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26.6.4 The Gas-Shielded Flux-Cored Process The gas-shielded flux-cored process may be looked on as a hybrid between selfshielded flux-cored arc welding and gas metal-arc welding. Tubular electrode wire is used (Fig. 26.6), as in the self-shielded process, but the ingredients in its core are for fluxing, deoxidizing, scavenging, and sometimes alloying additions rather than for these functions plus the generation of protective vapors. In this respect, the process has similarities to the self-shielded flux-cored electrode process, and the tubular electrodes used are classified by the American Welding Society (AWS) along with electrodes used in the self-shielded process. However, the process is similar to gas metal-arc welding in that a gas is separately applied to act as arc shield. The gas-shielded flux-cored process is used for welding mild and low-alloy steels. It gives high deposition rates, high deposition efficiencies, and high operating factors. Radiographic-quality welds are easily produced, and the weld metal with mild and low-alloy steels has good ductility and toughness. The process is adaptable to a wide variety of joints and has the capability for all-position welding.

26.6.5 Gas Tungsten-Arc Welding The AWS definition of gas tungsten-arc (TIG) welding is an arc-welding process wherein coalescence is produced by heating with an arc between a tungsten electrode and the work. A filler metal may or may not be used. Shielding is obtained with a gas or a gas mixture.

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Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website.

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B Balloon telemetry controller, 227 235 components, 228 configurations, 230 231 construction, 228, 230 operation, 231 parts list, 234 235 program code, 232 234 schematic, 229 BASIC STAMP 2 (BS2 IC), 1 16 advantages, 3, 5 9 alternative (see Alternative STAMP 2) BASIC STAMP I vs., 1 4 components/configuration, 5 construction approaches, 5, 7, 10 15 exercise, 12 16 features, 1 3 I/O instructions, 3 memory map, 8 pinouts, 5, 7, 9, 13, 267, 268 schematic, 6 serial cable connections, 7 BASIC STAMP 2E (BS2E-IC), 5 BASIC STAMP 2P (BS2P24, BS2P40), 3 357

FIGURE 26.6 Principles of the gas-shielded flux-cored process. Gas from an external source is used for the shielding; the core ingredients are for fluxing and metalconditioning purposes. (The Lincoln Electric Company.)

Essentially, the nonconsumable tungsten electrode is a torch a heating device Under the protective gas shield, metals to be joined may be heated above their melting points so that material from one part coalesces with material from the other part Upon solidification of the molten area, unification occurs Pressure may be used when the edges to be joined are approaching the molten state to assist coalescence Welding in this manner requires no filler metal If the work is too heavy for the mere fusing of abutting edges, and if groove joints or reinforcements such as fillets are required, filler metal must be added This is supplied by a filler rod that is manually or mechanically fed into the weld puddle Both the tip of the nonconsumable tungsten electrode and the tip of the filler rod are kept under the protective gas shield as welding progresses Figure 26.

7 illustrates the TIG torch In automatic welding, filler wire is fed mechanically through a guide into the weld puddle When running heavy joints manually, a variation in the mode of feeding is to lay or press the filler rod in or along the joint and melt it along with the joint edges All the standard types of joints can be welded with the TIG process and filler metal Materials weldable by the TIG process are most grades of carbon, alloy, and stainless steels; aluminum and most of its alloys; magnesium and most of its alloys; copper and various brasses and bronzes; high-temperature alloys of various types; numerous hard-surfacing alloys; and such metals as titanium, zirconium, gold, and silver The process is especially adapted for welding thin materials where the requirements for quality and finish are exacting.

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It is one of the few processes that is satisfactory for welding such tiny and thin-walled objects as transistor cases, instrument diaphragms, and delicate expansion bellows..

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