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FASTENING, JOINING, AND CONNECTING
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26.4 NATURE OF THE ARC
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An arc is an electric current flowing between two electrodes through an ionized column of gas called a plasma. The space between the two electrodes or, in arc welding, the space between the electrode and the work can be divided into three areas of heat generation: the cathode, the anode, and the arc plasma. The welding arc is characterized as a high-current, low-voltage arc that requires a high concentration of electrons to carry the current. Negative electrons are emitted from the cathode and flow along with the negative ions of the plasma to the positive anode, as shown in Fig. 26.3. Positive ions flow in the reverse direction. A negative ion is an atom that has picked up one or more electrons beyond the number needed to balance the positive charge on its nucleus thus the negative charge. A positive ion is an atom that has lost one or more electrons thus the positive charge. However, just as in a solid conductor, the principal flow of current in the arc is by electron travel. Heat is generated in the cathode area mostly by the positive ions striking the surface of the cathode. Heat at the anode is generated mostly by electrons. These have been accelerated as they pass through the plasma by the arc voltage, and they give up their energy as heat when striking the anode. The plasma, or arc column, is a mixture of neutral and excited gas atoms. In the central column of the plasma, electrons, atoms, and ions are in accelerated motion and are constantly colliding. The hottest part of the plasma is the central column, where the motion is most intense. The outer portion or the arc flame is somewhat cooler and consists of recombining gas molecules that were disassociated in the central column. The distribution of heat or voltage drop in FIGURE 26.3 Characteristics of the arc. the three heat zones can be changed. Chang(The Lincoln Electric Company.) ing the arc length has the greatest effect on the arc plasma. Changing the shielding gas can change the heat balance between the anode and cathode. The addition of potassium salts to the plasma reduces the arc voltage because of increased ionization. In welding, not only does the arc provide the heat needed to melt the electrode and the base metal, but under certain conditions it must also supply the means to transport the molten metal from the tip of the electrode to the work. Several mechanisms for metal transfer exist. In one, the molten drop of metal touches the molten metal in the crater, and transfer is by surface tension. In another, the drop is ejected from the molten metal at the electrode tip by an electric pinch. It is ejected at high speed and retains this speed unless slowed by gravitational forces. It may be accelerated by the plasma, as in the case of a pinched-plasma arc. These forces are the ones that transfer the molten metal in overhead welding. In flat welding, gravity is also a significant force in metal transfer. If the electrode is consumable, the tip melts under the heat of the arc, and molten droplets are detached and transported to the work through the arc column. Any arcwelding system in which the electrode is melted off to become part of the weld is described as metal arc. If the electrode is refractory carbon or tungsten there are no molten droplets to be forced across the gap and onto the work. Filler metal is melted into the joint from a separate rod or wire.
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Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website.
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