Key Engineering Materials Submitted: 2020-04-23

ISSN: 1662-9795, Vol. 861, pp 122-126 Accepted: 2020-05-09

doi:10.4028/www.scientific.net/KEM.861.122 Online: 2020-09-02
© 2020 Trans Tech Publications Ltd, All Rights Reserved

Welding Operation Technique of Welding Electrode Arc Welding

Overhead Welding Test Board
Xinghui Li1,a*
1
School of Mechanical Engineering, Jiangsu Prvince Xuzhou Technician Institute Xuzhou, Jiangsu,
China
a
email: 2804809396@qq.com

Keywords: electrode arc welding; test plate for overhead welding; operation technique

Abstract: Welding electrode arc welding, upside welding, single side welding, double side forming
welding operation technology is the most difficult welding process in manual arc welding operation.
It is an operation technology that senior welding operators must master, and it reflects the technical
level of the welding welder. . In this paper, the welding operation essentials and operation skills of
backing welding, filling welding and cover welding are studied for the welding operation of the
back welding test board, which creates a theoretical basis for the improvement of the welding
operator's operation skills.

Introduction
Welding electrode arc welding, upside welding, single-sided welding, double-sided free forming
is the most difficult welding process in manual arc welding. The test plate upside welding is the
most technically demanding and the most difficult operation in the competitive test pieces of
provincial welders. It can best reflect the level of operation of the welding welder. Generally
speaking, any welder who can complete the test plate upside welding is basically capable of
welding at various positions in the manufacture or maintenance of pressure vessels, so it has very
important practical significance.
There are two welding methods for plate-like back welding and bottom welding: continuous arc
method and arc extinguishing method[1]. The continuous arc method is an operation method for
short arc welding by continuously and regularly swinging the electrode; the arc extinguishing
method is that the arc is extinguished after a certain period of time when the arc is burned, and then
ignited and extinguished again, thereby making the molten pool Metal forming method. Both
methods have their own advantages. The arc-extinguishing method can ensure that the back weld is
well formed, and can effectively control the sagging of the weld and the concave of the top surface.
The disadvantage is that the welding process is in a discontinuous state, and defects such as porosity
and slag are prone to occur. The continuous arc method can make the welding process continuous
and can effectively guarantee the welding quality. However, improper operation methods will cause
the welding seam to sag and the surface to be concave. The continuous arc welding is more worthy
of promotion.

Test Board and Process Requirements

Test board requirements. The material of the test board is Q235B, and the specification is
100 mm × 12 mm × 300 mm. Adopt E5015 (J507) electrode, the electrode diameter is 3.2mm, the
welding position is overhead welding, single side welding is required. The form of the groove is
shown in Figure 1.

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 Key Engineering Materials Vol. 861 123

Fig. 1 Bevel form and size

Table 1 Assembly requirements

Blunt Starting End Starting tack End tack welding Anti-deform
thickness gap gap welding length length ation angle
[mm] [mm] [mm] [ mm] [mm] [°]
1.5~2 3 3.5 10~15 8~10 2~2.5

Welding process parameters. The welding process parameters are shown in Table 2.

Table 2 Welding process parameters

Welding level Welding current [A] Power polarity Thrust current [A]
DC positive
the bottom 90~100 90
connection
DC reverse
Fill layer 110~120 70
connection
DC reverse
Cover layer 110 50
connection

Angle of electrode. The angle between the electrode and the welding direction during welding is
shown in Figure 2.
Welding direction

(a) Left and right direction (b) Welding direction

Fig. 2 Electrode angle

Main Points of Welding Operation

Welding of the bottom layer. For the whole test plate, the welding of the bottom layer is the
key. During the welding process, the self-gravity of the weld pool metal is in equilibrium under the
action of the arc force and the surface tension of the liquid metal [2]. For specific operations, the
following requirements must be met: First, in order to ensure good fusion on both sides of the test
plate groove, the welding current should be slightly larger, and the welding current should be 90 ~
100 A; second, short arc application Welding, in order to protect the molten pool, and at the same
124 Advanced Materials and Engineering Materials IX

time use the arc force to support the molten iron in the molten pool, and transfer some of the
droplets to the back of the test piece (that is, above); third, make the subsequent molten pool cover
1/1 of the previous molten pool 2, and appropriately increase the welding speed to reduce the
penetration depth, reduce the gravity of the liquid metal itself, and avoid the sagging of the weld
metal; Fourth, maintain the correct way of transporting the strip, so that the welding rod is 90 ° to
the left and right sides of the test plate, And the angle between the welding direction and 70 ° ~
80 °. When welding, the back of the weldment should maintain a 2/3 arc column to facilitate the
transfer of droplets and protection of the molten pool. It should swing slightly from side to side
during transport. When welding close to the middle of the test plate, the gap is narrowed due to
deformation, at this time, the electrode can not be oscillated laterally, but arc welding in the welding
direction; Fifth, the electrode joint should be replaced quickly, and the joint part should be in a red
hot state Quickly start the arc and restore the welding state as soon as possible, so that the joint can
be well formed, and defects such as porosity and slag inclusion can also be reduced.
The polarity of the bottom welding can be DC reverse connection or DC direct connection
method. When the molten droplet is transferred to the molten pool during welding, it is hit by the
positive ions emitted from the direction of the molten pool. Since the mass of positive ions is larger
than that of electrons, the force that hinders the transition of the droplets is large, so that the welding
spatter is large. However, this operation method is simple and easy to learn, the arc is not easy to be
blown unevenly, and the back surface is well formed. The effect after welding is shown in Figure 3.

(a) Forward connection (b) Reverse connection

Fig. 3 Effect picture after welding

The DC reverse connection method requires the welder to have a solid basic skill, which is
difficult to master, but this arc-breaking welding method can flexibly control the temperature of the
molten pool and the back surface formation, and is not prone to defects and has a high flaw
detection pass rate. The effect after welding is shown in Figure 4.
Welding of filling layer. The filler layer adopts the arc welding method of left and right
swinging, and two points should be noted during operation: First, the electrode and the test plate
should be perpendicular to the left and right direction, so as to avoid the unequal thickness of the
filler layer weld and affect the weld formation[3]. In order to grasp the angle, some welders use
both hands to hold the welding pliers for welding, and the effect is good; Second, the slag between
the channels must be cleaned to avoid slag inclusions. The filling layer is preferably 2 layers. The
thinner welding layer can not only effectively ensure the internal quality of the weld, but also lay a
good foundation for the welding of the cover layer.
Welding of cover surface layer. The welding of the cover surface layer is related to the positive
formation of the weld of the test board. Weld seam residual height, residual height difference,
width, width difference and other items have specific requirements. Welders must maintain a calm
attitude and give full play to the technical level to make the front weld seam level and uniform. The
 Key Engineering Materials Vol. 861 125

most difficult thing to do when welding the cover layer is to control the amount of undercut. Most
players suffer from serious underbite and affect their performance[4].

Defects and Methods to Overcome

Stomatal. Blowholes are the most easily generated defects. Once surface blowholes appear, the
referee will judge the test board as 0 points. The reason for the pores is that the gas generated during
the welding process and the gas around the molten pool are absorbed by the liquid metal, and the
solubility drops sharply during the solidification process, the gas will precipitate out and form
bubbles, and it will remain in the weld if it is too late to escape during the floating process Pores are
formed in the metal. Ways to prevent the formation of pores: First, short arc welding is used to
prevent harmful gases from invading the molten pool to effectively protect the molten pool. In
addition, the distance of the droplet transfer can be shortened and the possibility of absorbing gas is
reduced. Second, the selection is reasonable Process parameters, the welding current should not be
too large when welding the filling layer and the cover layer, because when the welding current
increases, it will promote the refinement of the droplets, the amount of absorbed gas will also
increase, and the possibility of generating pores will increase Third, the rust and dirt on both sides
and between layers of the test plate groove should be removed as far as possible to reduce the root
cause of air holes.
Slag inclusion. During the welding process, because the slag between the welding layers is not
cleaned completely, and because of the welding speed Fast, the molten pool solidifies faster, and the
slag does not have time to float out of the molten pool and form slag inclusions[5]. Two points
should be noted when solving slag inclusions: One is to completely remove the slag between the
layers, especially the slag inclusions on both sides of the bottom seal and the groove are difficult to
remove, and it must be carefully cleaned with a pointed hammer and a hacksaw blade; the second is
the filling layer Welding strips should stay on both sides of the groove a little longer, not only to
allow sufficient time for the slag to float out, but also to make the weld seam smooth, laying a good
foundation for the welding of the cover layer.
Undercut. Undercut is the most difficult defect to overcome when welding the cover layer. The
reason is that the liquid metal at the undercut is gravity, which causes sag. In order to prevent
undercuts, the following three points should be achieved: First, the cover layer should be thin, and
should not exceed 2 to 3 mm; Second, the swing should be uniform when transporting the strip, and
the arc must be depressed on both sides of the groove to make the edge The melting of the part is
controlled at about 1 mm; the third is to select the appropriate welding current. When the 3.2mm
electrode is selected, the welding current is 110 A to avoid undercut defects caused by excessive
heat input[6].

Conclusion
The welding of the test pieces for the sheet metal back welding is strictly in accordance with this
process and technology. During the test, the welder is only allowed to clean the surface of the
weldment rust, oil and oxide scale. After the workpiece is positioned and fixed, no auxiliary tools
can be used to clean the weld seam. After that, it is only necessary to clean the welding slag and
spark splash on the surface of the weld to obtain a weld joint of higher quality. The following points
should be noted during the welding process:
(1) Welding stress on the bottom layer is to ensure that the meat is full and free of defects or as
few as possible.
126 Advanced Materials and Engineering Materials IX

(2) At the time of bottom welding, please pay attention to the use of DC positive connection, and
the other layers should pay attention to the thrust current.
(3) The slag of each welding layer should be cleaned, and each layer must be controlled
(4) When welding the filler layer, it is necessary to make full use of the arc itself to remove
defects, and ensure that there is sufficient welding meat height.
(5) The weld of the cover layer should be beautiful.

References
[1] Qiu Jiafei, Welder technology, third ed., China Labor and Social Security Press, Beijing, 2005.
[2] Feng Minghe, Welder skill training,third ed., China Labor and Social Security Press, Beijing,
2005.
[3] Si Zhongyao, Welding Handbook Volume 2, Machinery Industry Press, Beijing, 1992.
[4] China Employment Training Technical Guidance Center, Welder, China Labor and Social
Security Press, Beijing, 2009.
[5] Ren Xuan, Mi Guoqiang,Welding skill training, Machinery Industry Press, Beijing, 2008.
[6] Shen Huitang, Welding technology and high skills,Mechanical Industry Press, Beijing, 2003.