Gas Metal Arc Welding, (GMAW)

Description: GMAW is a type of welding that uses an electrical arc and continuously fed filler wire electrode to
join the work pieces together. The wire electrode and shielding gas (carbon dioxide) is fed through the welding
gun. The electrode used depends on the composition and having the same property of the work pieces.
Procedure: GMAW requires the welder to keep the distance between of the electrode and the work piece
constant. The welding gun is held in such a way that it bisects the angle of the welding surface. The torch should
remain vertical as it travels. The process and the set-up can be seen in diagram 1.1 in the appendix.
Gas Tungsten Arc Welding, (GTAW)
Description: GTAW is a welding process that utilizes a non-consumable tungsten electrode and metal filler to
form the weld. The weld area is protected by using argon or helium as the shielding gas. The filler metal used
depends on the composition and having the same property of the work pieces.
Procedure: GTAW requires the welder to feed filler metal while controlling the welding torch. The high
frequency generator provides a spark and when the electrode and the work piece are separated the welding arc is
formed about 1.53 mm apart. After that, the torch is move back slightly and tilted backward to about 70 from
the work piece while the filler metal in inserted about 20 from the work piece. The welder moves the torch in a
small circle which creates a weld pool which will be protected by the shielding gas. The filler rod is withdrawn
from the weld pool whenever the electrode moves forward, however it remains in the gas shield to prevent it
from oxidizing. The process and the set-up can be seen in diagram 1.2 and diagram 1.3 in the appendix.
Resistive Spot Welding
Description: Resistive spot welding is a process which the weld is formed by concentrating electrical current
through the work pieces on a tiny spot. The electrodes which are usually made form copper due to its low
electrical resistance, concentrates the current and exerts pressure on the work pieces. The resistance of the work
pieces will generate the heat to melt and the weld is form. This type of welding is limited to work pieces within
the thickness range of about 13mm to 130mm due to the size of its throat.
Procedure: The work pieces were put in between the electrodes and a small amount of pressure was applied to it
to keep it in place. The current from the electrodes is then applied. The welding time ranges from 0.01 to 0.63
seconds depending on the thickness of the metal, the electrode force and the diameter of the electrodes. When
the current is turn off, pressure is still apply by the electrode on the weld area as it cools. The process and the set-
up can be seen in diagram 1.4 in the appendix.
Shield Metal Arc Welding, (SMAW)
Description: SMAW is a welding process that utilizes a consumable electrode to create the weld. The electrode
is coated with a layer of flux which turns into vapour during the welding process that serve as a shielding gas and
also provides a layer of slag which protects the weld area.


Procedure: To produce the electrical arc, the electrode touches the work piece then pulled back. As electrical arc
melts the electrode, the flux on the electrode turns into shielding gases and molten slag. The welding gun is held
in such a way that it bisects the angle of the welding surface. The torch is kept at a 70 angle in relative to the
work pieces. The slag floats to the surface and creates a protective layer on the weld area when it solidifies. The
layer is then remove to reveal the finished weld. When the electrode is used up, the remaining electrode stub on
the electrode holder is replaced with a new electrode. The process and the set-up can be seen in diagram 1.5 and
diagram 1.6 in the appendix.
Theory & Metallurgical Aspect of Welding
GMAW can weld can be used for all types of materials with any kind of thickness. GTAW is limited to thinner
work pieces and cannot weld cast iron. Resistive spot weld can only be used on materials which can conduct
electricity and the thickness is limited to the size of the throat. SMAW can be used on all types on materials
except aluminium alloys with any kind of thickness. For the weldment of carbon and alloy steels, the work
pieces and filler material are heated above their melting point and this allows them to fuse together in the liquid
region. As it cools down, small nuclei of solids will form when its temperature hits the liquidus line. In this
phase, the weldment contains both solid called austenite, , and liquid, L. As it continues to cool down, the solid
nuclei will grow in size until it hits the solidus line were the weldment turns fully solid, . As it continues to cool
down, it will go into the + phase. Further cooling makes it reach the + Fe
3
C phase. The microstructural
change can be seen in diagram 1.7 in the appendix. The welding heat will transfer and affect the area of the
adjacent to the weld pool. This area is known as the heat affected zone. If temperature was high enough, the
structure will change into austenite. This might transform into martensite which is undesirable. The heat also
decreases the strength, hardness and toughness of the material due to recrystallization and grain growth. Besides
that, the heat transferred might also cause undesirable formation or coarsening of other phases.
Safety and Precaution
When doing SMAW, GTAW and GMAW, it is required for the welder to wear personal protective equipment
such as leather gloves, protective long sleeve jacket which protects the welder from being injured due to the heat
and flames generated when welding. Besides that, welding helmets with dark UV filtering plates have to be worn
to protect the eye from exposure to the intense UV light due to these welding process. Toxic gasses are also
released during the welding process. Therefore, the area where the welding process is being carried out has to be
properly ventilated. For resistive spot welding, the intensity of UV light generated is not as intense as compared
to the other three welding processes. However, eye protection is still required. The welder should wear proper
attires such as gloves and apron to protect against the spark and heat generated. The welder must be cautious not
to put any part of his or her body to the electrodes as the pressure exerted by the electrode will potentially cause
injury.




Appendix


Diagram 1.1: Techniques of Gas Metal Arc Welding


Diagram 1.2: Gas Tungsten Arc Welding

Diagram 1.3: Techniques of Gas Tungsten Arc Welding


Diagram 1.4: Resistive Spot Welding


Diagram 1.5: Shield Metal Arc Welding

Daigram 1.6: Techniques of Shield Metal Arc Welding



Diagram 1.7: Metallurgical Change across Weldment