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Mechanical Engineering

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Mechanical Engineering

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  1. Electrogas Welding • Electrogas Welding • A further development of electro slag welding process • Instead of resistance heating of molten slag, the electrode is melted by the arc heat in an inert gas environment, very similar to that of GMAW process • Very useful for vertical welding of thick plates up to a thickness of about 100 mm in a single pass • Led to large cost savings compared to conventional GMAW process for welding of very thick steel plates

  2. Electrogas Welding • Electrogas Welding • Solid or flux cored wire electrodes are used • Produces a smaller heat-affected zone (HAZ) • Better notch toughness as compared to electro slag welding • Gives an advantage of extra melting of electrode wire leading to high deposition rate and produces less molten base material thereby resulting in lesser HAZ

  3. Salient Features • It is an automatic welding process • It welds only in vertical direction • The weld pool is bound either by two sliding water cooled copper shoes or a sliding water cooled copper shoe in the front and ceramic backing strip at the back • The electrode is melted by a shielded arc • Constant current DC power supply is generally used • Electrode is kept positive

  4. Process • In the arc heat the electrode and the plate edges along the vertical groove melts forming a weld pool covered side ways with copper shoes • In the process the molten material at the lower end of the groove solidifies and the process continues till it reaches the upper end • Synchronization of the feeding of electrode and moving up of the shoes is extremely important • Any mismatch will lead to Arc unstability or Stubbing of electrode in the molten pool (may lead to disturbance

  5. Advantages EGW process has higher welding speed EGW process welds thicker plates in single pass High Deposition Rate as compared to manual welding Welded joints have better mechanical properties such as impact strength

  6. Limitations • Massive, expensive welding equipment and guidance system are required • This process is limited for making vertical weld joints

  7. Grain fully applied in Building of • Vertical Vessels • Storage tanks • Blast furnaces • Bridges etc. • Thick walled and large diameter pipes • Ship Building • Chemical Furnaces Applications

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