MANUAL WELDING PROCESSES
Gas welding
Manual metal arc welding
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Brief description
Brief description
The heat source is a flame which is produced with the acetylene (C2H2) fuel
gas and oxygen (O2). The gases flow through the welding torch in a volume
ratio of 1:1. After ignition, chemical reactions of these gases with each other
produce a flame which exhibits a reducing flame zone closely behind the
flame cone. The maximum temperature is 3,200°C. Acetylene constituents
are burned completely in the flame envelope with 1.5 parts of atmospheric
oxygen in addition. The welding flame is guided along the groove and
completely melts the areas to be joined. At the same time, a welding rod
(welding filler) is introduced into the molten zone by hand and fills the
welding groove when it melts off. The flame zone exerting a reducing effect
envelops the weld pool until it solidifies and protects it from the influence of air.
The heat source is an arc which burns between a covered stick electrode
(welding filler) and the workpiece. The arc melts the base material
completely (at temperatures above 5,000°C). At the same time, the core
rod (frequently mild steel) and covering of the stick electrode melt off in
the form of droplets. The covering consists of mineral substances and/
or cellulose. It has the tasks of improving the conductivity of the arc gap,
of protecting the weld pool from the ingress of air by forming gases and
slag and of incorporating the required alloying elements into the weld pool.
The type of covering substances also has an influence on the welding
behaviour with regard to the welding current type, the droplet size, the
weld pool viscosity, the welding position and the slag removability. The
stick electrode covering is selected according to the welding task.
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Areas of application
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Areas of application
Universal joint welding in all positions on thin-walled sheets and pipes
made of alloyed and mild steels with thicknesses up to 6 mm; preferably in
pipeline construction, bodymaking and in the installation field as well as for
repair welding work; due to the separately controllable complete melting of
the base material and the melting-off of the welding rod, it can be used for
the manufacture of defect-free welds even in the event of imprecise weld
preparation.
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Mild and alloyed steels, sheets, sections and pipes; workpiece thickness
as from 3 mm in all positions, even in building site conditions; in metal,
pipeline and tank construction, mechanical engineering as well as metalworking plants.
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Typical welding data
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Typical welding data
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Gas consumption:
Deposition rate:
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Stick electrodes:
approx. 100 l/h of acetylene and oxygen per
mm of workpiece thickness (the consumption
of gases is dependent on the flame size)
Ø 2.0 - 2.5 - 3.2 - 4.0 - 5.0 mm,
length: 250 – 450 mm
Welding current:
amperage according to the data
from the manufacturer
up to 0.5 kg/h
Deposition rate:
up to 3.5 kg/h
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Oxygen cylinder with pressure regulator
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Acetylene hose
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Welding nozzle
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Mains connection
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Welding power return lead
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Workpiece clamp
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Acetylene cylinder with pressure regulator
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Welding torch
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Welding flame
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Welding power source
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Stick electrode holder
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Workpiece
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Oxygen hose
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Welding rod
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Workpiece
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Welding power supply lead
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Covered stick electrode
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Arc
Gas-shielded metal arc welding
Brief description
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The welding installation consists of the welding power source, the shielding
gas supply, the wire feed device, the control unit and the hose package
with the welding torch. The shielding gas, the welding current and, as the
welding filler, a wire electrode are supplied to the welding torch through the
hose package. The welding current is conducted into the wire electrode
via a sliding contact in the contact tube of the welding torch. This results in
an arc visibly burning between the electrode and the workpiece. The wire
electrode melts off in the form of droplets. The supply of the welding current
immediately in front of the arc makes it possible to apply a high amperage
to the wire electrode (e.g. a wire electrode with a diameter of 1.0 mm and a
current-carrying capacity of 40 220 A). Both thin and thick cross-sections
can thus be joined in a defect-free and economically viable way. When
non-ferrous metals are welded, the weld pool is protected from the ingress
of air by inert shielding gases (noble gases such as argon or helium). The
process is then called metal inert gas (MIG) welding. Active shielding gases
(carbon dioxide or mixtures consisting of argon and carbon dioxide and/or
oxygen) are used when mild and alloyed steels are welded. The process is
then called metal active gas (MAG) welding.
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Areas of application
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Areas of application
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Mains connection
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Welding power source
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Wire electrode spool
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Shielding gas cylinder with pressure regulator
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Shielding gas hose
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Hose package
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Welding power return lead
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Workpiece clamp
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Welding torch
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Arc
T H E
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Typical welding data
Wire electrode:
common Ø 0.8 – 1.0 – 1.2 – 1.6 mm
wire feed speed: up to 15 m/min
Welding amperage:
up to 460 A with a wire electrode diameter of
1.6 mm, direct current or alternating current
Deposition rate:
W E L D E R ’ S
Typical welding data
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up to 7 kg/h
12.03.02_ABi_Anz_Poster_Schweißverfahren_115x55mm_Layout 1 02.03.12 17:22 Seite 1
F O R
Mild and alloyed steels, aluminium, copper, titanium and nickel materials
as well as other non-ferrous metals; can be used in all positions; on
components with thicknesses between 0.5 mm and 5 mm (in the case of
thicker workpieces, only the root layers are executed with this process);
utilisation in aerospace technology, precision mechanics, apparatus and
boiler construction as well as installations for the food sector. The shielding
gas coverage is disturbed by side wind. Therefore, welding cannot be
carried out in building site conditions.
Mild and alloyed steels (MAG) as well as aluminium and other non-ferrous
metals (MIG); can be used in all positions, on components with thicknesses
between 0.6 mm and 100 mm; side air may disturb the shielding gas
coverage (welding in building site conditions is problematical); wide area of
application, e.g. for the manufacture and repair of motor vehicles as well as
in structural steel engineering, metal construction, mechanical engineering
and apparatus construction.
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T E C H N O L O G Y
The heat source is an arc. It burns between a non-consumable tungsten
electrode (which is clamped in the welding torch) and the workpiece. In
the case of manual welding, the filler material is guided into the arc by
hand and is melted off there. The inert shielding gas (consisting of noble
gases such as argon or helium) flowing out of the welding torch protects
the glowing tungsten electrode, the weld pool and the adjacent material
regions from the effect of air. The thermal load-bearing capacity of the
tungsten electrode is limited. For this reason, it is not possible to achieve
any high deposition rates with this welding process.
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Brief description
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Anzeige:Layout 1
W O R L D .
GBW
27.12.2011
WIG
direct current in the case of steel, copper,
titanium and nickel, alternating current in the
case of aluminium, amperage: up to 250 A
with an electrode diameter of 4 mm
Shielding gas volume:
10 – 15 l/min
Deposition rate:
up to 0.5 kg/h
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Mains connection
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Welding power lead/shielding gas supply
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Workpiece clamp
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Shielding gas cylinder with pressure regulator
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Welding power return lead
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Workpiece
3
Shielding gas hose
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Welding torch
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Arc
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Welding power source
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Tungsten electrode
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Welding rod
Seite 2
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Issue
03
03
2011
2011
The ng
Weldi te
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Training for a High Quality Standard
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processes
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and allied
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