Welding Theory; Manual Metal Arc Welding (Mma) - Bohler WF 4000 CLASSIC Instrucciones De Uso

Porosity
Cause Grease, varnish, rust or dirt on the workpieces to
be welded.
Solution Clean the workpieces carefully before welding.
Cause Grease, varnish, rust or dirt on the filler material.
Solution Always use quality materials and products.
Keep the filler metal always in perfect condition.
Cause Humidity in the filler metal.
Solution Always use quality materials and products.
Keep the filler metal always in perfect condition.
Cause Incorrect arc length.
Solution Decrease the distance between the electrode and
the piece.
Decrease the welding voltage.
Cause Humidity in the welding gas.
Solution Always use quality materials and products.
Ensure the gas supply system is always in perfect
condition.
Cause Insufficient shielding gas.
Solution Adjust the gas flow.
Check that the diffuser and the gas nozzle of the
torch are in good condition.
Cause The weld pool solidifies too quickly.
Solution Decrease the travel speed while welding .
Pre-heat the workpieces to be welded.
Increase the welding current.
Hot cracks
Cause Incorrect welding parameters.
Solution Decrease the welding voltage.
Use a smaller diameter electrode.
Cause Grease, varnish, rust or dirt on the workpieces to
be welded.
Solution Clean the workpieces carefully before welding.
Cause Grease, varnish, rust or dirt on the filler metal.
Solution Always use quality materials and products.
Keep the filler metal always in perfect condition.
Cause Incorrect welding mode.
Solution Carry out the correct sequence of operations for
the type of joint to be welded.
Cause Pieces to be welded have different characteristics.
Solution Carry out buttering before welding.
Cold cracks
Cause Humidity in the filler metal.
Solution Always use quality materials and products.
Keep the filler metal always in perfect condition.
Cause Particular geometry of the joint to be welded.
Solution Pre-heat the pieces to be welded.
Carry out post-heating.
Carry out the correct sequence of operations for
the type of joint to be welded.
For any doubts and/or problems do not hesitate to contact
your nearest customer service centre.

7 WELDING THEORY

7.1 Manual Metal Arc welding (MMA)

Preparing the edges
To obtain good welding joints it is advisable to work on clean
parts, free from oxidations, rust or other contaminating agents.
Choosing the electrode
The diameter of the electrode to be used depends on the thick-
ness of the material, the position, the type of joint and the type
of preparation of the piece to be welded.
Electrodes of large diameter obviously require very high currents
with consequent high heat supply during the welding.
Type of coating Property
Rutile Easy to use
Acid High melting speed
Basic High quality of joint
Choosing the welding current
The range of welding current related to the type of electrode
used is specified by the manufacturer usually on the electrode
packaging.
Striking and maintaining the arc
The electric arc is produced by scratching the electrode tip on
the workpiece connected to the earth cable and, once the arc
has been struck, by rapidly withdrawing the electrode to the
normal welding distance.
Generally, to improve the arc striking behaviour a higher initial
current is given in order to heat suddenly the tip of the electrode
and so aid the arc establishing(Hot Start).
Once the arc has been struck, the central part of the electrode
starts melting forming tiny globules which are transferred into
the molten weld pool on the workpiece surface through the
arc stream.
The external coating of the electrode is being consumed and
this supplies the shielding gas for the weld pool, ensuring the
good quality of the weld.
To prevent the molten material globules cause the extinguish-
ing of the arc by short-circuiting and sticking the electrode to
the weld pool, due to their proximity, a temporary increase of
the welding current is given in order to melt the forming short-
circuit (Arc Force).
If the electrode sticks to the workpiece, the short circuit current
should be reduced to the minimum (antisticking).
Carrying out the welding
The welding position varies depending on the number of runs;
the electrode movement is normally carried out with oscillations
and stops at the sides of the bead, in such a way as to avoid an
excessive accumulation of filler metal at the centre.
Use
All positions
Flat
All positions
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