P (post weld heat)
X = Lowest temp with impact strength 
E = Solid electrode 
X = L (low) M, H (High) Manganese content / c= composite E
X = ?
X= ?
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15
Q

PAW

A

Plasma Arc Welding

  • Very similar to GTAW (water hose analogy)
  • DC - constant voltage power source
  • Tungsten electrode (recessed) to create arc
  • Uses plasma gas forced through office resulting in constriction of arc - More force
  • more localized heat source (full penetration up to 1.2 in thick

TWO TYPES OF OPERATION
- TRANSFERED - arc between tungsten electrode and workpiece (conductive materials welding/cutting due to greater amount of heating of the workpiece)

  • NONTRANSFERED - arc between tungsten electrode and copper orifice (nonconductive materials welding/cutting)

TWO GASES REQ. - Shield gas & orifice (plasma) gas

PROS-

  • Deep penetration
  • Can use “Key Hole” welding
  • Localized heat source
  • Faster speeds than GTAW - less distortion
  • better visibly for welder due to longer standoff
  • Tungsten electrode is recessed - not as likely for inclusion

CONS

  • limited to welding 1in thickness or less
  • Cost of equipment is slightly greater than that for GTAW
  • Greater operator skill needed
  • Complex equipment
  • Inclusion caused by too high of current
    - Tungsten
    - Copper orifice melting
  • Tunneling - Keyhole is not complete filled
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16
Q

“Key Hole” Welding

A

performed on square butt joints with NO root opening

positive indication of complet penetration and weld unifomity

the concentration of heat penetrates through the material and forms a small key hole then as you move along the join is melts back together

no elaborate joint preparation needed

Fast travel speeds

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17
Q
ESW
common use?
process 
ARC?
used for 
PROS
CONS
A

Electroslag Welding

  • not as common for use
  • used for think metals placed edge to edge (vertical joints)
  • water cooled copper shoes used to cool welds
  • Welds in a single pass (bottom to top) position is considered flat sue to electrode location
  • NOT considered ARC welding
    (there is an initial arc then it goes out and the heat from the flux melts joints together
  • RESISTANCE heating of slag
  • used for CARBON STEEL

PROS

  • Can weld heavy sections
  • High (highest) disposition rate
  • Can use multiple electrodes
  • No special joint preparation
  • alignment easily maintained - no angular distortion

CONS

  • can only weld thinker materials 3/4” of thicker
  • extensive set up time
  • not good for thin metals
  • gross porosity can occur due to wet flux or pressure leak -form copper shoes
  • Gain growth due to extensive heat
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18
Q

OAW
Current / Energy
Process
Shielding

A

Oxyacetylene Welding “oxyfuel weldings”

  • Energy for weld is created by FLAME
  • CHEMICAL welding method
  • Shielding is accomplished by the flame as well
    (no flux or external shielding needed)
  • Equipment - (oxygen tank / acetylene Tank, Pressure regulators / torch )variety of tip SZ / connecting hose)
    - acetylene dissolved in liquid acetone
    - unstable at pressures over 15 PSI
    - Cylinder must remain upright
    - Fuel adjusted to produce a natural flame
    - More oxygen = oxidizing flame
    - More acetylene = carburizing Flame
  • Welding of thin metals - best for thin sections

PROS

  • Simple / Portable / small / inexpensive
  • No electricity needed

CONs
- Dangerous
- flame does not provide concentrated heat
(edge should have thin feather edge)
- Therefore assure adequate fusion
- Degraded weld properties if flame is oxidized/carburized
- Slow process
- Requires HAND FED FILLER material
- High skill lever required

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19
Q

OAW - Electrode Identification RGXX (RG45)

A
R = ROD
G = GAS
XX = Strength
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20
Q
SW
Process 
power source 
Equipment 
pros 
cons 
Shielding?
A

Stud Welding

  • ARC process - between stud and base metal
  • Used to weld studs / attachments
  • Used on many metals & many industries (bridge/building)
  • DC power source
  • Can be automated
  • Can use gas shielding for aluminum
  • Equipment - mechanical gun / power supply / control unit
    (4 cycles)

PROS
- little skill needed
- economical and effective
- eliminated need for hole drilling, tapping or other welding
- Easy to inspect (need to be flush and 360d fusion
(inspect with a hammer, pulled or torque)

CONS

  • Malfunction can produce poor welds
  • TWO possible discontinuities (caused by improper settings or water, heavy rust, or mill scale on the base metal)
    - Lack of 360deg flash
    - Incomplete fusion at interface
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21
Q
LBW?
Process?
Contact ?
Shielding?
Filler?
Details?
Energy usage?
PROS?
CONS?
A

Laser Beam Welding

  • Fusion Joining process
  • Non-contact process - no pressure required
  • Shielding can be used and filler is sometimes needed
  • High energy laser beam causes some of the metal at the joint to vaporize
  • LASER (light amplification by stimulated emission of radiation
  • Key hole welding is used
  • used for welding and cutting
  • Small cross section / small spot size at workplace though the use of reflective type focusing / very narrow and deep weld bead
  • Power level = 25 kW

PROS

  • Can be used over long distances through fiber optics and mirrors
  • Full penetration / single pass welds (up to 1 1/4in thick / 32mm)
  • Low heat input
  • 10:1 depth to width ratio (when in key hole more)
  • Focused on small areas / close components
  • Variety of metals
  • Not influenced by magnetic field
  • No vacuum / X-ray shielding required (like Electron beam)

CONS

  • Complex / expensive (100K)
  • Square butt joints required
  • work pieces often faced together
  • Fast calling rate produced cracks / traps porosity / & caused embrittlement in HAZ
  • Plume of vapors is produced - can be controlled with plasma
22
Q
EBW?
Process?
Contact ?
Shielding?
Filler?
Details?
Energy usage?
PROS?
CONS?
A

Electron Beam Welding

  • Fusion Joining process
  • Beam of high energy electrons
  • FOUR BASIC VARIABLES
    ( beam accelerating voltage / beam current / beam focal spot size / weld travel speed
  • Key hole welding is used
  • used for welding and cutting
  • Small cross section / small spot size at workplace though the use of reflective type focusing / very narrow and deep weld bead
  • Power level = 50mA-100Ma (much more than LBW

PROS

  • Full penetration / single pass welds
  • Can be moved around and in diff shapes
  • Fast travel speed
  • Low heat input
  • 10:1 or more - depth to width ratio (when in key hole more)
  • Focused on small areas / close components
  • Variety of metals

CONS

  • Complex / expensive
  • vacuum / X-ray shielding required
  • Square butt joints required
  • work pieces often faced together
  • Fast calling rate produced cracks / traps porosity / & caused embrittlement in HAZ
  • Need to be vacuumed and are evacuated
  • Takes more time to evacuate
  • Influenced by magnetic field
23
Q

RW Types

A

RSW = Resistance spot welding

RSEM = Resistance seam welding

PW = Projection welding

24
Q

RW

Process 
Used for 
Filler / Flux?
Types?
Variables?
A

Resistance welding (RW)

two electrodes apply force and hold metal in intimate contact. Current is then passed through electrodes and the workpiece

  • Heat obtained from RESISTANCE of the workpiece
  • Application of PRESSURE
  • SHEET METAL applications (1/8in thick)
  • No Filler of Flux used
  • 3 TYPES
    - RSW = Resistance spot welding (most common)
    - RSEM = Resistance seam welding
    (series of overlapping spot welds)
    - PW = Projection welding
    (dimples / projections formed / multi welds at a time)
  • Workpiece must be clean
  • Semi-automatic / fully automatic
  • Extensive use in automotive industry

VARIABLES (Welding current, welding time, electrode force, and electrode material and design)

25
Q

what is the difference between Brazing / Soldering ?

A

Brazing
- Filler Materials Mealting above 840f [450c] degrees

Soldering
- Filler Materials Mealting below 840f [450c] degrees

26
Q

Brazing / Soldering

A

Joining of metals without melting base metal
just melting filler material creates the bond that can be as strong as the base metal. This bond his due to 2 reasons
1) must have LARGE SURFACE area
2) The gap distance between the 2 metals in minimal
(max 0.010 in [0.25mm]
- Joints must be really clean
- Heat is applied using one of several heating operations
- after filler reaches melting point CAPILLARY ACTION pulls the filler into the tight spaces
- many diff. Brazing filler types

PROS

  • Can join all types of metals and some NON METAL items
  • and those that can’t be welded
  • inexpensive
  • no melt through or distortion

CONS

  • parts must be extremely clean
  • design must have sufficient surface area
  • Can have voids and unbound areas is not
  • Localized heat can cause problems like melting or erosion of BM
27
Q

CAPILLARY ACTION

A

Phenomenon which causes a liquid to be pulled into a tight space between two surfaces

28
Q

Brazing filler types

A

wires, strips, foil, paste & Preforms

29
Q

Brazing filler metal classifications

A

B = Braze
followed by the abbreviation of the most prominent chemical element included

BAg = Silver
BAu = Gold

“R” before the B means chemistry is identical to with copper and copper alloy gas welding rods

30
Q

Brazing Methods

A

TB = Torch brazing / oxyfuel flame (manual or semi auto)

FB = Furnace brazing / Controlled , many at once

IB = Induction B / placed inside induction coil to heat metal

DB = Dip brazing immersed in molten bath

IRB Infrared B = high intense infrared light source

31
Q
OFC
Process 
similar to?
fuels 
PROS 
CONS
A

Oxyfuel Gas Cutting

oxyfuel flame to heat metal to it KINDLING temperature (Steel = 1700f) then it will oxidize and burn

CHEMICAL cutting process

Almost the same as OAW - instead of welding - cutting

Fuels that can be used (Mathane (natural gas) / acetylene / propane / gasoline / methyl acetylene-propadiene (MPS)

  • consider - cost , availability, safety, cutting speed, amount of oxygen needed to burn, preheating

PROS

  • inexpensive / portable
  • shop and field application
  • cuts can be thin or thick
  • reasonably accurate
  • can cut several layers at a time with stack cutting system

Cons
- Limited to cutting carbon and alloy steel
- Additional cleaning after cut to pre edge
- HAZ - additional hardness for machining after cut
(Adding pre / post heat will help this problem)
- safety hazards

32
Q

Kerf

A

Width of the cut produced by a cutting process

33
Q

Drag

A

offset between the cut entry and the exit point, measured along the cutting edge

34
Q
CAC-A
Process 
fuels 
PROS 
CONS
A

Air Carbon Arc Cutting

Uses carbon electrode to create an arc for heating
then with high pressure steam of comprised air it mechanically removes the molten metal

  • CONSTANT current source / and compressed air
  • Uses copper jaws with holes for air to pass through
  • arc melts metal
  • Can produce gouge or cut (Uniform U groove prep)
  • Any nonflammable compressed gas can be used
  • Compressed air is the best and cheapest

Pros
- Efficient

Cons

  • Need copper electrode holder
  • Safety related
  • noisy / dirty - need PPE
  • need fire watch
  • Clean up before welding
35
Q
PAC
Process 
similar to?
fuels 
PROS 
CONS
A

Plasma Arc Cutting

  • Similar to PAW - but uses much more power
  • uses TRANSFERRED ARC due to increased heating
  • 8k-10k degrees

Pros

  • Cuts what OFC won’t
  • high quality cuts
  • increased cutting speed for carbon steel

Cons

  • Kerf is large - edges may not come out square
  • higher cost the OFC
36
Q

Mechanical Cutting

A

use of grinders, saws, shearing, turning, drilling, planning, chipping & milling

37
Q

AC

A

Alternating current

the polarity alternates at 60 cycles per second

38
Q

Alphanumeric

A

combo of letters and #’s used as designations

39
Q

DCEN

A

Straight polarity

Direct curent electrode Negative

40
Q

DCEP

A

reverse polarity

Direct curent electrode Positive

41
Q

Plasma

A

Ionized gas stream

42
Q

ferrous

A

Metals that are primarily iron based such as steel

43
Q

Flux

A

Material used to hinder the formation of oxides and other undesirable substances in molten metal and on solid metal surfaces - to resolve or remove these substances

44
Q

Reactive gas

A

gas that will combine chemical with other materials

45
Q

Slag

A

non metallic product produced from the mutual dissolution of flux and nonmetallic impurities in some welding and brazing processes

46
Q

Solid solution

A

for metals, one solid dissolving into another solid

47
Q

Tensile strength

A

LBS per Sq In (PSI)

Calculated by dividing the maximum load by the cross- section area

SI units are megapascal (MPa)

48
Q

Weld

A

Localized coalescence of metal or nonmetals

heating material to welding material

with or without use of filler metal

49
Q
SMAW ELECTRODE F GROUPS 
F1
F2
F3
F4
A

EXX20, EXX24, EXX27
EXXX2, EXXX3, EXXX4
EXX10 , EXXX1
EXXX5, EXXX6, EXXX8 (LOW HYDROGEN / PROPER STORAGE AT 250 DEG

50
Q
SMAW ELECTRODE SUFFIXES  (BE FAMILIAR)
A1
B1
B2
B3
B4
W
A
.5% MO
.5% MO ; .   5% CR
.5% MO;      1.25% CR
1.0% MO;    2.25% CR
.5% MO;      2.0% CR
WEATHERING
51
Q

Arc blow

A

CAN BE FIXED BU AC CURRENT

CAUSE BY MAGNETIC FIELD