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copper, making preheating of heavy sections necessary to give
proper fusion of weld and base metal.
Types of electrodes
Arc welding electrodes are classified into a number of groups
depending on their applications. There are a great number of
electrodes used for specialized industrial purposes which are not of
particular interest for everyday general work. These include some
low hydrogen types for high tensile steel, cellulose types for welding
large diameter pipes, etc. The range of electrodes dealt with in this
publication will cover the vast majority of applications likely to be
encountered; are all easy to use and all will work on even the most
basic of welding machines.
Metals being joined & electrode comments
Mild steel
6013 ideal electrodes for all general purpose work. Features include
outstanding operator appeal, easy arc starting and low spatter.
Cast iron
99% nickel suitable for joining all cast irons except white cast iron
Stainless steel
318l-16 high corrosion resistance. Ideal for dairy work, etc. on
stainless steels.
6.0 Operation
WarnInG
When using an open arc process, it is necessary to use correct
eye, head, and body protection.
6.1 MMa Welding Guide
Effects of MMA welding various materials
High tensile and alloy steels
The two most prominent effects of welding these steels are the
formation of a hardened zone in the weld area, and, if suitable
precautions are not taken, the occurrence in this zone of under-bead
cracks. Hardened zone and under-bead cracks in the weld area may
be reduced by using the correct electrodes, preheating, using higher
current settings, using larger electrodes sizes, short runs for larger
electrode deposits or tempering in a furnace.
Manganese steels
The effect on manganese steel of slow cooling from high
temperatures is enbrittlement. For this reason it is absolutely
essential to keep manganese steel cool during welding by quenching
after each weld or skip welding to distribute the heat.
Cast iron
Most types of cast iron, except white iron, are weldable. White iron,
because of its extreme brittleness, generally cracks when attempts
are made to weld it. Trouble may also be experienced when welding
white-heart malleable, due to the porosity caused by gas held in this
type of iron.
Copper and alloys
The most important factor is the high rate of heat conductivity of
6.2 Basic tIG Welding Guide
TIG welding cable connection
Connect the TIG torch to the - terminal and the work return lead
to the + terminal for direct current straight polarity. Direct current
straight polarity is the most widely used polarity for DC TIG welding.
It allows limited wear of the electrode since 70% of the heat is
concentrated at the work piece. Connect the gas hose on the TIG
torch to the gas outlet. Move the selector switch on the front panel of
the machine to the LIFT-TIG position.
Torch starting in Lift TIG mode
Ensure the gas supply is switched on to the machine. Briefly contact
the tip of the tungsten electrode down onto the work piece with the
torch at around 70
0
from vertical. Depress the trigger to start the gas
flow and switch on the power, lift the torch up from the work piece
to draw out an arc. To prevent melting of the end of the tungsten the
machine will increase the output current when it detects the rise in
arc voltage as the tungsten is lifted from the work piece. At the end
of the weld release the torch trigger and the power will slope down
and switch off.
Torch starting in HF mode
Ensure the gas supply is switched on to the machine. Hold the torch
with the tip of the tungsten approx 2-3 mm from the job. Depress the
trigger to start the gas flow and switch on the power. At the end of
the weld release the torch trigger and the power will slope down and
switch off.
TIG welding guide ranges
Electrode diameter
AC current
(amps)
DC current
(amps)
0.040” (1.0mm)
15-30
20-60
1/16” (1.6mm)
60-120
75-150
3/32” (2.4mm)
100-180
150-250
Tungsten electrode types
Type
Application
Colour
Thoriated 2%
DC welding of mild
steel,
Stainless steel and
Copper
Red
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