What is the difference between base metal and weld metal

In this case, the amount of parent material melted, shown by the red dotted line, is considerable. In the diagram at bottom right, full penetration joints with unprepared, virtually zero gaps, can be achieved with the high heat input Submerged Arc Welding SAW process up to a certain maximum plate thickness. The dilution factor is mostly understood and contained with the welding of similar materials, as the welding consumables are designed to give acceptable joint properties for the majority of dilution situations.

However, it becomes a concern in certain areas, e. In such cases the final alloy composition of the weld can be compromised and steps taken to address the final alloy content must be taken. This can be by either by judicious selection of filler or the addition of barrier layers when overlaying. These kind of solutions will fall into the realm of welding engineering and welding procedure development. Flammable Range The range over which a gas at normal temperature NTP forms a flammable mixture with air.

Flat Welding Position A welding position where the weld axis is approximately horizontal and the weld face lies in an approximately horizontal plane. Flashback A recession of the flame into or back of the mixing chamber of the torch. Flashback Arrestor A device to limit damage from a flashback by preventing the propagation of the flame front beyond the point at which the arrestor is installed.

Flashing The violent expulsion of small metal particles due to arcing during flash butt welding. Flux Material used to prevent, dissolve, or facilitate removal of oxides and other undesirable surface substances. Friction Welding A solid welding process which produces coalescence of material by the heat obtained from a mechanically induced sliding motion between rubbing surfaces.

Friction Stir Welding A solid-state welding process, which produces coalescence of material by the heat obtained from a mechanically induced rotating motion between tightly butted surfaces. Forehand Welding A welding technique where the welding torches or gun is pointed toward the direction of welding. Fusion The melting together of filler metal and base metal substrate , or of base metal only, which results in coalescence. Gas Welding Welding with the heat from an oxy-fuel flame, with or without the addition of filler metal or pressure.

Globular Transfer In arc welding, a type of metal transfer in which molten filler metal is transferred across the arc in large droplets. Groove Weld A weld made in a groove between two members. Hard-Facing Surfacing applied to a workplace to reduce wear. Heat-Affected Zone That section of the base metal, generally adjacent to the weld zone, whose mechanical properties or microstructure, have been altered by the heat of welding.

Hermetically Sealed Airtight. Heterogenous A mixture of phases such as: liquid-vapor or solid-liquid-vapor. Hot Crack A crack formed at temperatures near the completion of weld solidification. Hot Pass In pipe welding, the second pass which goes over the root pass. Inclined Position In pipe welding, the pipe axis angles 45 degrees to the horizontal position and remains stationary. Incomplete Fusion A weld discontinuity where fusion did not occur between weld metal and the joint or adjoining weld beads.

Incomplete Joint Penetration A condition in a groove weld where weld metal does not extend through the joint thickness. Inert Gas A gas that normally does not combine chemically with the base metal or filler metal. Intergranular Penetration The penetration of filler metal along the grain boundaries of a base metal. Interpass Temperature In a multi-pass weld, the temperature of the weld area between passes.

Ionization Potential The voltage required to ionize add or remove an electron a material. Joint The junction of members or the edges of members that are to be joined or have been joined.

Kerf The width of the cut produced during a cutting process. Keyhole A technique of welding in which a concentrated heat source penetrates completely through a work-piece forming a hole at the leading edge of the molten weld metal. Lap Joint A joint between two overlapping members in parallel planes.

Laser A device that provides a concentrated coherent light beam. Laser Beam Cutting A process that severs material with the heat from a concentrated coherent beam impinging upon the work-piece. Laser Beam Welding A process that fuses material with the heat from a concentrated coherent beam impinging upon the members to be joined. Leg of Fillet Weld The distance from the root of the joint to the toe of the fillet weld. Liquidus The lowest temperature at which a metal or an alloy is completely liquid.

Mandrel A metal bar serving as a core around which other metals are cast, forged, or extruded, forming a true, center hole. Manifold A multiple header for interconnection of gas or fluid sources with distribution points.

Martensitic An interstitial, super-saturated solid solution of carbon in iron, having a body-centered tetragonal lattice. Manual Welding A welding process where the torch or electrode holder is manipulated by hand. Mechanical Bond The adherence of a thermal-spray deposit to a roughened surface by particle interlocking. Mechanized Welding Welding with equipment where manual adjustment of controls is required in response to variations in the welding process.

Melting Range The temperature range between solidus and liquidus. Melt-Through Visible reinforcement produced on the opposite side of a welded joint from one side. Metal Cored Arc Welding A tubular electrode process where the hollow configuration contains alloying materials. Metal Cored Electrode A composite tubular electrode consisting of a metal sheath and a core of various powdered materials, producing no more than slag islands on the face of the weld bead.

Molecular Weight The sum of the atomic weights of all the constituent atoms in the molecule of an element or compound. Monochromatic The color of a surface that radiates light, containing an extremely small range of wavelengths. Neutral Flame An oxy-fuel gas flame that is neither oxidizing nor reducing. Open-Circuit Voltage The voltage between the output terminals of the welding machine when no current is flowing in the welding circuit.

Orifice Gas In plasma arc welding and cutting, the gas that is directed into the torch to surround the electrode. Oxidizing Flame An oxy-fuel gas flame having an oxidizing effect excess oxygen. Peening The mechanical working of metals using impact blows. Pilot Arc A low current continuous arc between the electrode and the constricting nozzle of a plasma torch that ionizes the gas and facilitates the start of the welding arc.

Plasma A gas that has been heated to at least partially ionized condition, enabling it to conduct an electric current. Plasma Arc Cutting PAC An arc cutting process using a constricted arc to remove the molten metal with a high-velocity jet of ionized gas from the constricting orifice. Plasma Arc Welding PAW An arc welding process that uses a constricted arc between a non-consumable electrode and the weld pool transferred arc or between the electrode and the constricting nozzle non-transferred arc.

Plasma Spraying PSP A thermal spraying process in which a non-transferred arc is used to create an arc plasma for melting and propelling the surfacing material to the substrate. Plug Weld A circular weld made through a hole in one member of a lap or T joint. Porosity A hole-like discontinuity formed by gas entrapment during solidification. Post-Heating The application of heat to an assembly after welding, brazing, soldering, thermal spraying, or cutting operation.

Postweld Heat Treatment Any heat treatment subsequent to welding. Preform The initial press of a powder metal that forms a compact. Preheating The application of heat to the base metal immediately before welding, brazing, soldering, thermal spraying, or cutting.

Preheat Temperature The temperature of the base metal immediately before welding is started. Procedure Qualification Demonstration that a fabricating process, such as welding, made by a specific procedure can meet given standards. Pull Gun Technique Same as backhand welding.

Pulsed Power Welding Any arc welding method in which the power is cyclically programmed to pulse so that the effective but short duration values of a parameter can be utilized. Pulsed Spray Welding An arc welding process variation in which the current is pulsed to achieve spray metal transfer at average currents equal to or less than the globular to spray transition current. Push Angle The travel angle where the electrode is pointing in the direction of travel.

Rake Angle Slope of a shear knife from end to end. Reducing Flame A gas flame that has a reducing effect, due to the presence of excess fuel. Reinforcement Weld metal, at the face or root, in excess of the metal necessary to fill the joint. Reverse Polarity The arrangement of direct current arc welding leads with the work as the negative pole and the electrode as the positive pole of the welding arc. Root Opening A separation at the joint root between the work pieces. Root Crack A crack at the root of a weld.

Shielding Gas Protective gas used to prevent atmospheric contamination. Solid State Welding A group of welding processes which produces coalescence at temperatures essentially below the melting point of the base materials being joined, without the addition of a brazing filler metal. Solidus The highest temperature at which a metal or alloy is completely solid. Spatter Metal particles expelled during welding that do not form a part of the weld.

Spray Transfer In arc welding, a type of metal transfer in which molten filler metal is propelled axially across the arc in small droplets. Stick-Out The length of unmelted electrode extending beyond the end of the contact tube in continuous welding processes. Straight Polarity Direct current arc welding where the work is the positive pole. Stress Relief Heat Treatment Uniform heating of a welded component to a temperature sufficient to relieve a major portion of the residual stresses.

Stress Relief Cracking Cracking in the weld metal or heat affected zone during post-weld heat treatment or high temperature service. Stringer Bead A weld bead made without transverse movement of the welding arc. Submerged Arc Welding A process that welds with the heat produced by an electric arc between a bare metal electrode and the work. Substrate Any material upon which a thermal-spray deposit is applied.

Synergistic An action where the total effect of two active components in a mixture is greater than the sum of their individual effects. Tack Weld A weld made to hold parts of a weldment in proper alignment until the final welds are made. Tenacious Cohesive, tough. Tensile Strength The maximum stress a material subjected to a stretching load can withstand without tearing.

Thermal Conductivity The quantity of heat passing through a material. Thermal Spraying A group of processes in which finely divided metallic or non-metallic materials are deposited in a molten or semimolten condition to form a coating.

Thermal Stresses Stresses in metal resulting from non-uniform temperature distributions. Thermionic The emission of electrons as a result of heat. Throat In welding, the area between the arms of a resistance welder. Torch Standoff Distance The dimension from the outer face of the torch nozzle to the work piece. Transferred Arc In plasma arc welding, a plasma arc established between the electrode and the work-piece. Underbead Crack A crack in the heat-affected zone generally not extending to the surface of the base metal.

Undercut A groove melted into the base plate adjacent to the weld toe or weld root and left unfilled by weld metal. Vapor Pressure The pressure exerted by a vapor when a state of equilibrium has been reached between a liquid, solid or solution and its vapor. Viscosity The resistance offered by a fluid liquid or gas to flow. Weldability The capacity of a material to be welded under the fabrication conditions imposed into a specific, suitably designed structure and to perform satisfactorily in the intended service.

Weld Bead The metal deposited in the joint by the process and filler wire used. Welding Leads The work piece lead and electrode lead of an arc welding circuit. Welding Wire A form of welding filler metal, normally packaged as coils or spools, that may or may not conduct electrical current depending upon the welding process used. Weld Metal The portion of a fusion weld that has been completely melted during welding.

Weld Pass A single progression of welding along a joint. The result of a pass is a weld bead or layer. Weld Pool The localized volume of molten metal in a weld prior to its solidification as weld metal. Note: When one member makes an angle with the other member, greater that degrees, the leg length size is of less significance than the effective throat which is the controlling factor for the strength of a weld.

Filter lens eye protection. Filter plate eye protection. The prefixes macro or micro indicate relative size. Fixed Automation. Flange weld. Flange weld size of weld. Flat position. Flexible Automation. Flux cored arc welding-electrogas.

Additional shielding may or may not be obtained from an externally supplied gas or gas mixture. Flux cored electrode. Alloying materials may be included in the core. External shielding may or may not be used. Shielding is obtained from the flux contained within the electrode core. Additional externally supplied shielding gas can also be used.

Can work as well as stick on dirty or rusty material. Out-of-position welding, Deep penetration for welding thick sections, Increased metal deposition rate. Forehand welding. Full fillet weld. Fusion face. Fusion welding. Fusion zone. Gas metal arc welding GMAW. Shielding is obtained entirely from an externally supplied gas or gas mixture. See also pulsed power welding. Gas shielding arc welding.

Gas tungsten arc welding GTAW. Shielding is obtained from a gas or gas mixture. Pressure may or may not be used and filler metal may or may not be used. This process has sometimes been called TIG welding, a nonpreferred term.

Globular transfer arc welding. Groove angle. Groove face. Groove radius. Groove type. Groove weld. The standard types of groove welds are double-bevel-groove weld, double-flare-bevel-groove weld, double-flare-V-groove weld, double-J-groove weld, double-U-groove weld, double-V-groove weld single-bevel-groove weld, single-flare-bevel-groove weld, single-flare-V-groove weld single-J-groove weld, single-U-groove weld, single-V-groove weld, square-groove weld.

Groove weld size of weld. The size of a groove weld and its effective throat are one and the same. Ground Connection. See Workpiece Connection for the difference between work connection and ground connection. Ground Lead. OD ID — 14 in. Hand shield. A hand shield is equipped with a suitable filter plate and is designed to be held by the hand. Hard facing. Article: Strengthening Metal Parts with Hardfacing.

Heat-affected zone HAZ. Helmet eye protection. A helmet is equipped with a suitable filter plate and is designed to be worn on the head. High Frequency. Used in TIG welding for arc ignition and stabilization. Horizontal fixed position pipe welding. Horizontal rolled position pipe welding. How to Correctly Size a Generator. Inadequate joint penetration. Incomplete fusion.

Induction heating. See induction heating systems. Inert gas. See also protective atmosphere. Infrared radiation. Intergranular penetration. Intermittent weld. Interpass temperature. Inverter Welding Power Source. Inverters are more portable and lighter weight than traditional transformer-rectifiers, making them easier to maneuver around the job site. Inverters can also save money in energy costs over traditional-type power sources since: Greater transformer efficiencies are realized through the use of ferrite cores in the inverter's power transformer.

This reduces the current losses resulting in lower idle currents in the supply conductors. The inverter transformer coils are physically smaller than common transformers. A smaller coil translates to less wire wrapping around the core - less wire means fewer losses and greater efficiency.

The inverter's power electronic components have been carefully designed to reduce losses and extend operating life. Many inverters use a copper conductor. Copper has higher thermal and electrical conductivity compared to aluminum, which will minimize losses and maximize efficiency.

Operating at higher frequencies than conventional welders, inverters require less output inductance for smooth operation. The energy needed for stick welding or for globular transfer welding processes is stored in capacitors allowing for smaller output chokes. The compact design and relatively small physical size of an inverter welder means shorter leads and cables or even direct connections between power components.

Shorter current paths translate to lower resistances and better efficiencies. Because the inverter is designed to inherently have low losses, smaller cooling fans are required. This means less power is needed for moving cooling air and, again, greater efficiency. The smaller size of the components inside the inverter machine translate into less heat to dissipate and again, greater efficiency. Jimmy Jammer.

The semi-automatic weld oscillator controls the positioners and turning rolls. Joined buildup sequence. Joint clearance. In brazing this distance is referred to as that which is present either before brazing, at the brazing temperature, or after brazing is completed. Joint design. Joint efficiency. Joint geometry. Joint penetration. Joint penetration may include root penetration. Joint welding procedure. Keyhole TIG. It requires no edge beveling, uses as little as 10 percent of the gas normally required, and produces highly repeatable, X-ray quality welds with superb cap and root aesthetics.

Kilogram kg. It's what you get when you multiply the voltage the force that moves electrons around a circuit by the amps electrical current. Kilovolt-amps measure what's called the 'apparent power' of a generator. This is different from kilowatts kW , which measure the 'true power'. This shows you how much power is being converted into useful, working output.

If kW is how much power you can work with, kVA tells you how much is being used in the system overall. Primary kW is the actual power used by a power source when it is producing its rated output. Secondary kW is the actual power output of a welding power source. Kilowatts are found by taking volts times amps divided by 1, and taking into account any power factor.

Lap joint. The layer may consist of one or more weld beads laid side by side. Leg of a fillet weld. Lightly coated electrode. This eliminates imperfections and color saturation to create the clearest view of the base material, arc and puddle.

Lincoln AC Aluminum Pulse. By switching the polarity of the arc, heat input is reduced and deposition rates are enhanced. When welding thicker material requiring increased penetration, or when requiring increased cleaning action to break through heavy oxide layers, bypass AC Auto Balance and adjust manually for full control.

The memory capability enables users to load and save weld settings, while its adjustable features allow for a customized welding session. CheckPoint provides full visibility of your welding operations faster, cleaner and more efficiently.

From real-time dashboard snapshots to in-depth weld analytics, CheckPoint's framework is built to provide essential welding data the way you need it for whatever your role may have. Lincoln Chopper Technology. A chopper is composed of a transistor switch and a diode. Choppers were developed for engine driven welders to offer the same control over the welding arc as the inverter machines. This allows more consistent arc performance across product lines.

Choppers are ideal for the customer searching for an inexpensive option for low cost, high quality arc performance. Lincoln Cougar Push-Pull Guns. Lincoln CrossLinc. Voltage changes are communicated from the wire feeder to the power source using existing welding cables. Powered by a Lincoln Inverter Technology. Some of the advantages an inverter has are smaller magnetic components chokes and transformers , higher efficiency, and a fast response to the welding arc.

Inverter power sources were first introduced into the welding industry in the early s. The initial attraction of the inverter was its small size and easy portability. For example, a rectifier-based machine, could weigh as much as four times that of an inverter-based machine.

Less space is needed and the inverter unit is easily moved around the job site. As the popularity and reliability of the inverter increased, the capabilities were expanded. Over the last decade, Lincoln Electric has invested heavily in developing inverter technology, producing highly reliable inverter machines. This advanced pulsed welding process maximizes arc performance while effectively controlling heat-input. Multi-Turn Wire Speed Adjustment Adjust wire speed remotely at the gun with fine resolution so there is no need to travel back to the power source.

Tool-less Drive Roll Tension Large thumbscrew makes fine adjustment of drive roll pressure effortless. Set screw allows for coarser adjustment if needed for steel. An input cable assembly must be used to connect the control module to the power source: 1. K 10 ft. Can also be used with non-Lincoln CV power sources. The control module is not required when connecting Magnum spool guns to Lincoln and Red-D-Arc models that have built-in wire-feed control circuits. See operator manual IM for details.

Narrow groove for. The control module allows the spool gun to be used with any welder possessing the following characteristics: 1. CV welding output. A VAC control circuit output. An output contactor internally or externally energized with closure or VAC, respectively. See also IM and IM operator manuals. Lincoln Magnum Spool Guns and Accessories. This gives Micro-Start TIG very stable low current welding and provides it with the ability to eliminate erratic high frequency and weld thin materials in a consistent, high quality manner.

Lincoln is the first manufacturer to offer a background circuit from which an operator can weld and smoothly transition to, or from, higher outputs. Micro-Start TIG is capable of independently welding off of its electronic power supply when the amperage is down to the minimum rated 2 amps. The technology assists the transformer SCR choke circuit with its special electronic welding circuit instead of completely relying on chokes to smooth the arc as do conventional machines.

The result is a very stable and smooth output at low amperage levels. This is because the new technology makes it easy to overcome the most common TIG welding issues with machines that overcome the most common performance limitations.

Also, once the high frequency initiates the DC arc, the control circuit prevents the high frequency from coming on again during crater fill. In effect, the high frequency is no longer needed because Micro-Start technology provides tremendous low amperage stability for the machine. It does this using an electronic low amp welding power supply to supplement the main power supply. The starting circuit offers just enough energy to heat the tungsten and establish a more stable plasma flow to the work piece.

This starting sequence is short and provides precise control over starting conditions. In effect, Micro-Start II technology is so effective that most operators cannot detect that the high frequency was used during starting. In many traditional, low amperage TIG applications, operators have trouble maintaining a smooth, stable arc. This is because the machine's choke cannot store enough energy between SCR firings to stabilize the arc. These erratic outages can lead to inconsistencies in the weld.

When the operator first depresses the foot pedal, this separate power supply starts and welds independently of the Precision TIG main welding circuit i. As the operator further depresses the foot pedal to increase the current, the main welding circuit turns on and provides additional amperage.

This gives the Precision TIG very stable low-current welding capability and provides the customer with the ability to weld thin materials in a consistent, high-quality manner. It also yields a tight and stable arc in spray transfer. The 9. Developed by Lincoln Electric. Lincoln Ready. Advanced options and settings are simple to access.

STT uses high frequency inverter technology with advanced waveform control to produce a high-quality weld with less spatter and smoke. Easy to operate and can achieve good weld penetration with low heat input. The result is nearly double deposition rates and faster travel speeds. All that cable can create a difference in voltage, or voltage drop, between the power source and the weld. For example, if 24 volts is set on the welding power source, as a result of electrical resistance through the cables, only 20 volts may actually be available at the wire feeder.

This would result in a cold weld. True Voltage Technology TVT calculates this drop and gives the true voltage set at the wire feeder by adjusting the power source to compensate for the voltage drop. In this example, 24 volts is preset at the wire feeder. TVT senses there is a 4 volt drop due to long weld cables and compensates by increasing the welder power source output to 28 volts. The result is that the desired 24 volt is available at the welding arc. A patent pending adjustable baffling system inside the helmet directs air away from eyes to keep them from getting dry.

Indicator lights will also signal when output voltage during welding is above or below 30 volts DC. Local preheating. Local stress relief heat treatment. Longitudinal sequence. Machine welding. The equipment may or may not perform the loading and unloading of the work.

Macro Testing. Manual welding. Visible root reinforcement is produced. Melting range. Melting rate. Metal cored electrode. Minor amounts of ingredients providing such functions as arc stabilization and fluxing of oxides may be included. External shielding gas may or may not be used. Metal electrode. Metallic bond. This is a primary bond arising from the increased spatial extension of the valence electron wave functions when an aggregate of metal atoms is brought close together.

This arc welding process uses a spooled, continuously fed filler metal consumable electrode. Shielding is provided by externally supplied gas or gas mixtures. Easiest process to learn, High welding speeds possible, Provides better control on thinner metals, Cleaner welds possible with no slag, Same equipment can be used for flux-cored welding.

Only inert gases or gas mixtures are used for the shielding gas when MIG welding. Typical inert gases used for MIG welding are argon and helium. These gases are usually used for MIG welding of aluminium and other non-ferrous metals. Active gas mixtures have been developed primarily for welding steels. Typical shielding gases are mixtures of argon, carbon dioxide and oxygen e.

The composition of the shielding gas has a substantial effect on the stability of the arc, metal transfer and the amount of spatter. The shielding gas also affects the behaviour of the weld pool, particularly its penetration and the mechanical properties of the welded joint. Standard MIG gun not included. Provides optimum and precise molten puddle controL. A Miller Technology Exclusive. Guarantees delivery of all power promised. Helps eliminate sticking of the electrode at arc start. Miller Arc-Drive.

Found on the Deltaweld System. For beginner to advanced-level weld students, this system simulates multiple welding processes, blending real-world and computer-generated images into an unique, augmented reality environment. Eliminates the need for a remote control at arc end. Also adjusts for voltage spikes within the entire range. Provides convenience in any job setting and is ideal for dirty or unreliable power.

Reduces fuel consumption, exhaust emissions and noise levels on the Trailblazer engine drive. Miller Automatic Start at Idle. Allows emailing, storage and transfer of welding programs. Miller Coolmate 3. Delivers a smoother, more consistent arc that can be tailored to match the application, material, fit-up and welder technique. Found on Trailblazer and Big Blue engine drives. Extends engine life and reduces fuel consumption. Reduces fuel consumption, exhaust emissions and noise levels on select models of the Trailblazer.