metal fabrication introduction to common welding and cutting processes 2015
TRANSCRIPT
Metal Fabrication
Introduction to common welding and cutting processes
2015
Choosing the best weld process gas
Why do we need a weld process gas?- Protects the weld pool- Assists in stabilising the arc- Assists in metal (droplet) transfer
(MIG/MAG)- Helps maintain metallurgical
properties of the material
Also…- Influences productivity - Influences weld quality- Influences the working
environmental
MIG/MAG
TIG
02_EN_M_Mar_2015
MIG/MAG Welding
Metal Inert Gas (MIG)
• Inert the process gas DOES NOT react with the weld material
Metal Active Gas (MAG)
• Active the process gas DOES react with the weld material
Ar
Ar
CO2
O2
H2
N2
Can be 100% CO2
Mixture of one or more of these gases in an inert base gas
He
He
MIG/MAG Welding Equipment
MIG/MAG Welding
Welding wire(electrode)
Contact tip
Weld
Parent Material
Weld process gas
Gas shroud
MIG/MAG Welding
Example of welding
TIG Welding
Tungsten Inert Gas
• Inert the process gas DOES NOT react with the weld material
Ar
• Active the process gas DOES NOT react with the weld material
H2
Mixture (up to 5%) in an inert base gasTAG terminology not used
Ar
He
He
TIG Welding Equipment
TIG Welding
Filler material
Weld
Parent material
Weld process gas
Tungsten electrode
Gas shroud
TIG Welding
Summary MIG/MAG & TIG
• Independent input of filler wire ...
• Requires a skilled operator
• Non-consumable electrode process
• Lower productivity / higher quality than MIG/MAG
• Semi-mechanized / robotic welding possible but not as common as in MIG/MAG
• Automatic feeding of filler wire
• Easy to use & highly productive
• Consumable electrode i.e. filler wire is the electrode
• Semi-mechanized / robotic welding (common)
• Can generate spatter - may require post-weld cleaning (time = cost)
TIGMIG/MAG
• Definition:Light Amplification by the Stimulated Emission of Radiation: LASER
• Laser Cutting is fast and precise
Laser Cutting
Laser Cutting
• Laser Gases (resonator gases – CO2 lasers
only)- Typically used for the laser beam either as a
premixed cylinder or as individual cylinders
- Low flow rates – small volumes
• Process assist gases (all laser types)- To assist in the removal of metal from the cut
area
- High pressures, high flow rates
CO2
N2
O2
N2
Carbon steel
Stainless steel
He
O2
N2
Ferrous materials: carbon steel
Ar
Non Ferrous: stainless steel (and aluminium)
Reactive materials such as titanium
Air Low cost – low-quality alternative
Laser Cutting – process assist gases
• Similar to TIG Welding
• Non-consumable Tungsten electrode
• Used a constricted plasma-arc created by an additional water cooled
plasma nozzle
• Electrode protected inside the torch
TIGPLASMA
Plasma Arc Welding
Plasma Arc Welding
Two distinct gas streams
• Plasma gas is inert the gas DOES NOT react with the weld or the tungsten electrode
Ar
• Weld process gas similar to TIG can be inert or active the process gas DOES react with the weld material
H2
Mixture (up to 15%) in an inert base gas
Ar
He
He
Plasma Arc Welding
Tungsten electrode
Gas shroud
Plasma gas
Nozzle
Weld
Weld process gas
Plasma Arc Welding
• Electric arc is the heat source
• Specialised welding process
• Independent input of filler wire but protected electrode and easy arc starting ... more suitable than TIG for automation
• Uses a plasma and a weld process gas (inert / active-reducing)
• Non-consumable electrode process
• Mechanized / robotic welding common
• Common problem – no problems but relatively expensive and complex torches vs. TIG
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