What is Arc Welding - Definition, Types, Working, Advantages and Disadvantages - Mechanical Booster

介绍：

焊接is the Joining Process, which is used in almost all Industries. The Engineers working in the Welding department requires to have good knowledge of different Joining processes in detail. Apart from the Engineers, Welders also need to have good knowledge because it is used in their day-to-day lives. Arc Welding is the most widely used Welding process because of its simplicity. Although there are various issues concerning the process, there are specific applications for which we can use it. Under this Article, we will be learning about Arc Welding process in detail from Working to Application. So, Let’s get started.

Definition and Basic Terminologies:

电弧焊接过程用于产生升高温度并融化连接金属的电弧，从而使它们成为单个金属件。该连接过程使用的是可以提供所需电压和电流的变压器，以产生所需的火花，足以融化要连接的金属。我们可以使用D.C.（直流电流）或A.C.（交替的电流），具有消耗量和不足的电极。

Arc Welding Circuit Diagram

Fig:基本电路图的弧焊接

重要的Terminologies used are as follows:

1. Electrodes:The Positive and Negative point of the terminal between which a high amount of Voltage difference is maintained, is called Electrode.

2.工件：The Metal which is going to be Joined are called as Workpiece. It is also called as Base metal.

3. Flux:它是焊接中使用的碳酸盐和硅酸盐材料的组合，焊接形成了工件周围的屏蔽环境。

4. . Welding Machine:根据焊接的需求和强度提供电流的机器，并连接电极的正末端和负末端。

5. Arc Voltage:The Voltage that runs across the WeldingArc.

电弧焊接的主要部分：

Following are the main parts of Arc Welding:

1. AC/DC机器：

The Machine provides the required current and Voltage for the production of Arc.

2. Electrode:

There are two Electrodes, Positive and Negative. The Arc has been produced due to the high voltage difference between these Electrodes.

3. Cable and Cable Connectors:

Cables are used to connect the Electrodes to produce current and develop the required Potential difference.

4.接地夹：

它确保电路在电源和工件之间关闭。

5. Chipping Hammer:

It is used to remove the extra Electrode deposited on the Joined Workpiece.

6.焊接头盔：

它可以保护火花进入眼睛和脸部其他部位。因此建议选择best helmets for weldings.

7.安全护目镜：

它是专门设计的，旨在保护眼睛免受有害的紫外线和红外辐射。

8. Wire Brush:

It is used to clean the Weld surface and remove the rust, slag, Etc.

9.手套：

It is used to protect the Hands from touching hot parts of the components and protect them from the falling sparks

10.围裙或夹克：

They protect other Body parts from Sparks, UV, and Infrared radiation.

Working Mechanism of Arc Welding

通过了解闪电的工作，可以轻松理解工作机制。它是由于真空层的电离而创建的，这使它们成为一个很好的导体。从天空到底部的整层有助于将照明转移到地面上。照明罢工变得非常热的地方，并且可以在一段时间后看到该点。

如果您能理解从天空中闪电的工作，那么了解弧焊的工作很容易。用能量源代替天空，用产生的弧形闪电，并用需要连接的金属来代替地面。产生的电弧会加热不同的金属，并使其成为单个金属件。

The Working Mechanism is divided into three parts:

Formation of Arc
Heating the Workpiece and melting
Solidification and Joining

Creation of Arc:

Arc is formed between two points if there exists an electric potential difference between them. The formation of Arc from the Electric Potential difference happens through the dielectric breakdown. It is a phenomenon in which the particles between the two points break down, temperature becomes very high, and the arc is produced. The Increase in temperature depends upon the current supplied and Voltage maintained. Therefore, big transformers are used to provide current directly to the Welding Machine.

Plasma State

Apart from the most commonly occurring three states of matter- Solid, liquid, and gases, we have two more States of Matter successfully established and stabilized. These are Plasma, Bose-Einstein Condensate.

图3：不同的物质状态

Explaining in simple sentences; Plasma state is a high temperature, High Energy state, which is a combination of Neutral atoms and Ionized particles. During Arc Welding, the potential difference between the two points becomes so high that the particles between the points are ionized, and electrons are removed from the adjacent atom to neutralize them. Hence, a state is created where the temperature and energy is very High, and Ionized particles and Neutral atoms are present together.

完成工作：

It is a fusion Welding process used to join two metal pieces. The Supplied voltage is sufficient to create a good amount of heat between the Electrode and the metal piece (around 6500⁰F), which melts the metal. The produced Arc is guided towards the joining point, and both the Pieces melt and solidifies together to become single Metal Piece.

To Understand the working of Arc Welding more Clearly. Watch the Video :

不同类型的电弧焊接：

弧焊接过程可以在各种基础上进行分割。在这里，我们将主要根据电极进行讨论，无论使用的电极是消耗还是不耗时。

The figure below briefly describes the complete classification of different types of Arc Welding process on the basis of Electrodes:

基于消耗电极的类型：

消耗电极的六种不同类型的过程如下：

1.金属惰性气体（MIG）/金属活性气（MAG）焊接：

它也称为气金属电弧焊接（GMAW）。在这里，我们使用一种惰性气氛来创造弧形，以保护连接金属免受污染。

要了解MIG/MAG焊接的工作，请观看此视频

2. Shielded Metal Arc Welding (SMAW):

It is also called Stick Welding or Manual Metal Arc Welding. The Welded metal that is formed is protected from the atmosphere by the shielding gas and slag produced.

要了解屏蔽金属电弧焊接的工作，请观看此视频

3. Flux-cored Arc Welding (FCAW):

Thistype of Weldingcan be a good substitute for SMAW. It uses the gas formed by the Flux to shield from the Air, to save the metal from Contamination. The Shielded gas is produced by the continuous supply of Flux-cored Electrode.

要了解磁通量弧形焊接的工作，请观看此视频

4. Submerged Arc Welding (SAW):

它在不断喂养的电极和工件之间产生弧线。ARC创建了熔融通量的封面，该通量会在金属周围产生气体屏蔽，以免腐蚀。

To understand the working of Submerged Arc Welding, watch this Video

5. Electro-Slag焊接（ESW）：

This Welding process uses a Molten Slag, created by the heat of Electrical Supply, to cover the Weld Surface. The created Slag resist the passing of Current, which in turn creates the Heat for Metal to melt. The Metal solidifies on getting in contact with Water.

要了解电矿石焊接的工作，请观看此视频

6. Arc Stud Welding (SW):

This type of Arc Welding is used to join Metal pieces with Stud components, such as Nut, bolt, etc.

To Understand the working of Arc Stud Welding, watch this Video

基于不需要的电极：

根据不需要的电极，有两种类型的焊接过程，如下：

1.钨惰性气体焊接（TIG）：

This type of Welding process is also called as Gas Tungsten Arc Welding (GTAW). It uses a non-consumable electrode for the production of Arc. The Produced Arc works as a Shielding gas to protect Metal from Corrosion.

要了解Tungsten插入气焊接的工作，请观看此视频

2. Plasma Arc Welding (PAW):

该过程在金属和电极之间产生弧形。在这里，等离子体气体与屏蔽气体分离，该气体负责产生细和深焊缝。

要了解等离子体电弧焊接的工作，请观看此视频

Issues with Arc Welding:

尽管这种焊接由于各种子类别的可用性而在行业中找到了许多应用程序，但它具有各种问题。它们主要分为两种不同类型，如下：

1. Corrosion Related Issues:

We have seen from the types explanation that all works on creating a Shielded environment to save the metal from Contamination. Due to very high temperatures, Molecules around the Metal break down into smaller molecules such as Oxygen, which can react at such a high temperature to convert it into metal Oxide, and corrosion will start.

为了使金属免于污染，使用惰性气氛（如MIG，TIG等），或使用屏蔽气氛（SMAW等）。这有助于通过不与大气相互作用来节省金属免于污染。更重要的是，要注意的是，如果要焊接的金属件具有不同的成分，腐蚀效果可能很严重。

2. Safety Related Issues:

焊接can be dangerous and unhealthy practice without any precautions. We need to use a proper PPE (Personal Protective equipment) Kit before doing Welding. The main Health-related Issues Includes:

（i）吸入物质：

在焊接过程中，焊工会暴露于不同类型的物质，这可能是危险的。例如，在磁通焊接期间，产生的烟雾含有各种对健康有害的氧化物。因此，在执行任何焊接过程之前，我们应该遮盖脸部。

(ii) Interference with Pacemakers:

该过程产生高频交替电流，该电流可能会干扰距动力单元2米的起搏器，距焊接部位1米。

(iii) Eye Damage:

This Welding process produces high-Intensity Spark, which can cause a high amount of damage to the eyes. When looked at directly during the Welding operation, eyes can turn red and create Pain for days. Hence, we need to use Welding goggles to protect our eyes during Welding compulsorily.

(iv) Heat, fire, and Explosion Hazards:

The temperature rise in the core of Welding can be as high as 6500⁰F, which can create much Heat. The Sparks created can fall on the Body, or an explosion can occur. Hence, during Welding, we should cover our Body with adequately designed equipment. We should also take care that no explosive material is present near the Welding area.

优点:

除了所有问题外，它都提供了不同的优势，因为它用于许多行业。其中一些如下：

适合任何环境：不同的焊接过程机制使用这种类型的屏蔽在特定环境中进行。我们可以在任何环境中使用电弧焊接过程。
不洁金属的使用：The process can be performed directly on dirty metals, and there is no need to clean the Surface.
可移植性：The material used in this process is highly portable
Low Cost:The Welding process is straightforward; hence it is of very low cost.

缺点：

Apart from the Issues related to Corrosion and Safety, there are other disadvantage of this process, which are as follows:

技能的要求：A very highly skilled person is required to give a perfect Surface finish.
Thin Metal:This process has some problems working with Thin Metals.

应用程序:

The most common application of this type of Welding process is in the Automotive, Aerospace, Oil and Gas, Power, and Construction based Industries.

FAQs:

问1：我们将无法使用电弧焊接？

Answer:We can use it almost everywhere. Although it can’t be used by beginners as there are many safety requirements. It is also not effective in Joining two dissimilar metals.

问2：谁是起搏器？

ANS：Pacemakers are implantable defibrillator, which is affected by the frequency of Alternating current during Welding.

问3：电弧焊接中如何产生残余应力？

Answer:During Heating and Instantaneous Solidification develops some amount of residual stress in Metal during Arc Welding. To eliminate this, the Solidification is done after some time of Heating.

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介绍：