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FIGURE 26.6 Principles of the gas-shielded flux-cored process. Gas from an external source is used for the shielding; the core ingredients are for fluxing and metalconditioning purposes. (The Lincoln Electric Company.)
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Essentially, the nonconsumable tungsten electrode is a torch a heating device. Under the protective gas shield, metals to be joined may be heated above their melting points so that material from one part coalesces with material from the other part. Upon solidification of the molten area, unification occurs. Pressure may be used when the edges to be joined are approaching the molten state to assist coalescence. Welding in this manner requires no filler metal. If the work is too heavy for the mere fusing of abutting edges, and if groove joints or reinforcements such as fillets are required, filler metal must be added. This is supplied by a filler rod that is manually or mechanically fed into the weld puddle. Both the tip of the nonconsumable tungsten electrode and the tip of the filler rod are kept under the protective gas shield as welding progresses. Figure 26.7 illustrates the TIG torch. In automatic welding, filler wire is fed mechanically through a guide into the weld puddle. When running heavy joints manually, a variation in the mode of feeding is to lay or press the filler rod in or along the joint and melt it along with the joint edges. All the standard types of joints can be welded with the TIG process and filler metal. Materials weldable by the TIG process are most grades of carbon, alloy, and stainless steels; aluminum and most of its alloys; magnesium and most of its alloys; copper and various brasses and bronzes; high-temperature alloys of various types; numerous hard-surfacing alloys; and such metals as titanium, zirconium, gold, and silver. The process is especially adapted for welding thin materials where the requirements for quality and finish are exacting. It is one of the few processes that is satisfactory for welding such tiny and thin-walled objects as transistor cases, instrument diaphragms, and delicate expansion bellows.
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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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FIGURE 26.7 Principles of the gas tungsten-arc process. If filler metal is required, it is fed into the pool from a separate filler rod. (The Lincoln Electric Company.)
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26.6.6 Submerged-Arc Welding Submerged-arc welding differs from other arc-welding processes in that a blanket of fusible granular material commonly called flux is used for shielding the arc and the molten metal.The arc is struck between the workpiece and a bare wire electrode, the tip of which is submerged in the flux. Since the arc is completely covered by the flux, it is not visible, and the weld is run without the flash, spatter, and sparks that characterize the open-arc process. The nature of the flux is such that very little smoke or visible fumes are developed. The process is either semiautomatic or fully automatic, and the electrode is fed mechanically to the welding gun, head, or heads. In semiautomatic welding, the welder moves the gun, usually equipped with a flux-feeding device, along the joint. Flux feed may be by gravity flow through a nozzle concentric with the electrode from a small hopper atop the gun, or it may be through a concentric nozzle tube connected to an air-pressurized flux tank. Flux may also be applied in advance of the welding operation or ahead of the arc from a hopper run along the joint. In fully automatic submerged-arc welding, flux is fed continuously to the joint ahead of or concentric with the arc, and fully automatic installations are commonly equipped with vacuum systems to pick up the unfused flux left by the welding head or heads for cleaning and reuse. During welding, the heat of the arc melts some of the flux along with the tip of the electrode, as illustrated in Fig. 26.8. The tip of the electrode and the welding zone are always surrounded and shielded by molten flux, surmounted by a layer of unfused flux. The electrode is held a short distance above the workpiece. As the electrode progresses along the joint, the lighter molten flux rises above the molten metal in the form of a slag. The weld metal, having a higher melting (freezing) point, solidifies
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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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