Tamil Welding Notes 22413t

Mh;Nfh \Py;l; gw;witg;G gw;witg;G Kiwfs;

gw;witg;GcgNahfj;jpy; cs;s rjtPjk; ,e;jpah

1.

Mh;f; gw;witg;G

2.

kiwe;j Mh;f; gw;witg;G (Submerged Arc)

7%

3.

Nf]; cgNahfpj;J gw;witg;G (MIG)

7%

4.

Nf]; lq;];ld; Mh;f; gw;witg;G (TIG)

Kd;Ndwpa ehLfs;

84%

30٪ 8% 60% (40% Solid wire, 20% Core wire)

2%

2%

Mh;Nfh \Py;l; vd;why; vd;d? Mh;Nfh \Py;l; vdgJ %d;W thAf;fs; Mh;fhd;> Mf;]P[d;> kw;Wk; fhpky thA ,itfspd; fyg;G MFk;. ,e;j thAf;fspd; xt;nthd;wpd; jdpj;jd;ikahy; gw;witg;G Kiwapy; gy gyd;fs; fpilf;fpwd. Mh;fhd; (Argon): Mh;f;if ey;y Kiwapy; Vw;gLj;jTk;> nkl;ly; khw;wk; ey;y Kiwapy; elf;fTk; Fiwe;j ];Ngl;lh;fs; (SPATTERS) mikaTk; cjTfpwJ. Mf;]p[d; (oxygen): Mh;f;if xUKfg;gLj;jTk;> %y cNyhfj;ij gw;witg;ig ed;Kiwapy; elf;fTk; cjTfpwJ. fhpky thA (fhh;gd;-il-Mf;i]L - Co2):,J Nfhg;ig Nghy ngdpl;Nu\iD (PENETRATION) cz;lhf;fp> ey;y cWjpahd gw;w itg;ig epiy epWj;JfpwJ.

Mh;Nfh \Py;l; gw;witg;G I.rp.vg;. (I.C.F.) Mh;Nfh\Py;l; Adpth;ry; thA fyg;ig gp.X.rp (B.O.C.) cjtpAld; cgNahfg;gLj;j Jtq;fpAs;sJ. Mh;Nfh\Py;l; Adpth;ry; thA fPNo cs;s rjtPjj;jpy; fye;Js;sJ. -

86% Mh;fhd; 12% fhpky thA (Co2) kw;Wk; 2% Mf;]p[d; (O2)

,e;j thA fyg;G iky;l; ]Pby; (MILD STEEL) 3(mm) kp.kP. fdj;jpypUe;J 16 kp.kP (mm) rhjhuz gw;witg;gpw;F cjTfpwJ. ,e;j thA fyg;ig cgNahfg;gLj;Jtjpdhy; cz;lhFk; gyd;fs;. 1.

Mh;f;if (ARC) epiy epWj;Jjy; kw;Wk; Fiwe;j ];Ngl;lh;]; (Spatters).

2.

nty;l; nkl;ly; cUtk; ed;F mike;J> nty;l; nkl;ly; cgNahfj;ij Fiwj;jy; (SAVINGS IN WELD METAL).

3.

Ntfkhd gw;witg;G> ,jdhy; cw;gj;jp mjpfkhf;fp> Ml;fspd; nryit Fiwj;jy; (Readuce labour costs)

4.

gw;witg;gpd; juj;ij cah;j;jp ghfq;fs; tPzhtij jtph;j;jy;.

fhpky tha;tpw;F (Co2) gjpyhf Mh;Nfh\Py;l; cgNahfg;gLj;Jtjdhy; Vw;gLk; gzr; rpf;fdq;fs;: ilg; mg; [hapd;l; (TYPE OF T) tahpd; msT (WIRE SIZE) nty;bq; fz;b\d;

-

ghJfhg;G thAtpd; cah;T (Increase the Shielding gas) tahpd; (Wire) cgNahfj;jpy; Fiwg;G

-

];g;Nu buhd;];gh; (SPRAY TRANSFER) 370%

-

20.5%

kpd;rhu cgNahfj;jpy; Fiwg;G

-

18.5%

nkhj;jj;jpy; cgNahfj;jpy; Vw;gLk; rpf;fd Fiwg;G (wire, Gas & power)

-

5%

Ml;fspd; nryT Fiwg;G

-

18%

nkhj;jj;jpy; gw;witg;G Fiwg;G

-

9.5%

-

12kp.kP (mm) (H.V.F. FILLET) 1.2kp.kP. (mm)

Mh;Nfh \Py;l; Adpth;ry; cgNahfj;jpdhy; Vw;gLk; gyd;fs;:1. 2. 3. 4. 5. 6. 7. 8.

ed;F Mh;f; (ARC) epiy epWj;Jjy; vy;NyhUk; cgNahfg;gLj;Jjy; kpf Fiwe;j mf;]pNl\d; (Oxidation) tah; (Wire) cgnahfk; Fiwj;jy; Fiwe;j tisT> neypTfs; (Low Distortion) Ntfkhf nray;gLjy; ];g;Nu/gy;];/bg; buhd;];gh; (SPRAY/PLUSE/DIP TRANSFER) kl;lkhd gPl; mikg;G kw;Wk; ngdpl;Nu\d; (PENETRATION) (tpuy;fs; my;yJ itd; Nfhg;ig Nghd;w ngdpl;Nu\d;)

Nrkpg;Gfs;: 1. 2.

tah; (Wire) cgNahfj;jpy; Nrkpg;G 15% Kjy; 30% tiu. nty;bq; Neuj;jpy; Nrkpg;G 15% Kjy; 30% tiu

Fwpg;G: 1.

nty;bq; \Py;l;> N\l; ek;gh; 13 - gpy;lu; fpyhi] cgNahfg;glj;j Ntz;Lk;.

2.

thA xOFjy; vy;yh ,lj;jpYk; fl;LgLj;jp> thA tPzhFtij jtph;f;f Ntz;Lk;. Vndd;why; Mh;fhd; thAtpd; tpiy mjpfk;.

3.

Md;b ];Ngl;lh; cgNahfpf;fj; Njitapy;iy.

(tpuy;fs; my;yJ itd; Nfhg;ig ngdl;nu\d;)

thA ntl;Ljy;: vh; fhh;gd; topKiw fUtpfs;: Mh;f; fhh;gd;> Mh;f; fl;bq;fps; cgNahfpf;fg; gLk; fUtpfs; gpd; tUtd: AC, DC my;yJ AC/DC ntd;bq; kp\pd; Vh; fk;u]h; my;yJ fk;gu];l; Vh; rpypz;lh;. fk;gu];l; Vh; X]; Vh; fh;gd;> Mh;f; lhh;r; fUtp mjDld; Vh; n[l; bit]; mike;jpUf;Fk;. vyf;NuhL: vyf;NuhL fh;gd; tbtj;jpYk; my;yJ fpuhigl; tbtj;jpYk; my;yJ fhh;gd; fpuhigl; ,uz;lk; fye;j tbtj;jpy; ,Uf;Fk;. Vh;fhh;gd; fl;bq; vyf;NuhL %d;W tifg;gLk;:i) ii) iii)

DCEP gpisd; DCEP nrk;G G+rg;gl;lJ AC nrk;G G+rg;gl;lJ

nrk;G G+rg;gl;l vyf;NuhL Mf;]pNlrd; Mtij Fiwf;Fk; mJ vyf;Nuhil Fspikahf itj;jpUf;f cjTk;. thA ntl;Ljy;:nra;tjw;fhf cjTk; fhh;gd; vyf;NuhL 4 kp.kP. kjy; 25.4 kp.kP tiu ntt;NtW tbtq;fspy; tUk;. thA ntl;Ljy; nra;Kiw:xU fUtpapd; mfyj;ijAk; moj;ijAk; itj;J vyf;Nuhil Njh;e;njLf;f Ntz;Lk;. thA ntl;Ljy; nra;Ak; NghJ Vh; (ePuhtp) ];hPk; Mh;if Nehf;fpNa ,Uf;f Ntz;Lk;. ,J Mh;f; Vw;gLk; ,lj;jpy; cs;s cNuhfq;fis Cjp ntspNa js;Sk;. nth;bfy; Nfhzj;jpy; thA ntl;Ljy; NkypUe;J fPo; nra;a Ntz;Lk;. mg;gb nra;Ak; NghJ Mh;f; Vw;gLk; ,lj;jpypUe;J cUFk; epiyapy; cs;s cNyhfq;fis GtpaPh;g;gpd; Jiz nfhz;L mfw;Wk;. Mhprhz;ly; Nfhzj;jpy; thA ntl;Ljy; nra;Ak; NghJ tyJ Gwkhf Muk;gpj;J ,lJ Gwkhf ,Uf;f Ntz;Lk;. JiyNky; Nfhzj;jpy; thA ntl;Ljy; nra;Ak;NghJ vyf;NuhL Xy;lhpy; cs;s ikaf; Nfhl;bw;F ,izahf vyf;Nuhil nghWj;j Ntz;Lk;.

Vyf;NuhL tpl;lj;jpw;Nfw;g kpd;rhu nghUj;jk; fPNo nfhLf;fg;gl;Ls;sJ vyf;NuhL tpl;lk;

kpd;rhu nghUj;jk; (Mk;gpah;) DCEP

AC vyf;NuhL (Mk;gpah;)

INCH 5/32

MM 4.0

MIN 90

MAX 150

MIN -

MAX -

3/16

4.8

150

200

150

200

1/4

6.4

200

400

200

300

5/16

7.9

250

450

-

-

3/8

9.5

350

600

300

500

1/2

12.7

600

1000

400

600

5/8

15.9

800

1200

-

-

3/4

19.1

1200

1600

-

-

1

25.4

1800

2200

-

-

gw;witg;gpd; NghJ Vw;gLk; nghJhd FiwghLfs; Xu jukhd gw;witg;G vd;gJ rPuhd tl;l tbtkhfTk;> rhpahd mfyk; cilajhfTk;> ed;whf CLUtpAk; ,Uf;Fk;. ntspg;Gwj; Njhw;wj;jpy; ve;j FiwghLfSk; ,d;wp ,Uf;Fk;. FiwghLfs;:FiwghL vd;gJ> gw;witf;fg;gl;l cNyhdj;jpy; mjw;F Njitahd tYitAk;> cWjpiaAk; juhJ. FiwghLfis ,uz;L tifahf gphpf;fyhk;:i) ii)

ntspg;Gw FiwghLfs; cs;Gw FiwghLfs;

ntspg;Gw FiwghLfs;:cs;Fop (or) gs;sk;:0 (Undercut) xU gs;sk; my;yJ fhy;tha; Nghy; cNyhfj;jpy; gw;witf;fg;gl;l ,lj;jpy; fhzg;gLk;. fhuzq;fs;:kpd;rhuk; mjpfkhf ,Ue;jhy; gw;witf;gpd; Ntfk; mjpfkhf ,Ue;jhy; cNyhfk; gw;witg;gpd;NghJ mjpfkhf #lhdhy; gw;witg;G fk;gpapd; Nfhzk; jtwhf ,Ue;jhy; gw;witg;gpd; NghJ gw;witf;Fk; jpir my;yJ gw;witg;Gf; fk;gpf;Fk;> cNyhfj;jpw;Fk; milg;gl;l J}uk; khw;wg;gl;lhy; mtw;iw jLf;f:cWjpg;gLj;jpf; nfhs;f:-

rhpahd rhpahd rhpahd rhpahd

kpd; msT gw;witg;G Ntfk; kpd;rhug;gha;r;ry; Nfhzk; (gw;witg;G fk;gpapd;)

mjpfkhf cNyhfk; epuk;gpaJ:- (Over lap) ,J cUfpaepiyapy; gw;witg;G fk;gpapy; ,Ue;J gw;witf;f Ntz;ba cNyhfj;jpy; CLUthtpl;lhy; Vw;gLk;.

fhuzq;fs;: (Causes) -

Fiwthd kpd; msT gw;witg;gp;d; Ntfk; Fiwe;jhy; gw;witg;Gf;fk;gpf;Fk;> gw;witf;f Ntz;ba cNyhfjjpw;Fk; ,ilNa cs;s J}uk; gw;witg;Gf;fk;gpapd; tpl;lj;ij tpl mjpfkhf ,Ue;jhy; (Long Arc) gw;witg;Gf; fk;gpapd; tpl;lk; (Dia) mjpfkhf ,Ue;jhy;

mtw;iw jtph;f;f (Remedies) -

rhpahd rhpahd rhpahd rhpahd

kpd; msT gw;witg;gpd; Ntfk; Arc Length tpl;lKs;s gw;witg;Gf; fk;gp cNyhfj;jpd; fzj;jpw;Nfw;g

CJ Jis (Porosity) CJ Jis my;yJ thAg; ig vdg;gLk; ,J gy Ez;zpa Jisfis gw;witg;gpd; Nky; nfhz;ljhf ,Uf;Fk;. fhuzq;fs;:mRj;jq;fs; gw;witf;f Ntz;ba cNyhfj;jpNyh> gw;witg;Gf; fk;gpapNyh ,Ue;jhYk;> kw;Wk; ry;gh; mjpfkhf ,Ue;jhYk; rhpahf Rj;jk; nra;ag;glhj NrUk; ,lq;fs; ,Ue;jhy; ,it Vw;gLk;.

mtw;iw jLf;f:cNyhfj;jpy; ,Ue;J vz;nza;> ngapz;l;> J}rp Nghd;wtw;iw ed;whf Rj;jk; nra;J ePf;fp tpLtjhy; mtw;iw jLf;fyhk;. ed;whf fha;e;j gw;witg;Gf; fk;gpfis cgNahfpg;gjhy; jLf;fyhk;. Long Arc-I cgNahfpf;f $lhJ. rpwpa cNyhfk; (Spatters) rpwpa cjug;gl;l cUfpa cNyhfq;fs; gw;witg;gpd; NghJ gw;witf;fg;gLk; ,lj;ij jtpu kw;w ,lq;fspy; rpjwp ,Ug;gJ rpjwpa cNyhfk; vdg;gLk;. fhuzq;fs;:-

kpd;msT mjpfkhf ,Ue;jhy; kpd;rhuk; ghAk; jpir jtwhf ,Ue;jhy; (DC only). Long Arc cgNahfpj;jhy; rhpahd fyit G+rg;glhj gw;witg;Gf; fk;gp cgNahfpj;jhy; ,it Vw;gLk;.

mtw;iw jLf;f (Remedies):-

rhpahd kpd; msit cgNahfpj;jy; kpd;rhug; gha;r;riy rhpahd jpirapy; mikj;jy; (DC only) rhpahd Arc length cgNahfpj;jy; rhpahd gw;witg;Gr; fk;gpia cgNahfpj;jy;

cNyhfj;jpd; Kid cUfptply;:-

fhuzq;fs;:-

gw;witg;Gf; fk;gpapd; msT mjpfkhf ,Ue;jhy; kpd; msit mjpfkhf cgNahfpj;jhy; mtw;iw jLf;f rhpahd msthd gw;witg;Gf; fk;gpia cgNahfg;gLj;Jjy; rhpahd kpd; msit cgNahfpj;jy; rhpahd Nfhzj;jpy; gw;witg;Gf; fk;gpia cgNahfg;gLj;Jjy; mjpfkhf gw;witg;G cNyhfj;ij gad;gLj;jp Throat-d; fdj;ij mjpfg;gLj;Jjy;.

gpsT (Crack):xU E}ypio ,ilntsp gw;witj;j cNyhfj;jpNyh> fPo; cNyhfj;jpNyh Vw;gLk;. fhuzq;fs;:-

cNyhfj;ij Ntfkhf Fspur; nra;jy;. jtwhd gw;witg;G top Kiwfs; gw;witg;Gf;F Kd;Dk;> gpd;Dk; cNyhfj;ij #LgLj;j jtwpdhy; (In case of carbon steels)

mtw;iw jLf;f:-

gw;witg;Gf;F Kd;Dk;> gpd;Dk; cNyhfj;ij rhpahd epiyf;F #LgLj;Jtjhy; nkJthf Fspur; nra;tjhy; rhpahd gw;witg;G Kiwfis ifahStjhy;.