MIG Welding Electrodes Wire Selection
11 Pages3388 Words56 Views
Added on 2021-06-17
MIG Welding Electrodes Wire Selection
Added on 2021-06-17
ShareRelated Documents
Running head: SELECTION OF ELECTRODES IN MIG WELDING PROCESS 1 Selection of Electrodes in MIG Welding ProcessName of the studentName of the universityAuthor Note:May 20 2018
Running head: SELECTION OF ELECTRODES IN MIG WELDING PROCESS 2i. Aim Welders face the challenge of selecting the electrode type and weld size to use in welding (Shih, et al., 2011). This project focusses on the process and considerations in choosing the weld size and electrode type. The welder must consider matching the type of wire to the type of metal being welded, the position to be welded, the resistance of the metal being welded to heat and the type of transfer (Hussain, et al., 2010). All these considerations resulting from effecting this project are mandatory in selecting the ideal welding electrode. There are other objectives this project seeks to fulfill such as: How to select electrodes in metal inert gas Considerations in selecting electrodes and wire sizeFinding out metals which are compatible for arc welding Background Metal inert gas (Gas metal arc welding) is an arc welding procedure which involves an electric arc between a metal and a consumable electrode generating the heat that is utilized in metal melting (Zhang, et al., 2011). Most of the time in welding engineers specify the electrode type and weld size but, in the case, where they do not specify there is need to identify the two. The criteria used to select the wire type is that it should match the base metal strength with the weld metal strength (Pal, et al., 2009). Literature Review Pal in his journal writes about the diameter of the wire used in metal inert gas welding processes. He indicates that the diameter of wire used in welding must be consistent to ensure that current is transmitted properly from the contact tip to the wire. He warns against undersized wires which may lead to dangers such as arcing between the wire and the inside diameter of the tip (Pal, et al., 2008). Kumar indicates that an increase in the base metal strength in advanced high strength steel makes the strength of welding more exposed to the defects of welding this can result in the rejection of the advanced high strength steel welded structures, this make it essential to select thebest quality and the most suitable welding consumables and to optimize the procedures involved in welding with a program that will ensure quality in welding the Advanced high strength steel (Kumar, et al., 2009). Tseng in his research on metal inert gas welding electrode selection indicates that the electrode serving as the filler metal at the weld must be compatible with the metal being welded. He points out that some metal alloys such as aluminum and steel are not compatible because of
Running head: SELECTION OF ELECTRODES IN MIG WELDING PROCESS 3the large difference between their melting point (Tseng, et al., 2011). However, most researchers on this topic do not point out clearly the criteria which should be applied in electrode selection. Significance The Metal inert gas electrodes are popularly referred to as Gas Metal Arc welding electrodes. This project involves the selection of electrodes on Metal inert gas welding process (Masubuchi, et al., 2013). Welders must select the electrode to use in welding in order to ensure that the welding process is effective. There are various considerations which must be put into perspective to ensure that the right electrode is selected such as the melting point of the electrodeversus the metal to be welded. This project seeks to provide a guide to welders on the considerations to make to avoid making mistakes when selecting electrodes in metal inert gas (MIG) welding process (Juang, et al., 2012). Most of the time in welding engineers specify the electrode type and weld size but, in the case, where they do not specify there is need to identify it. The principles used to select the wire type will be discussed and explored in this project. Innovations The proposed project is of a greatly innovative nature since it will make the process of electrode selection on metal inert gas welding easier and cost effective. The project will be a guide on how to select the metals based on the tensile strength in that the chosen metal must meet the minimum tensile strength requirements which is 70,000 psi for most metals and depends on the application. The electrode serving as the filler metal at the weld must be compatible with the metal being welded. Some metals alloys such as aluminum and steel are not compatible because of the large difference between their melting point. The project also concentrates on the diameter of the wire to be used as an electrode, the wire should be chosen in a way that the diameter is consistent to prevent arcing between the inside diameter of the tip and the wire (Tong, et al., 2011). 1 Pal, Sukhomay, Santosh K. Malviya, Surjya K. Pal, and Arun K. Samantaray. "Optimization of quality characteristics parameters in a pulsed metal inert gas welding process using grey-based Taguchi method."The International Journal of Advanced Manufacturing Technology44, no. 11-12 (2009): 1250-1260.2 Masubuchi, Koichi.Analysis of welded structures: residual stresses, distortion, and their consequences. Vol. 33. Elsevier, 2013.3 Hussain, Ahmed Khalid, Abdul Lateef, Mohd Javed, and T. Pramesh. "Influence of welding speed on tensile strength of welded joint in TIG welding process."International journal of applied engineering research1, no. 3 (2010): 518.4 Zhang, H. T., J. C. Feng, Peng He, B. B. Zhang, J. M. Chen, and L. Wang. "The arc characteristics and metal transfer behaviour of cold metal transfer and its use in joining aluminium to zinc-coated steel."Materials Science and Engineering: A499, no. 1-2 (2009): 111-113.5 Tseng, Kuang-Hung, and Chih-Yu Hsu. "Performance of activated TIG process in austenitic stainless steel welds."Journal of Materials Processing Technology211, no. 3 (2011): 503-512.6 Kumar, A., and S. Sundarrajan. "Optimization of pulsed TIG welding process parameters on mechanical properties of AA 5456 Aluminum alloy weldments."Materials & Design30, no. 4 (2009): 1288-1297.
Running head: SELECTION OF ELECTRODES IN MIG WELDING PROCESS 47 Shih, Jing-Shiang, Yih-Fong Tzeng, and Jin-Bin Yang. "Principal component analysis for multiple quality characteristics optimization of metal inert gas welding aluminum foam plate."Materials & Design32, no. 3 (2011): 1253-1261.v. Approach and methodologya. Experimental design The principle used is that when choosing the electrode (MIG wire) consideration is put on the type of metal being welded in that the wire chosen must match the metal being welded. Otherconsiderations in play in this project are position to be welded, resistance to heat and the type of transfer (Kumar, et al., 2009).Choosing the Electrode DiameterWelding wire diameter must be chosen carefully to avoid effects on weld deposition. This experiment uses laser micrometer inspection methods to inspect the welding metal diameter. Chemical CompositionThere are two methods that will be used in choosing the metal with the right chemical composition to ensure effectiveness in the welding process, the methods are as follows:a.Controlled chemical compositionIn this method it is ensure that the chosen metal has been tested by the manufacturer for chemicalcomposition before production. In this way the specific steel coil properties are matched with desirable qualities in steel electrodes. b.Use of Lot Control by Heat Number In this method an experiment will be conducted to verify that the electrode’s chemical composition of its heat is within the specifications for the use its intended to serve. The ANOVA TestThe ANOVA test will be conducted to test the parameters of the electrode to be used such as its tensile strength. Several potential electrodes will be tested for the properties in the table below:Level Travel Speed VoltageCurrent123Delta
End of preview
Want to access all the pages? Upload your documents or become a member.
Related Documents
Selection of electrodes on Mig Assignment PDFlg...
|7
|2241
|99
Minimizing Distortion in Fusion Weldinglg...
|10
|3137
|1
Assignment On Literature Plannerlg...
|5
|1601
|31