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SMAW Shielded Metal Arc Welding. OFW/OFC OXY FUEL WELDING OXY FUEL WELDING OXY FUEL CUTTING OXY FUEL CUTTING.

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Presentation on theme: "SMAW Shielded Metal Arc Welding. OFW/OFC OXY FUEL WELDING OXY FUEL WELDING OXY FUEL CUTTING OXY FUEL CUTTING."— Presentation transcript:

1 SMAW Shielded Metal Arc Welding

2 OFW/OFC OXY FUEL WELDING OXY FUEL WELDING OXY FUEL CUTTING OXY FUEL CUTTING

3 Purge To blow or clean out the lines on the Oxy/Acetylene setup To blow or clean out the lines on the Oxy/Acetylene setup

4 Flux Powdered coating around the electrode used in SMAW process. Powdered coating around the electrode used in SMAW process. 1) Cleans metal/weld while welding 1) Cleans metal/weld while welding 2) Cools Metal/weld/electrode while welding 2) Cools Metal/weld/electrode while welding 3) Stabilizes the arc while welding 3) Stabilizes the arc while welding 4) Keeps out atmospheric gases from the molten puddle 4) Keeps out atmospheric gases from the molten puddle

5 Electrode Flux covered conductive rod used as filler in the SMAW process Flux covered conductive rod used as filler in the SMAW process

6 Slag Protective coating over completed weld made up of burnt flux, impurities that have rose to the top of weld which aid in the cooling process. Protective coating over completed weld made up of burnt flux, impurities that have rose to the top of weld which aid in the cooling process.

7 Crater Indentation in the weld (below base metal) usually happens at the end of the weld Indentation in the weld (below base metal) usually happens at the end of the weld

8 Arc Length Distance between the tip of the electrode and the base metal. Also known as Arc Gap. Distance between the tip of the electrode and the base metal. Also known as Arc Gap. Long Arc = large Gap Long Arc = large Gap Short Arc = Small Gap Short Arc = Small Gap Shorter the Gap = Cooler the Arc Shorter the Gap = Cooler the Arc Longer the Gap = Hotter the Arc Longer the Gap = Hotter the Arc

9 Rod Angle Angle the electrode is held from the base metal Angle the electrode is held from the base metal 1)Base Angle (BA) 1)Base Angle (BA) 2)Direction of Travel Angle (DOTA) 2)Direction of Travel Angle (DOTA)

10 Porosity Gas Pocket in/on the weld that is a defect in the weld. Gas Pocket in/on the weld that is a defect in the weld. Long arc will cause Long arc will cause Dirty base metal Dirty base metal Broken flux from the rod. Broken flux from the rod.

11 Fusion Combining or joining of two materials Combining or joining of two materials

12 Penetration Depth of Fusion Depth of Fusion

13 Ductility Ability of metal to be bent or stretched without breaking Ability of metal to be bent or stretched without breaking 1) Rolled 1) Rolled 2) Bent 2) Bent 3) Stretched 3) Stretched

14 Alloy What metal is made up of (Elements) What metal is made up of (Elements) 1) Periodic Table 1) Periodic Table Zinc Zinc Magnesium Magnesium Iron Iron

15 Flashback/Backfire Hissing or Popping sound from tip of torch caused by gas and flame going back into the tip. Hissing or Popping sound from tip of torch caused by gas and flame going back into the tip. 1) Tip to close 2) Dirty Tip 3) Malfunction of equipment

16 Amps The measure of Electrical Flow The measure of Electrical Flow 1) electrons traveling 1) electrons traveling 2) Water running out of a garden hose would be compared to Amps 2) Water running out of a garden hose would be compared to Amps 3) Water Flow/Electrical Flow 3) Water Flow/Electrical Flow

17 Volts Measure of Electrical Pressure Measure of Electrical Pressure 1) Force of electrons 1) Force of electrons 2) Compared to your finger over a running garden hose to generate more pressure. 2) Compared to your finger over a running garden hose to generate more pressure. 3) water pressure/Electrical pressure 3) water pressure/Electrical pressure

18 Puddle Molten metal that follows the electrode, this solidifies to create the weld. Molten metal that follows the electrode, this solidifies to create the weld.

19 Arc Flash/Flash Burn Dangerous lights produced during Arc Welding that damage your eyes/skin if not protected with shaded/filtered lens or protective clothing. Dangerous lights produced during Arc Welding that damage your eyes/skin if not protected with shaded/filtered lens or protective clothing. Dangerous lights: Ultraviolet/Infrared Dangerous lights: Ultraviolet/Infrared Arc Flash: Burns unprotected eyes Arc Flash: Burns unprotected eyes Flash Burn: Burns unprotected skin Flash Burn: Burns unprotected skin SMAW <125 amps shade 10 SMAW <125 amps shade 10

20 Flash/Arc Burn Ultraviolent/Infrared Light

21 Butt Joint

22 Corner Joint Outside Inside

23 Edge Joint

24 T Joint

25 Lap Joint

26 Electrode #’s Tensile Strength 60 = 60,000 psi 70 = 70,000 psi 80 = 80,000 psi 90 = 90,000 psi Welding Position 1 = All Positions 2 = Flat/Horizontal 3 = Flat Only Special Characteristics 0 = Deep/DC + / Fast Freeze 1 = Deep/AC/DC + / Fast Freeze 3 = Shallow /AC/DC+/DC- 8 = Medium / AC/DC+/Low Hydro

27 E Electrode X 1000 lbs sq inch Tensile Strength Position Special Characteristics Current Type Flux Characteristics Metal Type Penetration

28 E Electrode 60,000 psi All Position Special Characteristics Deep Penetration Cellulose Potassium flux Fast Freeze AC/DC+ (current)

29 E ,000 psi All Position Electrode Special Characteristics Deep Penetration Cellulose sodium flux Fast Freeze DC+ (current)

30 E ,000 psi All Position Electrode Special Characteristics Medium Penetration Iron Powder Low Hydrogen flux AC/ DC+ (current)

31 E ,000 psi All Position Electrode Special Characteristics Shallow Penetration Titania Potassium flux AC / DC+ / DC - (current)

32 Electrode #’s Quiz Slide Tensile Strength 60 = 60,000 psi 70 = 70,000 psi 80 = 80,000 psi 90 = 90,000 psi Welding Position 1 = All Positions 2 = Flat/Horizontal 3 = Flat Only Special Characteristics 0 = Deep/DC + / Fast Freeze 1 = Deep/AC/DC + / Fast Freeze 3 = Shallow /AC/DC+/DC- 8 = Medium / AC/DC+/Low Hydro E Electrode 80 80,000 psi tensile strength 2 Flat/Horizontal Position 1 Fast Freeze Deep Penetration AC/DC + E Electrode 60 60,000 psi tensile strength 3 Flat Position Only 8 Low Hydrogen Flux Medium Penetration AC/DC +

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35 B. Welding Procedures (Cont.) b. A tapping movement is where the electrode is quickly tapped on the surface of the metal to prevent it from sticking to the base metal. b. A tapping movement is where the electrode is quickly tapped on the surface of the metal to prevent it from sticking to the base metal.

36 4 Things Required for a Good Weld Amp Setting : Heat and (proper current type) Amp Setting : Heat and (proper current type) Travel Speed Travel Speed Rod Angle: (Base Angle/Direction of Travel Angle) Rod Angle: (Base Angle/Direction of Travel Angle) Arc Length: Gap Should Equal Diameter of Electrode Arc Length: Gap Should Equal Diameter of Electrode

37 B. Welding Procedures (Cont.) 8. There are two methods used in starting the arc. 8. There are two methods used in starting the arc. A striking movement is similar to striking a match. A striking movement is similar to striking a match.

38 Welding Positions Flat Flat Horizontal Horizontal Vertical : V Up/V Down (v up Gives deeper penetration) Vertical : V Up/V Down (v up Gives deeper penetration) Overhead Overhead

39 Flame Types

40 Oxygen Odorless Gas Odorless Gas Colorless Gas Colorless Gas Line Colors Green Line Colors Green Right Handed Threads on Fittings Right Handed Threads on Fittings

41 Types of Combustible Gases 3 types commonly Used for Fuel in Oxy/Fuel Welding and Cutting 3 types commonly Used for Fuel in Oxy/Fuel Welding and Cutting Acetylene Acetylene Propane Propane Mapp Gas (methylacetylene-propadiene propane) Mapp Gas (methylacetylene-propadiene propane)

42 acetylene Colorless Gas Colorless Gas Garlic Odor Garlic Odor Unstable after 15psi Line Pressure Unstable after 15psi Line Pressure Absorbed into Acetone (cork) to allow higher pressures in Tank Absorbed into Acetone (cork) to allow higher pressures in Tank Red Colored Hoses w/ Left Handed Threads Red Colored Hoses w/ Left Handed Threads

43 Duty Cycle The amount of time a welding machine can be operated continuously The amount of time a welding machine can be operated continuously 70% Duty Cycle= 70% of an hour 70% Duty Cycle= 70% of an hour 70% Duty Cycle = 7 minutes every 10 min 70% Duty Cycle = 7 minutes every 10 min

44 Polarity DC+DC- DC+DC- DCEPDCEN DCEPDCEN Reverse PolarityStraight Polarity Reverse PolarityStraight Polarity


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