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    Shielded Metal Arc Welding (Stick Welding)

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    Anonymous mRBbdopMKf
    Shielded metal arc welding (SMAW), also known as stick welding, is commonly used for farms, construction sites, and pipelines. It uses consumable electrodes coated in flux that produces a protective gas and removes impurities from the weld. When using SMAW, welders must take safety precautions like covering their skin to prevent burns and wearing protective eyewear. The document provides information on electrode types, characteristics, storage, and how to set up and operate SMAW equipment properly to produce quality welds.

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    Shielded Metal Arc Welding (Stick Welding)

    Uploaded by

    Anonymous mRBbdopMKf
    117 views26 pages
    Shielded metal arc welding (SMAW), also known as stick welding, is commonly used for farms, construction sites, and pipelines. It uses consumable electrodes coated in flux that produces a protective gas and removes impurities from the weld. When using SMAW, welders must take safety precautions like covering their skin to prevent burns and wearing protective eyewear. The document provides information on electrode types, characteristics, storage, and how to set up and operate SMAW equipment properly to produce quality welds.

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    Original Title

    Stick Welding

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    Shielded metal arc welding (SMAW), also known as stick welding, is commonly used for farms, construction sites, and pipelines. It uses consumable electrodes coated in flux that produces a protective gas and removes impurities from the weld. When using SMAW, welders must take safety precautions like covering their skin to prevent burns and wearing protective eyewear. The document provides information on electrode types, characteristics, storage, and how to set up and operate SMAW equipment properly to produce quality welds.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    117 views26 pages

    Shielded Metal Arc Welding (Stick Welding)

    Uploaded by

    Anonymous mRBbdopMKf
    Shielded metal arc welding (SMAW), also known as stick welding, is commonly used for farms, construction sites, and pipelines. It uses consumable electrodes coated in flux that produces a protective gas and removes impurities from the weld. When using SMAW, welders must take safety precautions like covering their skin to prevent burns and wearing protective eyewear. The document provides information on electrode types, characteristics, storage, and how to set up and operate SMAW equipment properly to produce quality welds.

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    Shielded Metal Arc Welding

    (stick welding)
    Uses
     Farms

     Service Stations
     Large Construction Sites

     Pipelines

    (Most used type of Welding!!!!)


    SMAW Safety
     Cover all skin to prevent Radiation burns
     Cover hair to prevent sparks setting hair
    on fire
     Wear ear plugs to protect from noise and
    burning ear drums with sparks
     Use a 14 shade welding helmet to protect
    eyes
     Wear safety glasses at all times

     Make sure pants pockets are empty


    Duty Cycle
     “Lengthof time a welder can be used
    continually at its rated output in any
    10 minute period”
    – Thunderbolt AC/DC machines are 20%
    duty cycle
     At 150 amps DC welder can be used for 2
    minutes in a 10 minute period.
     At 100 amps DC can be used about 5
    minutes in a 10 minute period.
    Electrodes
     SMAW uses a consumable electrode
    that contains a flux coating
     The flux produces a protective gas
    around the weld
    – CO (Carbon Monoxide)
    – H2 (Hydrogen)
     Removes impurities from the molten
    metal
     Forms slag to protect weld as it cools
    Electrode Care
     Electrodes must be kept dry
    – Dampness will introduce hydrogen into
    the weld causing cracking or brittleness
    – Damp electrodes may cause the flux to
    “blow away”
    – Questionable electrodes should be
    baked at 250° F for several hours.
     Ourelectrodes are stored in a dry
    oven
    Electrode Identification
    Electrode Characteristics
    AWS Current
    Class Covering Requirements Position Characteristics

    EXX 10 Cellulose DCEP All Deep Penetration,


    Sodium With Ripples

    EXX 11 Cellulose AC, DCEP All Deep Penetration,


    Potassium Flat Decking With Ripples

    EXX22 Rutile DCEN, AC Flat, Horiz. Fillet Deep Penetration,


    Sodium With Ripples

    EXX 24 Rutile AC, DCEP, DCEN Flat, Horiz. Fillet High Deposition
    50% Iron Shallow Penetration
    Powder
    EXX 27 Mineral AC,DCEP, DCEN Flat, Horiz. Fillet High Deposition
    50% Iron Shallow Penetration
    Powder
    Electrode Characteristics continued
    AWS Current
    Class Covering Requirements Position Characteristics

    EXX 12 Rutile DCEN, AC All Mild to Medium Penetration


    Sodium

    EXX 13 Rutile AC, DCEP, DCEN All Mild Penetration


    Sodium

    EXX 14 Rutile AC, DCEN All Medium Penetration


    30% Iron
    Powder
    EXX 18 Low-Hydrogen DCEP, AC All Medium Penetration
    30% Iron
    Powder
    EXX 28 Low-Hydrogen AC, DCEP Flat, Horiz. Fillet High Deposition
    50% Iron
    Powder
    Our Electrodes
     E6013
    – E= Electrode
    – 60= 60,000 psi Tensile Strength
     Tensile
    Strength= Maximum pull stress in
    pounds per square inch that a specimen will
    withstand.
    – 1= All positions
    – = High titania potassium
    Our Electrodes
     E6011
    – E= Electrode
    – 60= 60,000 psi Tensile Strength
    – 1= All positions
    – 1= High-Cellulose, potassium flux
    composition

     Theseelectrodes are good for low


    carbon Steel
    Electricity
     DC- Direct Current
    – Electrons Flow From Negative to Positive
    Type of DC we will use
     DCEP (Direct Current Electrode
    Positive)
    – Electricity flows from through ground
    clamp to the work across the arc and
    back to the welder
    – Arc Temperatures reach 6500 to 7000°F
    DCEP
    (Direct Current Electrode Positive)
    Setting up the Welder
    AC vs. DC
     DC  AC
    – Heat Concentrated – Heat Concentrated
    at Work piece at Electrode

    – Forceful, Digging – Lower Penetration


    Arc
    – Increased
    – Medium to Deep Deposition Rates
    Penetration  (used for welding
    thin metal)
    Approximate Amperage
    Settings
    Approximate Electrode Amperage Settings

    Fast Freeze Fill Freeze Fast Fill Low Hydrogen


    E6010 - E6011 E6013 - E7014 E7024 - E7028 E7018

    Diameter of Current Setting Current Setting Current Setting Current Setting


    Electrode
    Inches(Millimeters) Amperes Amperes Amperes Amperes

    3/32 in (2.4 mm) 40 - 90 75 - 105 85 - 155 70 - 140


    1/8 in (3.2 mm) 75 - 130 100 - 165 100 - 175 90 - 185
    5/32 in (4.0 mm) 80 - 160 135 - 225 160 - 270 140 - 230
    3/16 in (4.8 mm) 110 - 225 185 - 280 220 - 330 210 - 300
    7/32 in (5.6 mm) 200 - 260 235 - 340 270 - 410 230 - 380
    1/4 in (6.4 mm) 220 - 325 260 - 425 315 - 520 290 - 440
    Setting up the Welder
    1. Plug ground cable into the (-)
    terminal
    2. Plug the electrode holder cable into
    the (+) terminal
    3. Turn on the welder
    4. Select DCEP (Direct current
    electrode positive e
    5. Select correct amps
    Striking the arc
     Scratch method
    – Start with electrode 3/8” from where
    you wish the weld to begin
    – Drag the electrode along the metal until
    the arc begins
     Straight down Method
    – Hold electrode straight up and down and
    tap metal until arc begins
    Starting The Arc
    Running a Bead
     Important to keep
    – Proper arc gap
     About 3/16”
     Should sound like sizzling bacon

    – Forward motion
     Need to maintain proper bead width (about
    2-3 times the width of the electrode)
    – Electrode angle
     Tipped forward 20° in the direction of travel
    Restarting Interrupted Bead
    1. Strike Arc Here

    2. Move Electrode
    to Crown of Crater

    3. Resume Travel
    Forward
    Finishing a Bead
     Run bead onto scrap piece of metal
    connected to work piece
     Reverse electrode direction at end of
    weld to fill the crater
    Cleaning the Bead
    A protective layer of slag will be
    formed on the weld
     Allow weld to cool than chip slag with
    a chip hammer
     Wire brush to remove all slag

     Slag must be removed before


    another weld can be added.
    Sample Beads For Quality
    Welding

    Good Amps Amps Arc Length Arc length Travel Travel


    too low too high too short too long speed too speed too
    slow fast

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