1. Welding Inspection and Metallurgy

2. Welding Inspection and Metallurgy
Welding Processes
These 6 welding process types and their advantages and disadvantages based on intended application should be thoroughly understood prior to examination day. The following is a brief overview of;
- Shielded Metal Arc Welding (SMAW)
- Gas Tungsten Arc Welding (GT AW)
- Gas Metal Arc Welding (GMAW)
- Flux Core Arc Welding (FCAW)
- Submerged Arc Welding (SAW)
- Stud Arc Welding (SW)

3. Welding Inspection and Metallurgy
Shielded Metal Arc Welding (SMAW)
SMAW is the most widely used of the various arc welding
processes. SMAW uses an arc between a covered electrode
and the weld pool. It employs the heat of the arc, coming
from the tip of a consumable covered electrode, to melt the
base metal. Shielding is provided from the decomposition of
the electrode covering, without the application of pressure
and with filler metal from the electrode.

4. Welding Inspection and Metallurgy
Shielded Metal Arc Welding (SMAW)
Either alternating current (ac) or direct current (dc) may be employed, depending on the welding power supply and the electrode selected.
A constant-current (CC) power supply is preferred. SMAW is a manual welding process. See Figures 1 and 2 for schematics of the SMAW circuit and welding process.

5. Welding Inspection and Metallurgy
Shielded Metal Arc Welding (SMAW)

6. Welding Inspection and Metallurgy
Shielded Metal Arc Welding (SMAW)
Advantages
- Simple, inexpensive and portable
- Useable in tight places
- Less sensitive to wind and drafts than other processes
- Useable with most common metals and alloys
Limitations
- Slow welding compared to GMAW or SAW
- Cleaning problems due to slag left from electrode covering

7. Welding Inspection and Metallurgy
Gas Tungsten Arc Welding (GTAW)
GTAW is an arc welding process that uses an arc between a non-consumable tungsten electrode and the weld pool. The process is used with shielding gas and without the application of pressure. GTAW can be used with or without the addition of filler metal (Autogenous).
The Constant Current (CC) type power supply can be used with either dc or ac, the choice depends largely on the metal to be welded.

8. Welding Inspection and Metallurgy
Gas Tungsten Arc Welding (GTAW)
Direct current welding is typically performed with the electrode negative (DCEN) polarity. (Called Straight Polarity)
DCEN welding offers the advantages of deeper penetration and faster welding speeds. Alternating current provides a cathodic cleaning (sputtering) that removes refractory oxides from the surfaces of the weld joint, which is necessary for welding aluminum and magnesium.

9. Welding Inspection and Metallurgy
Gas Tungsten Arc Welding (GTAW)
The cleaning action occurs during the portion of the ac wave, when the electrode is positive with respect to the work piece. See Figures 3 and 4 for schematics of the GTAW equipment and welding process.

10. Welding Inspection and Metallurgy
Gas Tungsten Arc Welding (GTAW)

11. Welding Inspection and Metallurgy
Gas Tungsten Arc Welding (GTAW)
Advantages
- High quality welds
- Little cleaning required after welding
- Superior root pass weld penetration
- May be used for Autogenous welds (no filler metal)
Limitations
- Slow welding compared to SMAW, GMAW or SAW
- Base and filler metals must be clean and shielding gasses must be contaminant free.
- Not easy to use in drafty environments due to loss of gas shielding.

12. Welding Inspection and Metallurgy
Gas Metal Arc Welding (GMAW)
GMAW is an arc welding process that uses an arc between continuous filler metal electrode and the weld pool. The process is used with shielding from an externally supplied gas and without the application of pressure. GMAW may be operated in semiautomatic, machine, or automatic modes. It employs a constant voltage (CV) power supply, and uses either the short circuiting, globular, or spray methods to transfer metal from the electrode to the work:

13. Welding Inspection and Metallurgy
Gas Metal Arc Welding (GMAW)
The type of transfer is determined by a number of factors.
The most influential are:
a. Magnitude and type of welding current.
b. Electrode diameter.
c. Electrode composition.
d. Electrode extension.
e. Shielding gas.

14. Welding Inspection and Metallurgy
Gas Metal Arc Welding (GMAW)
Short Circuiting Transfer (GMAW-S)
GMAW-S encompasses the lowest range of welding currents and electrode diameters associated with GMAW process.
This process produces a fast freezing weld pool that is
generally suited for joining thin section, out-of position, or
root pass. Due to the fast-freezing nature of this process, there is potential for lack of sidewall fusion when welding thick wall equipment or a nozzle attachment.

15. Welding Inspection and Metallurgy
Gas Metal Arc Welding (GMAW)
Globular Transfer
This process encompasses relatively low current (below
250 A). The globular transfer mode is characterized by a drop size with a diameter greater than that of the electrode. In general, this process is limited to the flat position and can produce spatter.

16. Welding Inspection and Metallurgy
Gas Metal Arc Welding (GMAW)
Spray Transfer
The spray transfer mode results in a highly directed stream
of discrete drops that are accelerated by arc forces. Spatter is negligible. Due to its high arc forces with high current, applying this process to thin sheets may be difficult.
The thickness limitation of the spray arc transfer has been overcome by the use of pulsed GMAW. Pulsed GMAW is a variation of the GMAW in which the current is pulsed to obtain the advantage of spray transfer at the less average currents than that of spray transfer mode.

17. Welding Inspection and Metallurgy
Gas Metal Arc Welding (GMAW)
Advantages
- The only consumable electrode process that can used with commercial metals and alloys
- Weld deposition rates are much higher than SMAW
- Minimal cleaning (no slag)
Limitations
- Welding is costly and complex more so than SMAW
- Sensitive to air drafts and loss of shielding.
- GMAW-S is subject to lack of fusion

18. Welding Inspection and Metallurgy
Flux Cored Arc Welding (FCAW)
FCAW is an arc welding process that uses an arc between continuous tubular filler metal electrode and the weld pool.
The process is used with shielding gas evolved from a flux contained within the tubular electrode ( a trade name is inner-shield), with or without additional shielding from an externally supplied gas.
Normally a semiautomatic process, the use of FCAW depends on the type of electrodes available, the mechanical property requirements of the welded joints, and the joint designs and fit-up. The recommended power source is the dc constant-voltage type, similar to sources used for GMAW.

19. Welding Inspection and Metallurgy
Flux Cored Arc Welding (FCAW)
Advantages
- Metallurgical benefits from the flux
- Slag supports and forms the weld bead
- High Deposition of weld metal
- Shielding is produced at the surface giving better protection against drafts
Limitations
- Welding is costly and complex more so than SMAW
- Heavy fumes requiring exhaust equipment.
- Slag removal between passes
- Backing material is required for root pass welds

20. Welding Inspection and Metallurgy
Submerged Arc Welding (SAW)
Submerged arc welding is an arc welding process that uses
an arc or arcs between a flux covered bare metal electrode(s) and the weld pool. The arc and molten metal are shielded by a blanket of granular flux, supplied through the welding nozzle from a hopper. The process is used without pressure and filler metal from the electrode and sometimes from a supplemental source (welding rod, flux, or metal granules). SAW can be applied in three different modes: semiautomatic, automatic, and machine. It can utilize either a CV or CC power supply. SAW is used extensively in shop pressure vessel fabrication and pipe manufacturing.

21. Welding Inspection and Metallurgy
Submerged Arc Welding (SAW)
Advantages
- Very High Deposition rates
- High and consistent quality
Limitations
- High current and 100% duty cycle
- The weld is hidden by flux making it harder to control
- Equipment is costly and not very portable
- Limited to shop work in the flat position

22. Welding Inspection and Metallurgy
Stud Arc Welding (SW)
SW is an arc welding process that uses an arc between a
metal stud or similar part and the work piece. Once the surfaces of the parts are properly heated, that is the end of the stud is molten and the work has an equal area of molten pool, they are brought into contact by pressure. Shielding gas or flux may or may not be used.
SW is limited to welding insulation and refractory support pins to tanks, pressure vessels and heater casing.

23. Welding Inspection and Metallurgy
Flux Cored Arc Welding (FCAW)
Advantages
- Faster than manual welding
- All position process
Limitations
- Primarily suited for carbon and low alloy steels
- Used only in a few applications

24. Class Quiz
1. A welding process that uses a consumable electrode and whose shielding gas is generated by the decomposition of the rod covering is the process ________.
a. GMAW
b. FCAW
c. SMAW
d. GTAW
2. The welding process that is well suited to making superior root passes because of good penetration is _________.
a. FCAW
b. SAW
c. GMAW-S

25. Class Quiz
3. Globular transfer can be utilized with the ________ process.
a. FCAW
b. SMAW
c. GMAW
d. GTAW
4. The welding process in which the welding arc is not normally visible is the _________ process.
a. GMAW-S
b. SAW
c. FCAW

26. Solutions
1. A welding process that uses a consumable electrode and whose shielding gas is generated by the decomposition of the rod covering is the ________ process.
c. SMAW
2. The welding process that is well suited to making superior root passes because of good penetration is the _________.
d. GTAW
3. Globular transfer can be utilized with the ________ process.
c. GMAW
4. The welding process in which the welding arc is not normally visible is the _________ process.
b. SAW