The Welding Machine PDF

The Welding Machine By: Mark Lorenzo B. Camarines Irish Maeveth A. Capahi Z136 BSME-2 Mtec 122 – Machineshop Theory and Practice What is Welding?  What is Welding? Welding is a fabrication process that joins materials, typically metals or thermoplastics, by causing coalescence. This is...

The Welding Machine By: Mark Lorenzo B. Camarines Irish Maeveth A. Capahi Z136 BSME-2 Mtec 122 – Machineshop Theory and Practice What is Welding?  What is Welding? Welding is a fabrication process that joins materials, typically metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material that cools to become a strong joint.  Welding Machines Transformer-Based Welding Machines Inverter-Based Welding Machines AC Welding Machines: These machines use DC Inverter Welding Machines: These are the most alternating current (AC) to create the arc. They are modern type of SMAW machines. They use typically simpler and less expensive but can be advanced electronics to convert AC power to DC less stable for certain types of electrodes. with high efficiency. They are lightweight, portable, and offer excellent arc stability and control. They can also provide features like adjustable amperage and improved power factor. Basic Welding Machine Parts Welding Processes Basic Advanced Shielded Metal Arc Welding Magnetic Pulse Welding (SMAW) Gas Tungsten Arc Welding (GTAW) or Friction Welding Tungsten Inert Gas (TIG) Welding Gas Metal Arc Welding (GMAW) or Ultrasonic Welding Metal Inert Gas (MIG) Welding Flux Cored Arc Welding Laser Welding Submerged Arc Welding Electron Beam Welding  Basic Welding Processes Shielded Metal Arc Welding Also known as Manual Metal Arc Welding (MMA) or informally as Stick Welding. It uses a consumable electrode coated in flux. When the electrode is struck against the workpiece, an electric arc is formed, melting the electrode and the base metal. The flux coating disintegrates, producing a shielding gas and slag that protect the weld pool from contamination. Applications: Construction, repair work, pipelines, and heavy equipment maintenance.  Basic Welding Shielded Metal Arc Welding Processes Electrodes  Basic Welding Shielded Metal Arc Welding Processes Electrodes Flux Coating Type Number Characteristics Applications Cellulose-Based 0 Deep penetration, gaseous shield Pipelines, root passes, vertical welding Rutile-Based 2 Smooth arc, easy slag removal General-purpose, sheet metal Rutile-Iron Powder 3 High deposition, thick slag Flat and horizontal welding Iron Oxide-Based 4 Smooth arc, dense slag High-speed welding, thick materials Low-Hydrogen 6 Crack-resistant, thin slag Structural steel, pressure vessels Iron Powder, Low-Hydrogen 8 High deposition, crack-resistant Structural welding, heavy fabrication Basic or Lime-Based 5 Low hydrogen, thin slag High-strength steels, critical applications  Basic Welding Shielded Metal Arc Welding Processes 5 Most Commonly Used Electrodes Electrode Coating Type Polarity Characteristics Applications Pipelines, structural steel, root E6010 Cellulose sodium DCEP Deep penetration, forceful arc passes E6011 Cellulose potassium AC or DCEP Versatile, good penetration General-purpose, field repairs Smooth arc, shallow E6013 Rutile potassium AC or DCEN Sheet metal, light fabrication penetration Structural steel, pressure E7018 Low-hydrogen iron powder AC or DCEP Low hydrogen, high strength vessels Heavy-duty, flat and horizontal E7024 Iron oxide and powder AC or DCEP High deposition, fast welding welding  Basic Welding Processes Gas Tungsten Arc Welding TIG welding (Tungsten Inert Gas). Uses a non-consumable tungsten electrode to create the arc. A separate filler rod is manually fed into the weld pool if needed. An inert shielding gas (usually argon or helium) protects the weld area from contamination. Applications: Aerospace, automotive, and high-precision welding of thin materials like stainless steel, aluminum, and titanium.  Basic Welding Processes Gas Metal Arc Welding MIG welding (Metal Inert Gas). Uses a continuously fed consumable wire electrode and a shielding gas (typically argon, CO2, or a mix) to protect the weld pool. The wire is fed automatically through a welding gun. Applications: Automotive repair, fabrication, and manufacturing of steel, aluminum, and other metals.  Basic Welding Processes Flux Cored Arc Welding Similar to GMAW, but uses a tubular wire filled with flux instead of a solid wire. The flux provides shielding, and in some cases, external shielding gas may also be used. Applications: Heavy fabrication, shipbuilding, and construction.  Basic Welding Processes Submerged Arc Welding Uses a continuously fed consumable electrode and a granular flux that covers the weld area. The arc is submerged under the flux layer, which prevents spatter, sparks, and UV radiation. Applications: Welding of thick materials in industries like shipbuilding, pressure vessel fabrication, and structural steelwork. Basic Welding Processes Process Full Name Key Features Best For Limitations Portable, works Slow, slag Shielded Metal Construction, SMAW outdoors, removal, skill Arc Welding repair, pipelines versatile required High precision, Slow, expensive, Gas Tungsten Thin materials, GTAW clean welds, no high skill Arc Welding critical welds slag needed Fast, easy to Not for outdoors Gas Metal Arc Automotive, GMAW use, minimal or thick Welding fabrication cleanup materials High deposition, Heavy Flux-Cored Arc Smoke/fumes, FCAW works with thick fabrication, Welding slag removal materials shipbuilding High speed, Limited Submerged Arc deep Thick materials, SAW positions, slag Welding penetration, no large structures removal  Advanced Welding Processes Magnetic Pulse Welding It is a solid-state welding process that uses magnetic forces to join materials. How? A high-intensity magnetic field is generated using a coil, which creates a repulsive force between two conductive materials. This force drives the materials together at high speed, creating a weld without melting the materials. Applications: Used for joining dissimilar metals (e.g., aluminum to steel) in automotive, aerospace, and electronics industries.  Advanced Welding Processes Magnetic Pulse Welding Machine  Advanced Welding Processes Friction Welding A solid-state welding process that joins materials using mechanical friction and pressure. How? One workpiece is rotated at high speed while pressed against another stationary workpiece. The friction generates heat, softening the materials, and pressure is applied to forge them together. Types: Rotary Friction Welding: Used for cylindrical parts. Linear Friction Welding: Used for non-cylindrical parts. Friction Stir Welding (FSW): Uses a rotating tool to join materials, commonly used for aluminum. Applications: Automotive, aerospace, and manufacturing of shafts, gears, and valves.  Advanced Welding Processes Friction Welding Machine  Advanced Welding Processes Ultrasonic Welding A solid-state welding process that uses high- frequency ultrasonic vibrations to join materials. How? Two materials are clamped together, and ultrasonic vibrations are applied to the interface. The vibrations create friction, generating heat and bonding the materials. Applications: Joining plastics, thin metals, and wires in electronics, medical devices, and packaging.  Advanced Welding Processes Ultrasonic Welding Machine  Advanced Welding Processes Laser Welding A high-precision welding process that uses a focused laser beam to melt and join materials. How? A laser beam is directed at the joint, creating a localized heat source that melts the material. A shielding gas (e.g., argon or nitrogen) is often used to protect the weld pool. Applications: Automotive, aerospace, electronics, and medical devices.  Advanced Welding Processes Laser Welding Machine  Advanced Welding Processes Electron Beam Welding A high-energy welding process that uses a focused beam of electrons to melt and join materials. How? Electrons are accelerated to high speeds and focused into a beam, which is directed at the joint. The kinetic energy of the electrons converts to heat, melting the material. The process is performed in a vacuum to prevent electron scattering. Applications: Aerospace, automotive, and high-precision industries (e.g., semiconductors and medical devices).  Advanced Welding Processes Electron Beam Welding Machine Advanced Welding Processes Process Key Features Applications Advantages Limitations Uses magnetic forces Dissimilar metals, Magnetic Pulse Limited to conductive to join materials; no automotive, No HAZ, fast, clean Welding materials heat. aerospace Uses friction and Shafts, gears, pressure to join No filler, high Limited geometries, Friction Welding automotive, materials; solid-state strength, no HAZ specialized equipment aerospace process. Uses ultrasonic vibrations to join Electronics, medical Fast, energy-efficient, Limited to small, thin Ultrasonic Welding materials; solid-state devices, plastics no consumables parts process. Uses a focused laser Automotive, High precision, Expensive, precise Laser Welding beam to melt and join aerospace, electronics minimal HAZ alignment needed materials. Uses a focused Aerospace, Electron Beam electron beam in a Deep, narrow welds, Expensive, requires semiconductors, Welding vacuum to melt and minimal HAZ vacuum chamber medical join materials. Maintenance: 1. Dry out the air inside the machine 4. Clean the wire feeder and drive rolls Disconnect power and consult the manual before any Remove dust and debris from the machine's interior maintenance procedure. Drying out the air prevents and clean drive rolls with a wire brush. This prevents wear, overheating, and electrical hazards. clogs and ensures smooth wire feeding. 2. Inspect electrical cables for potential tears 5. Check regulators and valves for leaks and cracks Inspect for leaks, indicated by rising pressure with a Check for tears and cracks; tighten connections and closed valve, which can cause porosity. Close the replace damaged cables. Use correctly sized cables cylinder valve before repairing hoses. per manufacturer specifications to avoid arc wandering and overheating. 6. Keep your machines up to date Regular maintenance prevents major problems and 3. Remove all traces of oil and fuel spills saves time, resources, and manpower. A well- Address gas leaks promptly, they are often caused maintained machine operates safely and efficiently by worn O-rings or loose connections. Regular for many years to come. maintenance and pre-process assessments can prevent costly repairs. Safety:  Personal Protective Equipment (PPE):  Electrical Safety: Welding Helmet: Use an auto-darkening 1. Ensure the machine is properly grounded to helmet with the appropriate shade level to prevent electric shock. protect your eyes and face from UV/IR radiation 2. Inspect cables and electrodes for damage and sparks. before use. Replace any frayed or damaged Gloves: Wear heat-resistant welding gloves to components. protect your hands from burns and electric 3. Avoid touching live electrical parts or shock. electrodes with bare skin. 4. Use dry, insulated gloves and stand on a dry Clothing: Wear flame-resistant clothing (e.g., surface to reduce the risk of electric shock. leather aprons, welding jackets) to protect against sparks and molten metal. Boots: Use steel-toed, insulated boots to protect your feet from falling objects and electric shock. Respiratory Protection: Use a respirator or fume extraction system to avoid inhaling harmful welding fumes and gases. Safety:  Fire Safety:  Ventilation 1. Keep a fire extinguisher nearby and ensure 1. Work in a well-ventilated area or use fume the work area is free of flammable materials. extraction systems to avoid inhaling toxic 2. Use welding curtains or screens to contain fumes and gases produced during welding. sparks and protect others in the area. 2. Training and Awareness: 3. After welding, check for smoldering materials 3. Only trained and qualified personnel should and allow hot workpieces to cool before operate welding equipment. handling. 4. Be aware of the risks associated with welding, including electric shock, fire, and exposure to harmful fumes. Safety:  Training:  Work Area Safety: Ensure proper training in welding techniques and 1. Keep the workspace clean and free of clutter safety procedures before operating equipment. to prevent tripping hazards. 2. Mark the welding area with signs or barriers to warn others. AND ALWAYS REMEMBER! “THOU, SHALL NOT, KOMPYANS” Bonus THANK YOU COME AGAIN!