It is root gap for welding of two metals. You can use any dimentional units such as Inches or MM as per your prefererance. if you are using Inches as units for your input values then please refer decimal fractional chart to enter proper input values.
It is root face prepared during welding edges preparation for welding of two metals. You can use any dimentional units such as Inches or MM as per your prefererance. if you are using Inches as units for your input values then please refer decimal fractional chart to enter proper input values.
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It is height of welding material excess from top of the welding metal top face. You can use any dimentional units such as Inches or MM as per your prefererance. if you are using Inches as units for your input values then please refer decimal fractional chart to enter proper input values.
It is ecxess welding metal deposited from welding edges. You can use any dimentional units such as Inches or MM as per your prefererance. if you are using Inches as units for your input values then please refer decimal fractional chart to enter proper input values.
It is distance of root face from the top of the joining metals. You can use any dimentional units such as Inches or MM as per your prefererance. if you are using Inches as units for your input values then please refer decimal fractional chart to enter proper input values.
Plate Thickness of welding joining metal. You can use any dimentional units such as Inches or MM as per your prefererance. if you are using Inches as units for your input values then please refer decimal fractional chart to enter proper input values.
It is length of total weld joint. You can use any dimentional units such as Inches or MM as per your prefererance. if you are using Inches as units for your input values then please refer decimal fractional chart to enter proper input values.
Welding weight and Cost Calculator is used to calculate welding weight, welding cost, welding material requirement for all types of joints used in pressure vessel and other types of fabrication Industry where welding process is used.
With this information, and knowing the deposition rate of the process, it is possible to determine the arc time (the length of time that an arc is burning and depositing weld metal) and the amount of welding consumables required to fill the joint. Both of these are required in order to calculate the cost of making the weld. Costing will be dealt with in future Job Knowledge articles.
Determining the volume of a weld requires some knowledge of basic geometrical calculations to determine the area of the weld and multiply this figure by its length. The first step then is to calculate the cross sectional area of the joint.
With a fillet weld or a 45 single bevel joint this is relatively simple but the calculations become lengthier as the weld preparation becomes more complex. Fig.1 illustrates how simple this calculation is for an equal leg length fillet weld; the area of such a weld is half the square of the leg length, Z. When using this formula do not forget that welders seldom deposit precisely the size of weld called up on the drawing or in the welding procedure and that there may be some excess weld metal on the face of the weld.
An asymmetrical fillet weld is a little more difficult; the area of a triangle is given by the base Z2 times the height Z1 divided by 2 so when a fillet weld is deposited with unequal leg lengths the area can be calculated from multiplying the throat, a, by the length of the face I and divided by 2 as illustrated in Fig.2.
There are three factors that determine the volume of the weld in a single V butt weld. These are the angle of the bevel, b, the excess weld metal and the root gap, g, as illustrated in Fig 3. To calculate the area of this weld we need to be able to add together the areas of the four components illustrated in Fig.3.
To obtain the weight of weld metal this figure is then multiplied by the density of the alloy. Table 1 gives the density of some of the more common alloys in gm/cu.cm. Note that with some alloys the alloying elements can change the density quite significantly.
A J-preparation, however, adds another area into the equation; that of the half circle at the root of the weld, see Fig.4. The formulae given above to calculate 'c', the area of the two red components and the excess weld metal remain unchanged but the width of the cap must be increased by 2r. There are also the two areas, 'A' and 'B', to calculate and the two white root radius areas to be added to the total.
Having calculated the weight of weld metal required to fill a weld preparation it is then possible to calculate the weight of filler metal required (these two figures are not necessarily the same) and to estimate the time required to deposit this weld metal; both essential in order to arrive at a cost of fabricating the weld. This will be covered in future Job Knowledge articles.
E6010 - Good usability characteristics in all weld positions. They are characterized by a deeply penetrating, forceful, spray type arc. The slag is very thin and easily removed. The majority of applications are on mild steel. Typical applications include building and bridge structures, storage tanks, pipelines and shipbuilding. These electrodes are also suited for working on materials which are rusty, painted, galvanized of other "dirty" work surfaces.
E6011 - Designed to copy the usability characteristic and mechanical properties of the electrodes using alternating current power sources. Penetration, arc action, slag, and appearance are very similar to the 6010 electrodes. In addition to the coating ingredients found in the 6010 electrode small amounts of calcium and potassium are present to make it suitable for AC. Typical applications are the same as the 6010 electrode.
6013 - These electrodes are characterized by light to medium penetration, a rather quiet arc, and a dense slag completely covering the weld deposit. Slag removal is excellent and the arc can be established and maintained easily. These electrodes were made first for sheet metal applications, however, larger diameters are used for heavier weldments. The coating contains elements which permit establishing the arc at low open circuit voltages and low welding amperages. There is not an electrode which can truly be called an "all purpose" electrode, however, the E-6013 is sometimes called the "all Purpose" because of its many applications.
This electrode is popular in schools and welder training programs since they are usable with all types of welding power supplies and welding positions. Ordinarily the E-6013 would not be used for high amperage, high deposition rate applications.
7014 - These electrodes have similar coatings to the E-6013 with the addition of iron powder. The amount of flux and the percentage of iron powder varies between manufacturer and types within the class. The addition of the iron powder permits a higher deposition rate than the E-6013 and allows use of higher amperage and higher travel speeds. There is a greater amount of slag, however they are still usable in all weld positions. The addition of iron powder helps to stabilize the arc and reduce spatter at high amperage. The iron powder also adds to the filler giving higher deposition rates.
The E-7014 electrodes are all right for welding mild and low alloy steels. Weld beads are smooth with fine ripples. Penetration is low to medium which is good for poor fit-up jobs. The end view of fillet welds tends to be flat to slightly convex. The slag is easily removed, self-cleaning in many cases.
7018 - These electrodes are the most popular of the low hydrogen electrodes. The fillet welds made in the horizontal and flat positions are slightly convex in profile with a smooth finely rippled surface. The electrodes are characterized by a smooth, quiet arc with very low spatter. The penetration is low and high travel speeds can be used. This electrode is used for mild and low alloy steels, and some high carbon steels. High strength structural steels, plate fabrication, shipyards, pressure vessels, and piping systems are a few of the typical applications. The most severe x-ray quality standards can be met with the E-7018 series of electrodes.
7024 - These electrodes have coverings with high amounts of iron powder together with ingredients almost like those found in E-7014 and E-6013 electrodes. As a rule, the coatings on E-7024 electrodes are very high in iron powder, usually amounting to about half of the weight. The large amount of flux means that a higher welding amperage be used with an equivalent diameter electrode of another type. The slag produced will be almost self-peeling if proper welding techniques are used. Since there is a large amount of slag, these electrodes are not suited for out-of-position welding.
This electrode is often used for high deposition work on mild steel. Many weldments for structural applications and large machine and large machine components are welded with this electrode. Satisfactory welds for some jobs can be done on low alloy, medium and high carbon steels.
NOTICE - Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only; and final weld results can be affected by other variables and application-specific circumstances. The appropriateness of all parameters and settings should be evaluated and modified by the end user as necessary based upon application-specific requirements. The end user is solely responsible for selection and coordination of appropriate equipment, adoption and adjustment of default weld parameters and settings, and ultimate quality and durability of all resultant welds. Miller Electric expressly disclaims any and all implied warranties including any implied warranty of fitness for a particular purpose. 152ee80cbc
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