Gas metal arc welding

Arc welding is a type of welding that uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point. They can use either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes. The welding region is usually protected by some type of shielding gas, vapor, and/or slag.

Power supplies[link]

Engine driven welder capable of AC/DC welding.

A diesel powered welding generator (the electric generator is on the left) as used in Indonesia.

To supply the electrical energy necessary for arc welding processes, a number of different power supplies can be used. The most common classification is constant current power supplies and constant voltage power supplies. In arc welding, the voltage is directly related to the length of the arc, and the current is related to the amount of heat input. Constant current power supplies are most often used for manual welding processes such as gas tungsten arc welding and shielded metal arc welding, because they maintain a relatively constant current even as the voltage varies. This is important because in manual welding, it can be difficult to hold the electrode perfectly steady, and as a result, the arc length and thus voltage tend to fluctuate. Constant voltage power supplies hold the voltage constant and vary the current, and as a result, are most often used for automated welding processes such as gas metal arc welding, flux cored arc welding, and submerged arc welding. In these processes, arc length is kept constant, since any fluctuation in the distance between the wire and the base material is quickly rectified by a large change in current. For example, if the wire and the base material get too close, the current will rapidly increase, which in turn causes the heat to increase and the tip of the wire to melt, returning it to its original separation distance.^[1]

The direction of current used in arc welding also plays an important role in welding. Consumable electrode processes such as shielded metal arc welding and gas metal arc welding generally use direct current, but the electrode can be charged either positively or negatively. In welding, the positively charged anode will have a greater heat concentration and, as a result, changing the polarity of the electrode has an impact on weld properties. If the electrode is positively charged, it will melt more quickly, increasing weld penetration and welding speed. Alternatively, a negatively charged electrode results in more shallow welds.^[2] Non-consumable electrode processes, such as gas tungsten arc welding, can use either type of direct current (DC), as well as alternating current (AC). With direct current however, because the electrode only creates the arc and does not provide filler material, a positively charged electrode causes shallow welds, while a negatively charged electrode makes deeper welds.^[3] Alternating current rapidly moves between these two, resulting in medium-penetration welds. One disadvantage of AC, the fact that the arc must be re-ignited after every zero crossing, has been addressed with the invention of special power units that produce a square wave pattern instead of the normal sine wave, eliminating low-voltage time after the zero crossings and minimizing the effects of the problem.^[4]

Home and Hobby Power supplies[link]

Home and hobby arc welders for occasional light duty (under 1/4 inch plate) repair and construction are available from $100 and up as of 2011.

In the $100 to $200 range, many choices are available in welding power supplies such as output current at a given duty cycle, 120 Volts "house current" or 220 VAC and differing input amperages. At these low prices, any positive factor typically weakens another important factor. One seller offers this specification: "Duty Cycle: 45% @ 60 amps, 25% @ 80 amps," for their 120 volts, 20 amp input, "90 Amp Flux Wire Welder."

Duty cycle is a welding equipment specification which defines the number of minutes, within a 10 minute period, during which a given arc welder can safely be used. For example, an 80 amp. welder with a 60% duty cycle must be "rested" for at least 4 minutes after 6 minutes of continuous welding.^[5] Failure to observe duty cycle limitations could damage the welder. Commercial- or professional-grade welders can typically run at 100% duty cycle.

Consumable electrode methods[link]

Shielded metal arc welding

One of the most common types of arc welding is shielded metal arc welding (SMAW), which is also known as manual metal arc welding (MMAW) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or 'stick'. The electrode rod is made of a material that is compatible with the base material being welded and is covered with a flux that gives off vapors that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination. The electrode core itself acts as filler material, making a separate filler unnecessary. The process is very versatile, requiring little operator training and inexpensive equipment. However, weld times are rather slow, since the consumable electrodes must be frequently replaced and because slag, the residue from the flux, must be chipped away after welding.^[6] Furthermore, the process is generally limited to welding ferrous materials, though specialty electrodes have made possible the welding of cast iron, nickel, aluminium, copper and other metals. The versatility of the method makes it popular in a number of applications including repair work and construction.^[7]

Gas metal arc welding (GMAW), commonly called MIG (Metal Inert Gas), is a semi-automatic or automatic welding process with a continuously fed consumable wire acting as both electrode and filler metal, along with an inert or semi-inert shielding gas flowed around the wire to protect the weld site from contamination. Constant voltage, direct current power source is most commonly used with GMAW, but constant current alternating current are used as well. With continuously fed filler electrodes, GMAW offers relatively high welding speeds, however the more complicated equipment reduces convenience and versatility in comparison to the SMAW process. Originally developed for welding aluminium and other non-ferrous materials in the 1940s, GMAW was soon economically applied to steels. Today, GMAW is commonly used in industries such as the automobile industry for its quality, versatility and speed. Because of the need to maintain a stable shroud of shielding gas around the weld site, it can be problematic to use the GMAW process in areas of high air movement such as outdoors.^[8]

Flux-cored arc welding (FCAW) is a variation of the GMAW technique. FCAW wire is actually a fine metal tube filled with powdered flux materials. An externally supplied shielding gas is sometimes used, but often the flux itself is relied upon to generate the necessary protection from the atmosphere. The process is widely used in construction because of its high welding speed and portability.

Submerged arc welding (SAW) is a high-productivity welding process in which the arc is struck beneath a covering layer of granular flux. This increases arc quality, since contaminants in the atmosphere are blocked by the flux. The slag that forms on the weld generally comes off by itself and, combined with the use of a continuous wire feed, the weld deposition rate is high. Working conditions are much improved over other arc welding processes since the flux hides the arc and no smoke is produced. The process is commonly used in industry, especially for large products.^[9] As the arc is not visible, it typically automated. SAW is only possible in the 1F (flat fillet), 2F, (horizontal fillet), and 1G (flat groove) positions.

Non-consumable electrode methods[link]

Gas tungsten arc welding (GTAW), or tungsten inert gas (TIG) welding, is a manual welding process that uses a non-consumable electrode made of tungsten, an inert or semi-inert gas mixture, and a separate filler material. Especially useful for welding thin materials, this method is characterized by a stable arc and high quality welds, but it requires significant operator skill and can only be accomplished at relatively low speeds. It can be used on nearly all weldable metals, though it is most often applied to stainless steel and light metals. It is often used when quality welds are extremely important, such as in bicycle, aircraft and naval applications.^[10] A related process, plasma arc welding, also uses a tungsten electrode but uses plasma gas to make the arc. The arc is more concentrated than the GTAW arc, making transverse control more critical and thus generally restricting the technique to a mechanized process. Because of its stable current, the method can be used on a wider range of material thicknesses than can the GTAW process and is much faster. It can be applied to all of the same materials as GTAW except magnesium; automated welding of stainless steel is one important application of the process. A variation of the process is plasma cutting, an efficient steel cutting process.^[11]

Other arc welding processes include atomic hydrogen welding, carbon arc welding, electroslag welding, electrogas welding, and stud arc welding.

Corrosion issues[link]

Some materials, notably high-strength steels, aluminium, and titanium alloys, are susceptible to hydrogen embrittlement. If the electrodes used for welding contain traces of moisture, the water decomposes in the heat of the arc and the liberated hydrogen enters the lattice of the material, causing its brittleness. Stick electrodes for such materials, with special low-hydrogen coating, are delivered in sealed moisture-proof packaging. New electrodes can be used straight from the can, but when moisture absorption may be suspected, they have to be dried by baking (usually at 800 to 1000 °F (425 to 550 °C)) in a drying oven. Flux used has to be kept dry as well.^[12]

Some austenitic stainless steels and nickel-based alloys are prone to intergranular corrosion. When subjected to temperatures around 700 °C (1,300 °F) for too long time, chromium reacts with carbon in the material, forming chromium carbide and depleting the crystal edges of chromium, impairing their corrosion resistance in a process called sensitization. Such sensitized steel undergoes corrosion in the areas near the welds where the temperature-time was favorable for forming the carbide. This kind of corrosion is often termed weld decay.

Knifeline attack (KLA) is another kind of corrosion affecting welds, impacting steels stabilized by niobium. Niobium and niobium carbide dissolves in steel at very high temperatures. At some cooling regimes, niobium carbide does not precipitate, and the steel then behaves like unstabilized steel, forming chromium carbide instead. This affects only a thin zone several millimeters wide in the very vicinity of the weld, making it difficult to spot and increasing the corrosion speed. Structures made of such steels have to be heated in a whole to about 1,950 °F (1,070 °C), when the chromium carbide dissolves and niobium carbide forms. The cooling rate after this treatment is not important.^[13]

Filler metal (electrode material) improperly chosen for the environmental conditions can make them corrosion-sensitive as well. There are also issues of galvanic corrosion if the electrode composition is sufficiently dissimilar to the materials welded, or the materials are dissimilar themselves. Even between different grades of nickel-based stainless steels, corrosion of welded joints can be severe, despite that they rarely undergo galvanic corrosion when mechanically joined.^[14]

Safety issues[link]

Welding Safety Checklist

Welding can be a dangerous and unhealthy practice without the proper precautions; however, with the use of new technology and proper protection the risks of injury or death associated with welding can be greatly reduced.

Heat and sparks[link]

Because many common welding procedures involve an open electric arc or flame, the risk of burns from heat and sparks is significant. To prevent them, welders wear protective clothing in the form of heavy leather gloves and protective long sleeve jackets to avoid exposure to extreme heat, flames, and sparks.

Eye damage[link]

Auto Darkening Welding hood with 90x110 mm cartridge and 3.78 in. x 1.85 in. viewing area

Exposure to the brightness of the weld area leads to a condition called arc eye in which ultraviolet light causes inflammation of the cornea and can burn the retinas of the eyes. Welding goggles and helmets with dark face plates - much darker than those in sunglasses or oxy-fuel goggles - are worn to prevent this exposure. In recent years, new helmet models have been produced featuring a face plate that automatically self-darkens electronically.^[15] To protect bystanders, transparent welding curtains often surround the welding area. These curtains, made of a polyvinyl chloride plastic film, shield nearby workers from exposure to the UV light from the electric arc.^[16]

Inhaled matter[link]

Welders are also often exposed to dangerous gases and particulate matter. Processes like flux-cored arc welding and shielded metal arc welding produce smoke containing particles of various types of oxides. The size of the particles in question tends to influence the toxicity of the fumes, with smaller particles presenting a greater danger. Additionally, many processes produce various gases (most commonly carbon dioxide and ozone, but others as well) that can prove dangerous if ventilation is inadequate. Furthermore, the use of compressed gases and flames in many welding processes pose an explosion and fire risk; some common precautions include limiting the amount of oxygen in the air and keeping combustible materials away from the workplace.^[17]

Interference with pacemakers[link]

Certain welding machines which use a high frequency AC current component have been found to affect pacemaker operation when within 2 meters of the power unit and 1 meter of the weld site.^[18]

History[link]

Nikolay Benardos

While examples of forge welding go back to the Bronze Age and the Iron Age, arc welding did not come into practice until much later. In 1802, Vasily Petrov discovered the continuous electric arc^[19] and subsequently proposed its possible practical applications, including welding. The French electrical inventor Auguste de Méritens produced the first carbon arc torch, patented in 1881, which was successfully used for welding lead in the manufacture of lead-acid batteries.^[20] In 1881-1882 a Russian inventor Nikolai Bernardos created the electric arc welding method for steel known as carbon arc welding, using carbon electrodes. The advances in arc welding continued with the invention of metal electrodes in the late 19th century by a Russian, Nikolai Slavyanov (1888), and an American, C. L. Coffin. Around 1900, A. P. Strohmenger released in Britain a coated metal electrode which gave a more stable arc. In 1905 Russian scientist Vladimir Mitkevich proposed the usage of three-phase electric arc for welding. In 1919, alternating current welding was invented by C.J. Holslag but did not become popular for another decade.^[21]

Competing welding processes such as resistance welding and oxyfuel welding were developed during this time as well;^[22] but both, especially the latter, faced stiff competition from arc welding especially after metal coverings (known as flux) for the electrode, to stabilize the arc and shield the base material from impurities, continued to be developed.^[23]

A young woman arc welding in a munitions factory in Australia in 1943.

During World War I welding started to be used in shipbuilding in Great Britain in place of riveted steel plates. The Americans also became more accepting of the new technology when the process allowed them to repair their ships quickly after a German attack in the New York Harbor at the beginning of the war.^[24] Arc welding was first applied to aircraft during the war as well, and some German airplane fuselages were constructed using this process.^[25] In 1919, the British shipbuilder Cammell Laird started construction of merchant ship, the Fullagar, with an entirely welded hull;^[26] she was launched in 1921.^[27]

During the 1920s, major advances were made in welding technology, including the 1920 introduction of automatic welding in which electrode wire was continuously fed. Shielding gas became a subject receiving much attention as scientists attempted to protect welds from the effects of oxygen and nitrogen in the atmosphere. Porosity and brittleness were the primary problems and the solutions that developed included the use of hydrogen, argon, and helium as welding atmospheres.^[28] During the following decade, further advances allowed for the welding of reactive metals such as aluminum and magnesium. This, in conjunction with developments in automatic welding, alternating current, and fluxes fed a major expansion of arc welding during the 1930s and then during World War II.^[29]

During the middle of the century, many new welding methods were invented. Submerged arc welding was invented in 1930 and continues to be popular today. In 1932 a Russian, Konstantin Khrenov successfully implemented the first underwater electric arc welding. Gas tungsten arc welding, after decades of development, was finally perfected in 1941 and gas metal arc welding followed in 1948, allowing for fast welding of non-ferrous materials but requiring expensive shielding gases. Using a consumable electrode and a carbon dioxide atmosphere as a shielding gas, it quickly became the most popular metal arc welding process. In 1957, the flux-cored arc welding process debuted in which the self-shielded wire electrode could be used with automatic equipment, resulting in greatly increased welding speeds. In that same year, plasma arc welding was invented. Electroslag welding was released in 1958 and was followed by its cousin, electrogas welding, in 1961.^[30]

See also[link]

• Robot welding
• Signature image processing
• Welder

References[link]

Notes[link]

Sources[link]

• Cary, Howard B.; Helzer, Scott C. (2005), Modern Welding Technology, Upper Saddle River, New Jersey: Pearson Education, ISBN 0-13-113029-3 
• Kalpakjian, Serope; Schmid, Steven R. (2001), Manufacturing Engineering and Technology, Prentice-Hall, ISBN 0-201-36131-0 
• Lincoln Electric (1994), The Procedure Handbook of Arc Welding, Cleveland, Ohio: Lincoln Electric, ISBN 99949-25-82-2 
• Weman, Klas (2003), Welding processes handbook, New York: CRC Press, ISBN 0-8493-1773-8 

Further reading[link]

• ASM International (society) (2003). Trends in Welding Research. Materials Park, Ohio: ASM International. ISBN 0-87170-780-2
• Blunt, Jane and Nigel C. Balchin (2002). Health and Safety in Welding and Allied Processes. Cambridge: Woodhead. ISBN 1-85573-538-5.
• Hicks, John (1999). Welded Joint Design. New York: Industrial Press. ISBN 0-8311-3130-6.

External links[link]

• Arc Flash Awareness video (25:39) from U.S. National Institute for Occupational Safety and Health
• The American Welding Society
• Canadian Welding Association
• The Welding Institute

This biographical article needs additional citations for verification. Please help by adding reliable sources. Contentious material about living persons that is unsourced or poorly sourced must be removed immediately, especially if potentially libelous or harmful. (May 2010)

The Basics
The Basics at the Oxford Art Factory, 2010
Background information
Origin	Melbourne, Australia
Genres	Rock
Years active	2002–present
Labels	Independent, Albert Records
Associated acts	Gotye, Down Hills Home, Dog With Wheels, Blood Red Bird
Website	The Basics Official Website
Members
Wally De Backer Kris Schroeder Tim Heath
Past members
Michael Hubbard
Notable instruments
Lead guitar, drums, bass guitar.

The Basics ( /ˈbæzɪtʃ/ BAZZ-ich) are a three-piece band from Melbourne, Australia, formed by Wally De Backer and Kris Schroeder in 2002. Their style has been described as anything from 'indie-pop' to 'rock'n'roll' to 'pop-rock', though their records show they span a wide range of genres, including reggae, ska, country, and electro-pop. They are "recognised as one of Australia's hardest-working bands".^[1]

With close to 1000 shows in their ten-year career, their live performances are well-known for their sense of humour and energy.^[2]

Formation[link]

The Basics were formed after Kris met Wally at a party in Melbourne.^[3] The event was to see off the young aspiring producer, who was about to depart for Los Angeles, and together with a number of musician friends, the two jammed on some blues-rock standards. Later that night, they bonded over a mutual love of The Beatles, 70s and 80s cartoon theme songs and old Sierra adventure games.

Initially, they played around Melbourne as an acoustic guitar/drums combo, starting at The Opposition in Frankston and the House of Fools in Footscray, where in late 2002 they met Michael Hubbard and later invited him to join them on electric guitar.^[4] Though lacking any real experience with the instrument, Kris willingly purchased his first bass guitar, and the trio was born. During this time, the group start performing songs with more complicated three-part harmony.

During late 2002 and early 2003, The Basics recorded and released an album called Get Back through MGM Distribution. They began what was to become regular tours of the East and West coasts of Australia.

2004-2005: Current lineup[link]

Tim Heath joined the group in June 2004, after Michael decided to pursue his solo career, which has included being one half of Down Hills Home.^[4] Tim was reportedly the only person to reply to an advertisement in Melbourne's Beat Magazine looking for a new guitarist. Tim apparently answered the advertisement - which said the applicant "must have a love of 50s and 60s rock'n'roll" - thinking that he would be meeting "a couple of old guys to play with on the weekends over some beers". They soon recorded For Girls Like You.

The Basics in 2005 continued to tour and play small festivals, and after releasing For Girls Like You through MGM Distribution, they departed for a national tour of Australia, which lasted for two months and took them to every Australian state and territory. Stuart Padbury, a young Melbourne sound engineer, joined them on much of this tour. On returning, the band began demonstrating songs for a new album.

2006-2009: Touring and soundtracks[link]

In 2006, The Basics began recording what was to become known as Stand Out/Fit In. Taking several months, it was not completed until the end of the year, despite intentions to have it released in June. Instead, they held a successful 'album preview', where each of the tracks was demonstrated in 'rough form' accompanied by a music video for each (produced by Melbourne photographic artist James Bryans). The band also talked about the origins of the songs. This event brought a lot of attention to the band for the idea's originality. They pre-released a radio single 'Just Hold On' from the album. The band were invited to play the hugely popular Homebake Festival in Sydney, where they received a great response, after being introduced onto the stage by a short stocky Asian guy with big calves ("one of the highlights" wrote The Daily Telegraph).

In 2007, the band departed on a tri-state residency which saw them play Melbourne, Sydney and Brisbane every week for the month of April - a bold move which brought further attention to the band for its original idea.^[5] Riding on the wave of this tour, Schroeder, De Backer and Heath departed on their first overseas tour which saw them performing 26 shows around Japan, Norway and the United Kingdom.^[6] They also toured twice more up the East Coast, one of which was with popular Japanese band The Bawdies. Their song 'Rattle My Chain' was used in a series of commercials for Volvo Australia. The song 'Hey There!' featured in the British film The Bank Job - starring Jason Statham - and was used as the backing for a February 2007 short film directed by Tim Longhurst called The Rip. Their song 'Better' was featured in a surfing documentary about the invention of the shortboard in 1967.

In 2008, the band appeared on Australia's Channel 9 for Australia Day celebrations, performing two of their songs - 'Just Hold On' and 'Hey There!' - to an estimated audience of 2 million. Securing an Australian Government grant, they embarked on a two-month tour of Australia, specifically targeting "culturally underprivileged groups" in rural and regional schoolchildren and Indigenous communities. The programme had them holding masterclasses and performing alongside Indigenous groups in the remote Northern Territory and Queensland.^[7][8] Their initiative also had them raising money for the charity Lifeline^{[disambiguation needed ]}, their contribution to which was recognised with a plaque at the end of the tour. Season two of Californication starring David Duchovny featured their cover of the classic 'Have Love, Will Travel', most famously covered by 'The Sonics'.

In 2009, The Basics for the first time enjoyed the support of Australian radio network Triple J, which had reportedly snubbed the band's previous material.^[9] The singles 'With This Ship' and 'Like A Brother' were added to the station's playlist, and momentum carried The Basics overseas for a second tour of the United Kingdom and Norway, and also a series of shows in Dublin, Ireland. They were joined by the longtime front-of-house engineer Stuart Padbury, who had been mixing them since 2005. The band was often seen in the Grafton Street Mall in Dublin, busking to promote their concerts there. Their second show in Oslo, Norway, saw the band perform with Hot Tub, one of the members of the Norwegian boy band "Boyzvoice", in his first performance for several years. Season Eight of Scrubs featured the song 'Lookin' Over My Shoulder'.

Despite all this promise, the band's album Keep Your Friends Close - produced and part-recorded by Peter Cobbin at London's Abbey Road Studios - though enjoying many favourable reviews,^{[10][11][12][13]} failed to impress Richard Kingsmill, music director of Triple J. This effectively ended the band's apparent upward spiral and the resulting album launch tour was reportedly "trying".

2010: Hiatus and live album[link]

In 2010, following the band's fourth stint at the Tamworth Country Music Festival, and the recording of a yet-unreleased live album, an indefinite hiatus was announced on the band's websites. This was in part due to the impending release of a new album produced by Wally for his Gotye project, and also to reported tensions within the band following the previous year's disappointments.

However, this hiatus was soon broken with a two-month residency at the Northcote Social Club in Melbourne, which saw an apparent return to form.^[14] The band's EP "Wait For You" enjoys airplay on Triple J.^[15] The Basics also played a one-off show at Sydney's Oxford Art Factory.^[16]

On 20 August 2010, The Basics released their fourth LP /ðəˈbæzɪtʃ/, available free and exclusively from their website for digital download^[17]. The band had reportedly moved to expand their listenership through this free giveaway, though 300 "Deluxe" CD/vinyl versions have been printed. /ðəˈbæzɪtʃ/ was recorded at the Northcote Social Club on 6 February, "in front of a live studio audience", and like the previous record, was mixed by Peter Cobbin at Abbey Road Studios. Technically a self-titled album, the phonetics spell out the accurate pronunciation of the band’s name. Kris Schroeder: "For years we’ve worked at bringing our live energy into the studio and thus far it’s been a bit hit-and-miss. Our trick this time was to pull a switcheroo and bring the studio to us instead; the result is the best and closest to us we’ve sounded yet."

Melbourne thespian and Dog With Wheels bassist David Bramble - friends with Heath from university days - has occasionally joined the band on tour, playing keys, often while sporting a large moustache. Other guests have included Jake Mason (saxophone), also of Cookin' on 3 Burners and The Bamboos^{[disambiguation needed ]}, Gideon Brazil (saxophone, flute), Simon Imrei (guitar and vocals) and Monty MacKenzie (saxophone).

Covers have often made an appearance from various sources: to date, some of the bands covered have been Cream, The Kinks, The Rolling Stones, The Police, Neil Young, Bob Dylan, New Kids on the Block, Richard Berry, Sonny Curtis and The Crickets, JJ Cale, Harry Nilsson, Bill Scott, Ryan Adams and The Coasters (via The Beatles for their cover of Three Cool Cats).

Members[link]

Current

• Wally De Backer - drums, vocals (2002-present)
• Kris Schroeder - bass, vocals (2002-present)
• Tim Heath - guitar, vocals (2004-present)

Former

• Michael Hubbard - guitar, vocals (2002-2004)

Discography[link]

Albums[link]

• Get Back (15 January 2004)
• Stand Out/Fit In (5 May 2007)
• Keep Your Friends Close (25 September 2009)
• /ðəˈbæzɪtʃ/ (20 August 2010)

EP[link]

• For Girls Like You (11 July 2005)
• Lookin' Over My Shoulder (10 February 2007)
• Like A Brother (5 June 2009)
• Wait For You (21 May 2010)

Singles[link]

• Call It Rhythm & Blues (20 August 2004)
• Just Hold On
• With This Ship (22 February 2009)

Upcoming projects[link]

The band is taking a three year hiatus, with an announced return to the stage together in early 2014. Wally De Backer launched Making Mirrors under his Gotye act in August 2011, Tim Heath will be touring and recording with Blood Red Bird, and Kris Schroeder recorded a solo EP titled, Patience in the Face of Control, before leaving Australia to work with the Red Cross in Kenya for a two year sabbatical.

References[link]

External links[link]

• Official Website
• Myspace Website