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Welding Revision

This guide explores the complex processes of gas welding, focusing on the primary and secondary combustion stages of acetylene and oxygen. It details the types of flames, including oxidizing and carburizing flames, and their applications in welding different metals. Additionally, it covers the functions of transformer/rectifiers in welding, including voltage transformation and current control. Various welding techniques like MIG, TIG, and resistance welding are introduced, showcasing their methods and suitability for different materials.

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Welding Revision

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  1. Welding Revision LC Engineering

  2. Gas Welding Revision Stages of combustion Primary Combustion – Acetylene & Oxygen burn in the primary combustion zone to give off Carbon Monoxide and Hydrogen. C2H2+O2 2CO+H2 Secondary Combustion – oxygen is sucked in from the weld pool and is burned with Carbon Monoxide & Hydrogen to give off Carbon Dioxide and Water vapour. CO+H2+O2 CO2+H2O

  3. Types of Flames The Oxidising Flame This is a result of excess Oxygen. Approx 1.5 parts oxygen to 1 part acetylene. If used with steel the excess oxygen would contimnate the joint, so it is used for copper and some bronzes. It has a temp. of about 3500ºC max temp zone inner cone secondary combustion zone

  4. The Carburising Flame This is a result of excess Acetylene. Approx 0.9 parts oxygen to 1 part acetylene. Has a temp of approx 3150ºC and is used for welding alloy steels and aluminium alloys max temp zone inner cone secondary combustion zone C Acetylene feather

  5. Transformer/ Rectifier Transformer Rectifier • Dropping Voltage means current increases current, which is needed for welding. • There is a primary and secondary coil. • The number of windings on each coil controls the output current. • Primary 100 Turns and 220V and 10A • Secondary 200 coils = 110V & 20A • The Rectifier converts AC to DC. • It uses 4 diodes arranged in a diamond shape. • 2 diodes conduct in each half-cycle. • The capacitor ensures a smooth output.

  6. Transformer/Rectifier

  7. MIG/MAGS • Metal Inert Gas/Metal Arc Gas Shielded. • Semi-automatic Process • Consumable Electrode fed automatically. • Argon gas protects the weld pool like a flux. • No slag produced. • Suitable for steel. Argon Gas Wire Feed Welding Gun Electrode Power Plant NOTE: CO2 welding is a form of MIG/MAGS

  8. TIG/TAGS • Tungsten Inert Gas • Non –consumable Electrode. • Filler rod used. • Argon gas protects the weld pool like a flux. • Suitable for Aluminium& Stainless Steel. Filler Rod NOTE: Label the diagram using MIG/MAGS as a reference.

  9. A Transformer steps up and down the voltage to set welding currents. • The Rectifier converts AC to DC using a series of diodes.

  10. Resistance Spot Welding

  11. Resistance Seam Welding

  12. Submerged Arc Welding

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