esab training ppt-gunnebo

7/23/2019 Esab Training Ppt-gunnebo

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ESAB India

Your partner for welding

•Employs around 750 persons

•ESAB is represented in almost every part of the country

•Sales and support is established every industrial location

•5 manufacturing plants•Sales regions:

!orth

South

East

"est #entral



Taratala (Kolkata)Taratala (Kolkata)

Sriperumbudur (Chennai)Sriperumbudur (Chennai)

ESAB IndiaEquipment production centers



ESAB IndiaEquipment sales offices

New Delhi

Mumbai

Kolkata

Chennai

Napur



Process usageestimate 2010



Joining of Two metals by theapplication of Heat.

HEAT generation by thefollowing methods :- CHEMICALCHEMICAL

ELECTRICALELECTRICAL FRICTION FRICTION

ELECTRO-MAGNETIC ELECTRO-MAGNETIC



CHEMICALCHEMICAL Oxy-Fuel Combustion - Gas Welding Oxy-Fuel Combustion - Gas Welding

ELECTRICALELECTRICAL

Elet!i A! -Elet!i A! - A! Welding A! Welding

Lase! Welding Lase! Welding

"lasma Welding "lasma Welding

FRICTION FRICTION F!ition Welding F!ition Welding

F!ition #ti! Welding F!ition #ti! Welding

ELECTRO-MAGNETIC ELECTRO-MAGNETIC Magneti Welding



MMAW / SMAW PROCESS

i$ This is a group of processes in which the heat required forfusion is generated ! the electric arc for"ed etween a "etallic

electrode and the ase "etal# The electrode is consu"ed in the

arc and pro$ides the filler "etal for the %oint#

ii& Electric arc was disco$ered ! Sir 'u"phre! (a$! in

)*+)#iii& Oscar ,%ellerg of Sweden is credited with eing the pioneer

of "odern coated arc welding electrodes# -n ).+0 he was

granted a patent on co$ered electrodes# 1! ).+ first

welding generator was introduced in the 2#S# "ar3et#

i$& The electric arc is an ideal source of welding heat#

$& A"ong the arc processes MMAW is the "ost co""on0

$ersatile and ine4pensi$e one and accounts for o$er 5+6 of the

total welding in ad$anced countries and o$er .+6 of the total

welding in -ndia#



SETTIN !" #E$%IN &'((ENT

E$E&T(!%E %IA ) *+ , (E &'((ENT&'((ENT

E%E (EA(ATI!N/J!INT %ESIN/JI 0"I)T'(E T! (E%'&E %IST!(TI!N



T'E WE7(-89 ARC

A welding arc is the passage of electricit! across a gap etween an

electrode and the parent "etal or wor3#

Arc length is related to arc $oltage#



Common Welding Power

Sources Transformer – AC In AC Out

Conventional Rectier! AC In "C

Out Inverter #ased Rectier – AC In "C

Out



Choice of technolo!

Mains suppl!"eldin machine

Diode control "eldin machine

Thyristor control

"eldin machine

Inverter control

Moving core#ood weld

characteristics$

But no remote

Saturable reactor%emote possible$

But compromises

on weld qualit!

Auto select function

&'%&

(ull function control

Analo or Diital

"ith or "ithout )(C

CC or C* or both

"eldain output

Mo+in core&'%&

Maamp,h!ristorised

&'%&

(ull! th!ristorised

Normal reliabilit!

&'%&

-ih reliabilit!

.//m cables 01m cables

1/ or .//m

cables



Equipment for every arc welding process



Common Welding

Processes $anual $etal Arc Welding

%$$AW& $etal Inert 'as($etal Active

'as %$I'($A'& Welding Tungsten Inert 'as %TI'&

Welding Su)merged Arc Welding %SAW&



Product process

trainin

MIG/MAG

(also called Gas Metal Arc Welding)

C*

t!pe



'$AW %$I'&

Sim*le *rocess to learn fast welding s*eeds *ossi)le

cleaner welds wit+ no slags

same e,ui*ment used for -u. cored welding

all *osition ca*a)ilities *rovides greater control over t+inner material

/CAW%/lu. cored Arc welding

Preferred for rust surface

Out of *osition welding *ossi)le

"ee* *enetration for welding t+ic sections

Im*roved metal de*osition

'as or gasless ca*a)ilities



Advantages Of $I'Welding

The 1I /1A welding process pro2ides many ad2antages inman3al and a3tomatic metal 4oining for both low and highprod3ction applications. Its combined ad2antages whencompared to 11A# 5TI 0 SA# :

2 #elding can be done in all positions.

2 No slag remo2al re63ired. High weld metal deposition rate.

2 !2erall times for weld completion abo3t 7/8 that of co2eredelectrode.

2 High welding speeds. $ess distortion of the wor9piece.

2 High weld 63ality.

2 $arge gaps lled or bridged easily5 ma9ing certain 9inds ofrepair welding more e;cient.

2 No st3b loss as with co2ered electrode.


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"!oess $a!iables % GMAW

:AR-A17ES (ESCR-PT-O8

Welding Current 'as a non;linear relationship with electrode feed speed or"elting rate

Polarit!<Straight /Re$erse&

(CE8 = (irect Current Electrode 8egati$e or StraightPolarit!

(CEP = (irect Current Electrode Positi$e or Re$ersePolarit!

Arc :oltage An appro4i"ate "eans of starting the ph!sical arc length

Tra$el Speed The linear arc rate at which the arc is "o$ed along the weld %oint

Stic3 Out The distance etween the end of the electrode and thecontact tue

1urn 1ac3 A ti"e dela! etween wire feed unit starts to ra3e the wireuntil the power unit shuts off the welding current

Electrode(ia"eter

'igher electrode dia"eter requires higher current thanco"parati$el! s"aller dia"eter electrodes and produce

higher weld deposition

Shielding 9as Shields the "olten "etal fro" at"ospheric contact


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&u!n &a'

W(at is t(e signi)iane o) &u!n

&a' time*

I$ the burn back time is too short it

leaves a long piece o$ $iller %irepro&ecting a$ter %elding has stopped'

%ith resulting risk o$ the %ire $reeing

into the solidi$ying %eld pool

I$ the burn back time is too long it

reduces the stick out to such an e*tent

that there is a risk o$ the arc striking

$rom the %elding gun contact tip %hen

%elding is ne*t started

Stic3 out

Ti"e


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#(ielding Gases used in GMAW

#(ielding Gases +!o,ide a

s(ielding to t(e eld metal )!om

t(e atmos+(e!i ontat and (a,e

a +!onouned e))et on

• A! (a!ate!istis

• Mode o) metal t!ans)e!

• "enet!ation and eld bead +!o)ile

• #+eed o) elding

• .nde!utting tendeny

• Cleaning ation

• Weld metal me(anial +!o+e!ties

Ty+es o) s(ielding gases

used in GMAW a!e

• Ca!bon /ioxide 0CO 1 2

• A!gon

• Helium

• Oxygen

• Mixtu!es o) abo,e Gases



ate6Month67ear 5.

Shielding gases GMAW •1ild Steel:•7++< &!8

•Argon = >?8+< &!8

•Stainless steel:•Argon = 8< &!8

•Argon = 8< !8

•Al3mini3m:

•Argon•Argon = Heli3m

.//9 C'5 ma! need a heater



55

"oe! #ou!e C(a!ate!istis % GMAW

C2RRE8T0 A

:

O 7 T A 9 E 0 :

Constant $oltage C(a!ate!istis

T(e GMAW "oe! #ou!e s(ould (a,e a /!oo+ing C(a!ate!istis3

W(en elding is in +!og!ess t(e !elation beteen t(e Welding $oltage 0$2 and

t(e Welding Cu!!ent 0I2 is ex+!essed by t(e )olloing mat(ematial )o!mula

$ 4 56 7 8389 I



PARAMETERS (ESCR-PT-O8

Arc :oltage -t is the electrical potential etween the electrode and the wor3;piece

Slope Measured at two stale arc conditions of the C: characteristics

-nductance The inductance in the circuit controls the rate of current rise and in turn thepinch effect#

WELDING PREPRATION- GMAW

The GMAW Poer !o"rce sho"ld ha#e a Droo$ing %haracteristics&

When elding is in $rogress the relation 'eteen the Welding oltage () and the Welding%"rrent (I) is e$ressed '* the +olloing ,athe,atical +or,"la

. 0 1&12 I



5:

E#A& GMAW "!odut Range

/iode based GMAW

• MIGMATIC 198

• MIGMATIC 688

• "OWER COM"ACT 199

T(y!isto!ised GMAW

• A.TO : 688

• A.TO : ;88

In,e!te! based GMAW

• E#A&MIG <88i = C<88i

• ARI#TOMIG <88 = C<88 • ARI#TOMIG 688 = .688

• ARI#TOMIG 988 = .988



Principle o$ Material Trans$er

MI#6MA# weldin is performed in two wa!s

dependin on the transfer of the metal;

S)%A7 ,%ANS(E% "E<DIN#

'%

DI) ,%ANS(E% "E<DIN#



5=

Wire feed speed = welding current

Increased current (= wire feed speed) gives deeper penetration



ate6Month67ear 53

Voltage, MigMag

Increasing the voltage

• increases the arc lenth

• produces a hotter$ wider weld pool• reduces the short&circuitin frequenc! when

usin short&arc weldin >?larer droplets@• produces more spatter8

Too lo% a voltage produces a tendency to

spatter8

+hen %elding thin sheet materials' short,arc %elding $acilitates high production speeds

%ithout burning through the material -or such applications' use a lo% arc voltage

setting' %ith stable arc (use a high short,circuiting $re.uency)

-ih *oltae Medium *oltae <ow *oltae

<on arc lenth Medium arc lenth Short arc lenth

weld profile butt weld

weld profile fillet weld

"ith constant wire feed speed



ate6Month67ear 54

!ontact tip"to"

wor# distance$%Stic# &ut'(• If the welder lifts the torch5 the arc

length will remain constant b3t thewire stic9 o3t length is increased

• As we 3se a constant 2oltage

power so3rce5 2oltage will not bechanged

• Instead the c3rrent decreases:

• heat inp3t and penetration willdecrease

• If both wire feed speed and stic9o3t is increased:

• higher deposition rate will beachie2ed with the same c3rrent



ate6Month67ear 0/

)nductanceInductance affects MI#6MA# weldin when

short arc weldin8When welding with spray arc inductance influences only

the start.

/o% inductance0

• a distinct and concentrated arc

• somewhat more spatter

• for weldin thin wires and low currents

1igh inductance0

• softer arc• hotter process

• pool spreads somewhat better

• used for thicker wires

too high inductance results in fewer short circuits,

unstable arc and sputtering tendencies at low arc

voltages

/o% Medium 1igh



0.

*S+ torch construction

9as no>>le

Tip adaptor

Contact tip

Swan nec3

Current connector

-solation

W ldi t h f t



05

Welding torch frontend parts

•%earn to identify parts &

correct assembly

• #hec' front end parts

• #lean periodically

• %earn no((le cleaning and liner

replacement procedure



00

!hoose the right contacttip

Si(e of electrode

)ecommended no((le opening

Short arc#*+

Spray arc Ar,#*+ or pure Ar

!o((le -iff. !o((le -iff.0/ 0/1 0/+ 0/2 0/3

0/1 4/0 0/+ 4/4 0/3

4/0 4/+ 0/+ 4/5 0/54/+ 4/5 0/3 4/7 0/5

4/ 4/2 0/3 +/4 4/2$ 0/5



ate6Month67ear 0:

Wire feed unit " rollers

/eed roller t*es

• "eed rollers m3st s3it the wire diameter in 3se.

• (ollers are groo2ed for two or more di@erent wire diameters.

T3rn roller 7+ degrees for other groo2e.

• B type rollers for harder mild steel5 stainless and cored wires

• BC type rollers are for cored wires DB groo2e5 9n3rled

• ' type rollers for softer Al3mini3m wires



ate6Month67ear 01

•Electricit!

•Electromanetic fields

•*$I% and +isible liht radiation

•Air pollution

•(ire and Spatter

• Noise

•Eronomics

T+e welder3s woringenvironment

"elders are members of an occupational roup which is eposed to a

number of difrrent en+iromental problems

2$$ective protection can reduce the health risk



ate6Month67ear 0

4lectricit

Ris of electric s+ocs

• The le2el and d3ration of

the c3rrent• The c3rrent path thro3gh

the body

• The fre63encey of thec3rrent

-uman beins are etremel! sensiti+e to current that passes throuh thier bodiesSeriuos inur! can be caused b! curremt of ust 5/ to 0/ mA



ate6Month67ear 0=

Welding e,ui*ment

2! 34567,"

'pen circuit +oltae

DC Ma ..0*

AC Ma 3/ * rms



ate6Month67ear 03

567IR and visi)le lig+tradiation

• Eye damage

• S9in damage

• Thermal radiation

,he diffrent weldin methods i+e diffrent le+elof radiation

Mi6Ma

MMA

,i



ate6Month67ear 04

Air *ollution! /ume

"eldin fumes are a result of the +aporisation and oidation of different substancesIn the arc which is caused b! hih temperature

Material safet! data sheet are a+ailble for

each product specif!in the le+el and

conatent of the fume



ate6Month67ear :/

/ire and s*atter



ate6Month67ear :.

8oise



4rgonomics"hen weldin hea+! material manuall! and durin assembl! weldin

the loads are +er! static8 )ositionin weldin also i+e hih load8

esab training ppt-gunnebo

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