Topics in Welded Structures Day 1

Day One of an Online Course in conjunction with the University of Adelaide

Welding is an advanced science and is an integral process in manufacturing, defence, resources and construction industries. Industry-experts at AWS have developed this course to give Engineers the unique opportunity to learn more about the science, skills and risks of welding.

AWS Senior Welder Trainer Barry Bennet presents the materials in the videos below.

After reviewing each video please complete and submit the related questions

1. Introduction

AWS Barry delivers an introduction to the AWS Topics in Welded Structures Workshop 1.

The Workshop 1 & 2 are cancelled in the interest of safety.

While it is regrettable, the face-to-face demonstration Workshops are cancelled, the on-line video content has been prepared to deliver the content in lieu of face to face Workshop due to the escalating Covid pandemic.

2. Safety

Arc Welding is very hazardous, it is imperative that welders and other personnel in the vicinity of a welding arc are trained and aware of the hazards associated with electric arc welding.

In accordance with WHS / OHS legislation welding personnel are responsible and have a duty of care to ensure that all personnel in the vicinity of welds being made are safe.

Barry discussed hazards and PPE used in welding, JSEA/SWMS, and Step Back.

Work places where welding is conducted are generally very hazardous locations.

Welding personnel must also be aware of hazards in in surrounding areas, and the impact that arc welding may have on adjacent plant, equipment and the environment.

Fire and explosions are frequently associated with welding tasks.

3. Manual Metal Arc Welding – MMAW

This set of short videos relate to MMAW addressing core topics including:

  • Popular Electrode Types – Cellulosic, Rutile, Hydrogen Controlled
  • MMAW is a simple process utilising low cost equipment. No wire feeder as in GMAW processes.
  • An electrode hot box is used to store hydrogen controlled electrodes to avoid moisture pick up.
  • Arc blow can occur when welding with DC current.
  • The electromagnetic field surrounding the DC welding arc is disrupted at a change is the joint shape, typically at the end of a weld resulting is a disruption to the electromagnetic field.
  • The disruption results in weld metal droplets being propelled from the weld puddle.

4. Gas Metal Arc Welding – GMAW

This set of short videos relate to GMAW addressing core topics including:

  • Various combinations of inert and active gasses are used in the GMAW process.
  • The gas type to be used is an essential variable on the Welding Procedure Specification – WPS.
  • GMAW will deposit higher Kg/hr rate than MMAW. GMAW offers higher production speeds than MMAW and GTAW. GMAW is commonly used in automotive and structural steel manufacturing.
  • Metal Transfer modes include Pulse, Globular, Spray and Short Circuit sometimes referred to as DIP transfer.
  • Visual inspection by the welder is the first form of NDE applied to a weld.

5. Gas Tungsten Arc Welding – GTAW

This set of short videos relate to GTAW addressing core topics including:

  • GTAW is relatively slow in conventional terms, however is a process that can deliver top quality welds in exotic materials.
  • GTAW has a gas shielding, the supply pressure regulated like GMAW, with the final gas flow rate to the torch controlled by a flow meter L/min.

7. Thermal Cutting

The oxygen / Acetylene process will cut only ferrous materials.

7. Hydrogen Diffusion Experiment

Hydrogen Assisted Cold Cracking is discussed in the theory notes.

As the smallest known atom hydrogen gas will readily diffuse from hot weldments.

Barry runs the the experiment using a cellulosic electrode for effect.

It is a simple and effective display of hydrogen diffusing from solidified weld metal.

8. TiWS Day 1 Quiz

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