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TIG WELDING TRAINING or GTAW (Gas Tungsten Arc Welding)
 
 
 
 
  • This welding process uses a non-consumable tungsten electrode that heeds the metal base. So the electric current runs through a tungsten electrode, which heats the material base and creates an arc that afterward melts the wire and creates the weld pool. It’s used along with a shielded gas, such as argon, for protecting the weld pool against atmospheric contamination.
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  • Just like with MIG welding, you’ll an external gas supply. The gas used is usually either argon or a mix of argon and helium.
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  • TIG welding is one of the most difficult to learn and most inefficient welding processes. It requires a great amount of focus and skill because there’s only a tiny area between the arc and the material being welded.
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  • The advantage, on the other hand, is that it offers the ability to weld very thin materials and provides high quality clean weld that is extremely strong when done correctly. It can be used for welding the following metals: magnesium, copper, aluminum and nickel.
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  • The welding process is quite popular in industries working with non-ferrous metals. It’s often used in bicycle and aircraft manufacturing, as well as in manufacturing tubing, vehicles, and other.
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  • Main points:
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  • You get highest quality welds
  • Ability to weld thinner metals
  • Highly aesthetic weld beads
  • Extremely strong weld
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    TIG WELDING TRAINING SYLLABUS
     
  • Introduction to Welding Process
  • Welding Positions
  • Tungstan insert Gas Welding
  • Methods and Application of Tig Welding
  • Equipments and consumables used in Tig Welding process
  • * Tig Welding Equipments
  • * Shielding Gases
  • * Electrode Size
  • Power Sources in Tig
  • * Welding Current Polarities
  • Joint Design and Fabrication of Tig Welding
  • * Groove and Joints
  • * Welding Symbols
  • Weldablity and Metallurgy
  • * Types and Futureof Base Metals
  • * Metallurgical Future of Weld
  • Inspection of Welded Joints (Tig)
  • * Destructive Testing
  • * Non Destructive Testing
  • Welding Defects and Causes
  • Welding Documents and Records
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    ARC WELDING TRAINING
     
     
    ARC WELDING TRAINING SYLLABUS
     
  • Arc welding is a welding process that is used to join metal to metal by using electricity to create enough heat to melt metal, and the melted metals when cool result in a binding of the metals. It is a type of welding that uses a welding power supply to create an electric arc between a metal stick ("electrode") and the base material to melt the metals at the point of contact. Arc welders can use either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes.
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  • Introduction to Welding Process
  • Welding Positions
  • Arc Welding and its application
  • Power source used in welding process
  • Welding Consumables
  • Joint Design and Fabrication of welding
  • Joint and Grooves
  • Welding Symbols
  • Welding Defects and Causes
  • Causes for Defects of Base Metals
  • Preventive Measures
  • Welding Metallurgy and Weldability
  • Types and Features of Base Metals
  • Metallurgical Features of Weld
  • Tested and Inspection welded joints
  • Destructive Testing
  • Non Destructive Testing
  • Welding Document and Records
  • WPS, PQR, & WPQR Details
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    TYPES OF ARC WELDING
     
  • Arc welding training in chennai uses an electrical power source to create an arc between the base metal and the electrode stick or wire. The arc is struck once you turn on the welding machine, adjust the settings, get safety gear in place, and scratch or tap the electrode against the base metal. The hot arc melts the metals where they should be joined. The molten material – often with filler – can then be crafted into a weld.
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  • Arc welding are different types of arc welding. Which arc welding method you use depends mostly on the metal. Following is an overview of various kinds of arc welding techniques:
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    Flux-cored arc welding (FCAW)
     
  • This type of arc welding uses tubular electrodes filled with flux. While emissive flux shields the arc from air, nonemissive fluxes may need shielding gases. It is ideal for welding dense sections that are an inch or more thick because FCAW has a higher weld-metal deposition rate.
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    Gas metal arc welding (GMAW)
     
  • GMAW or MIG welding shields the arc with a gas like argon or helium or a gas mix. The electrodes have deoxidizers that prevent oxidation, so you can weld multiple layers. This method has several benefits: simple, versatile, economical, low temperatures, and easily automated. This is a popular welding technique for thin sheets and sections.
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    Gas tungsten arc welding (GTAW)
     
  • GTAW or TIG welding, is often considered to be the most difficult. Tungsten electrodes create the arc. Inert gases like argon or helium or a mix of the two is used to protect the shield. Filler wires add molten material if needed. This method is much “cleaner” as it doesn’t produce slag, making it ideal for welding jobs where appearance matters as well as thin materials.
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    Plasma arc welding (PAW)
     
  • This arc welding technique uses ionized gases and electrodes that create hot plasma jets aimed at the welding area. As the jets are extremely hot, this method for narrow and deep welds. PAW is also good for increasing welding speeds.
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    Shielded metal arc welding (SMAW)
     
  • SMAW is one of the simplest, oldest, and most adaptable arc welding methods, making it very popular. The arc is generated when the coated electrode tip touches the welding area and is then withdrawn to maintain the arc. The heat melts the tip, coating, and metal, so that the weld is formed once that alloy solidifies. This technique is typically used in pipeline work, shipbuilding, and construction.
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    Submerged arc welding (SAW)
     
  • SAW works with a granular flux that creates a thick layer during welding, which completely covers the molten metal and prevents sparks and spatter. This method enables deeper heat penetration because it acts like a thermal insulator. SAW is sued for high-speed sheet or plate steel welding. It can be semiautomatic or automatic. However, it is limited to horizontal welds.
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    Different Types of Welding Processes
     
  • 1. Flux-Cored Arc Welding (FCAW)
  • 2. TIG – Gas Tungsten Arc Welding (GTAW)
  • 3. MIG – Gas Metal Arc Welding (GMAW)
  • 4. Stick – Shielded-Metal Arc Welding (SMAW)
  • 5. Laser Beam Welding
  • 6. Electron-Beam Welding
  • 7. Plasma Arc Welding
  • 8. Atomic Hydrogen Welding
  • 9. Electroslag
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    Flux-Cored Arc Welding
     
     
     
  • Flux-cored arc welding is similar to MIG welding, as it also involves a wire feed process, but instead of the shielded gas, it uses a flux-cored wire to protect the arc from contamination. So unlike with MIG welding, you can weld with this type of welder outdoors and the windy conditions won’t affect the weld. This process is commonly used in construction as it offers high welding speed and portability.
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  • MIG welding is very common in the automotive industry. Automotive work usually requires versatility and strength and this weld provides strength that can withstand large forces. Other common uses of MIG welding include construction, maritime industry, plumbing and robotics.
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  • Main points:
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  • Can be used on dirty or rusty materials
  • Allows out-of-position welding
  • Allows deep penetration if you’re welding thicker metals
  • A higher metal deposition rate
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    MIG or MAG GMAW (Gas Metal Arc Welding)
     
     
     
  • The MIG welding process uses a wire welding electrode that is automatically fed through a welding gun. The fed electrode creates an arc on the base metal, which heats the material until it starts melting for fusing with another piece of material. This creates a high-strength weld that looks great and requires little cleaning.
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  • For MIG type of welding, you need to supply shielded gas for protecting the weld from contaminants in the air. Common types of gas used for this are carbon dioxide, oxygen, argon and helium.
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  • MIG welding can be used on both thick and thinner plate metals. You can use it to work on metals, such as stainless steel, copper, nickel, carbon steel, aluminum, and other.
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  • Some of the advantages of the MIG welding type is minimal weld cleanup, lower degree of required precision, reduced welding fumes and lower heat outputs. It’s also the easiest welding technique to learn. So it’s a great choice for a beginner welder.
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  • Though it also has its disadvantages. One of them is the weld’s sensitivity to external factors, such as wind, rain or dust. So the MIG welding processes should be carried out indoors, with the materials being cleaned of dirt and rust.
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  • Other disadvantages include the extra cost of getting shielded gas, inability to weld thicker metals, and inability to perform vertical or overhead welding.
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  • Main points:
     
  • Easiest to learn
  • Offers high welding speeds
  • Cleaner weld with less cleanup
  • Offers better control on thinner metals
  • The welder can also be used for flux-core welding
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    MIG WELDING TRAINING SYLLABUS
     
  • Introduction to Welding Process
  • Gas Metal Arc Welding (GMAW)
  • * Process and its Application
  • Welding positions
  • Equipments and consumables used in Mig GMAW Welding process
  • * Mig Welding Equipments
  • * Shielding Gases
  • * Electrode Size
  • Hazards Safety Measurement during GMAW
  • * Hazards
  • * Safety Equipments
  • Welding techniques for GMAW Process
  • Power Sources used in GMAW
  • * Welding Current Polarities
  • Welding Defects and Causes
  • * Study about defects
  • * Preventive measures of Welding Defects
  • Inspection of Welded Joints (Mig)
  • * Destructive Testing
  • * Non Destructive Testing
  • Welding Documents and Records
  • * WPS , PQR
  • * WPQR Details
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    Aluminum and magnesium Welding
     
     
     
  • Aluminum and magnesium are most often welded using alternating current, but the use of direct current is also possible, depending on the properties desired. Before welding, the work area should be cleaned and may be preheated to 175 to 200 °C (347 to 392 °F) for aluminum or to a maximum of 150 °C (302 °F) for thick magnesium workpieces to improve penetration and increase travel speed
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  • AC current can provide a self-cleaning effect, removing the thin, refractory aluminum oxide (sapphire) layer that forms on aluminum metal within minutes of exposure to air. This oxide layer must be removed for welding to occur.
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  • When alternating current is used, pure tungsten electrodes or zirconiated tungsten electrodes are preferred over thoriated electrodes, as the latter are more likely to "spit" electrode particles across the welding arc into the weld. Blunt electrode tips are preferred, and pure argon shielding gas should be employed for thin workpieces. Introducing helium allows for greater penetration in thicker workpieces, but can make arc starting difficult.
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  • Direct current of either polarity, positive or negative, can be used to weld aluminum and magnesium as well. Direct current with a negatively charged electrode (DCEN) allows for high penetration.
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  • Argon is commonly used as a shielding gas for DCEN welding of aluminum. Shielding gases with high helium contents are often used for higher penetration in thicker materials. Thoriated electrodes are suitable for use in DCEN welding of aluminum. Direct current with a positively charged electrode (DCEP) is used primarily for shallow welds, especially those with a joint thickness of less than 1.6 mm (0.063 in). A thoriated tungsten electrode is commonly used, along with a pure argon shielding gas
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    WPS PQR WPQR TRAINING ( ASME SEC-9 )
     
     
     
  • 1. Brief Introduction
  • 2. PQR / WPQR Testing
  • 3. Procedure Qualification Record (PQR)
  • 4. Welding Performance Qualification (WPQ)
  • 5. ASME Definitions for Welding Processes, Consumables and Welding Positions
  • 6. ASME Approval Range Calculator
  • 7. ASME P Material Numbers
  • 8. Graphic Representation of Welding Positions
  • 9. Multi Process Welding Procedures QW200.4 AND QW451.1
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    6G WELDING TRAINING
     
     
     
  • 1. Types of Welding Process
  • 2. Types of Joints & Welding Nomenclature
  • 3. Welding Parameters
  • 4. Welding Positions
  • 5. Concepts of 6G Welding
  • 6. 6G Welding Practical
  • 7. Welding Imperfections
  • 8. Welding Safety
  • These joints are usually set up with a 1/8" (+ or- 1/16") gap and almost no land. I would set it up with tight 1/8 gap and use 1/8 rod for the root. You are going to need some practice because it aint that easy unless you have done a bunch of them. Some 6g certification test pointers I can think of are:
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  • 1. Fit up matters as much or more than anything, make sure you have a good fit with no mismatch and even gap.
  • 2. Make sure you have a good purge and make sure you have a vent hole. More argon is not better, it will probable take 10 cfh or less to purge.
  • 3. The root and second pass should be the same amperage. After that you can increase amperage a bit but don’t get carried away.
  • 4. Don't get in a hurry; they will probably give a written procedure with interpass temperature limits. Meaning let it cool between passes, even if you are on a roll. Getting in a hurry won't help you.
  • 5. Learn how to freehand using a "hotfinger" in case the inspector has pet peeve against "walking the cup".
  • 6. Keep the red hot tip of the rod shielded in the argon and snip the wire if you forget or when you restart.
  • 7. Electrode angle for the root should be pretty dead nuts straight in.
  • 8. I would recommend a slight forward and back technique as opposed to the side to side you get when you walk the cup. I have seen both ways work and I have also seen cup walkers suck back the root pass.
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    Welding Electrode Qualification Test (WEQT)
     
     
    Welder And Welding Electrode Qualification Testing (EQT)
     
     
    Welding Electrode Qualification Testing(EQT)
     
     
     
  • welding electrode qualification test determines if weld filler metal meets the specified characteristics for its intended use. For example, if a piping system is to be used in sub zero temperatures then the base metal (pipe) and the welds used to join the pieces of pipe in the system must be able to withstand the rigors of sub zero environment. Mechanical testing determines impact toughness and tensile strength of the weld metal.
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  • welding electrode qualification testing involves making a weld using intended base metal and intended welding electrode according to a specified welding procedure that was created by a welding engineer. Welding parameters such as pre heat, welding volts, welding amperage and maximum interpass temperature must be strictly monitored while welding. The welding procedure outlines these values.
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  • welding electrode qualification test The weld is then tested using some non destructive testing methods like radiography (xray), magnetic particle testing and then is cut into pieces for the mechanical tests like the Charpy V notch which measures impact toughness and a tensile test measuring ductility and strength .
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  • welding electrode qualification test If the weld metal meets the required specifications then that electrode is approved for use in welding the product in specified conditions.
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    List of welding courses
     
    arc welding training in chennai , Flux-Cored Arc Welding (FCAW) training in chennai , tig welding training in chennai , TIG – Gas Tungsten Arc Welding (GTAW) training in chennai , mig welding training in chennai , MIG Gas Metal Arc Welding (GMAW) training in chennai , Stick Shielded Metal Arc Welding (SMAW) training in chennai , Laser Beam Welding training in chennai , Electron-Beam Welding training in chennai Plasma Arc Welding training in chennai , Atomic Hydrogen Welding training in chennai , Electroslag welding training in chennai , fcam welding training in chennai , gtaw welding training in chennai , gmaw welding training in chennai , smaw welding training in chennai , aluminium welding training in chennai , al welding training in chennai , ss welding training in chennai , stainless steel welding training in chennai ...