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Electrogas Welding ( EGW )

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        Electrogas welding (EGW) is a continuous vertical position arc welding process developed in 1961, in which an arc is struck between a consumable electrode and the workpiece. A shielding gas is sometimes used, but pressure is not applied. A major difference between EGW and its cousin electroslag welding is that the arc in EGW is not extinguished, instead remains struck throughout the welding process. It is used to make square-groove welds for butt and t-joints, especially in the shipbuilding industry and in the construction of storage tanks. 

       Electrogas welding can be applied to most steels, including low and medium carbon steels, low alloy high strength steels, and some stainless steels. Quenched and tempered steels may also be welded by the process, provided that the proper amount of heat is applied. Welds must be vertical, varying to either side by a maximum of 15 degrees. In general, the workpiece must be at least 10 mm (0.4 in) thick, while the maximum thickness for one electrode is approximately 20 mm (0.8 in). Additional electrodes make it possible to weld thicker workpieces. The height of the weld is limited only by the mechanism used to lift the welding head—in general, it ranges from 100 mm (4 in) to 20 m (50 ft).

       Like other arc welding processes, EGW requires that the operator wear a welding helmet and proper attire to prevent exposure to molten metal and the bright welding arc. Compared to other processes, a large amount of molten metal is present during welding, and this poses an additional safety and fire hazard. Since the process is often performed at great heights, the work and equipment must be properly secured, and the operator should wear a safety harness to prevent injury in the event of a fall.

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