Electric arc welding is a fusion welding process in which the heat required to melt the metal is obtained from the arc between the base material and the electrode. The AC power for the arc is obtained from a step-down transformer. The transformer receives current from the mains at 220 to 440 volts and then steps down to the required voltage, i.e. 80 to 100 volts.
Direct current for the arc welding equipment is usually obtained from an electric motor or a generator driven by a petrol or diesel engine. In the case of DC welding, the open-circuit voltage (for arc generation) is 60 to 80 volts, while the closed-circuit voltage (for holding the arc) is 15 to 25 volts.
First, the metal part to be welded is thoroughly cleaned to remove dust, dirt, grease, oil, etc. The workpiece is then firmly fixed in a suitable fixture. Insert the appropriate electrode into the electrode holder at an angle of 60 to 80° to the workpiece.
Inverter Automatic Submerged Arc Welding Machine
Select the appropriate current and polarity. The point is marked with an arc at the place where the welding is to take place. Welding is accomplished by bringing the electrode into contact with the workpiece and then separating the electrodes by the appropriate distance to create an arc.
When the arc is obtained, the intense heat generated melts the workpiece below the arc and forms a molten metal pool. A small depression is formed in the workpiece and molten metal is deposited around the edge of this depression. It is called an arc extinguisher. After the joint has cooled, the slag is easily brushed off. After welding, the electrode holder should be removed quickly to break the arc and cut off the current supply.
The welding machine used can be either an AC or DC welding machine. AC welders have step-down transformers that reduce the input voltage from 220-440 V to 80-100 V. DC welders consist of AC electric generator sets or diesel/gasoline engine generator sets or transformer rectifier welding sets.
AC motors usually use a 50 Hz or 60 Hz power supply. The efficiency of AC welding transformers varies from 80% to 85%. Energy consumed per kg. The amount of metal deposited is 3 to 4 kWh for AC welding and 6 to 10 kWh for DC welding. AC welding machines usually operate with a low power factor of 0.3 to 0.4, while the motors in DC welding have a power factor of 0.6 to 0.7.
Welding Holder
The function of the electrode holder is to hold the electrode at the required angle. Different sizes are available depending on the amperage rating of 50 to 500 amperes.
The function of the cable or wire is to carry the current from the machine to the workpiece. They are flexible and made of copper or aluminum. Cables are made of 900 to 2000 very fine wires twisted together to provide flexibility and greater strength. The wires are insulated by means of a rubber sheath, a reinforced fiber sheath, and a further thick rubber layer.
The function of the wire brush is to remove slag particles after chip removal with a chisel hammer. Sometimes, if available, a power wire wheel is used instead of a manual wire brush.
Steel Wire Brush
The function of the cable connector is to create a connection between the machine switch and the soldered electrode holder. Mechanical type connectors are used; as they can be easily assembled and disassembled. The connectors are designed according to the current capacity of the cables used.
The function of the chisel hammer is to remove the slag after the weld metal has cured. It has a chisel shape and points to one end.
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