Optimal Parameters for Prevention of Power Source Breakdown in SMAW

Abstract

Aim of study is to reduce the breakdown of power source used for welding process and also increasing its
duty cycle. The main requirement of a power source is to deliver controllable current at a voltage according to the
demands of the welding process being used. Each welding process has distinct differences from one another, both in the
form of process controls required to accomplish a given operating condition and the consequent demands on the power
source. Therefore, arc welding power sources are playing very important role in welding. The versatility of waveform
control is a major achievement of power source developers and manufacturers. To enable the exploitation of such
advanced capability however, the personnel in charge of utilizing the sophisticated equipment must have sufficient
training. We identify the problems like unstable arc generation with optimum arc length and also Power source break
down during overnight and continuous production. As observed in SMAW process as current increases, heat generated,
heat accumulated and rest time increases while duty cycle decreases. Parameters responsible for unstable arc length are
studied and solution for stable arc is obtained. Formula for desired duty cycle is obtained which can be controlled by
setting various parameters.