WK 5 SMAW Grade 9/10 Presentation

Prepari
ng
Welding
Consum
ables
1. Cored Wire
Description:
• Filled with flux that creates a self-
Types of shielding gas as it burns.
• No external shielding gas
Consuma Advantages:
required.
• Faster welding speed.
bles • Reduced spatter.
• Can be used in various positions.
Applications:
• Often used in environments where
external shielding gas would be
impractical.
2. Solid Wire
Description: Advantages: Applications:

Solid metal wire that High deposition rates. Suitable for welding in a
requires an external Clean welds with minimal controlled environment
shielding gas to protect the spatter. where shielding gas can be
weld pool from atmospheric used effectively.
contamination.
Used in
processes
like Shielded
Metal Arc
Welding
Description: (SMAW).
Coated with
flux that
provides
shielding as it
melts.
Versatile and
3. Rod Advantages:
can be used
in various
positions.
Electrode
Ideal for field
work and
maintenance.
Commonly
used for
welding in
outdoor or
Applications: less
controlled
environments
.
1. Shielded Metal Arc Welding
(SMAW)
•Consumable Used:
• Flux-Coated Electrodes
•Description:
Pairing • Electrodes are coated with
Consumables to flux that melts and creates a
shielding gas to protect the
Welding Processes weld from atmospheric
contamination.
•Key
Features:
• Self-Shielding: The flux
coating provides the
necessary protection during
the welding process.
• Versatility: Can be used in
various positions and
environments.
•Applications:
• Structural steelwork, repair
work, and maintenance.
Consu
Non-Consumable Tungsten Rod and
mable Separate Filler Metal
Used:
2. Gas-
Tungsten Descri A tungsten rod is used to create the arc,
while a separate filler metal is added to the
ption: weld pool.
Arc Key
Precise Control: Tungsten rod does not
melt, allowing precise control over the
Welding Featur welding process.

es: Clean Welds: Produces high-quality welds
with minimal spatter.
(GTAW) Applica Welding of thin materials, stainless steel,

tions: and aluminum.
Consumable Used:
• Wire Consumable (Spool-fed)
3. Gas Description:
• A continuous wire is fed from a spool

Metal Arc into the weld pool. An external shielding
gas protects the weld.
Welding Key Features:
• High Deposition Rate: Fast welding

(GMAW) with continuous wire feed.
• Versatile: Suitable for various metals
and thicknesses.
Applications:
• Automotive, fabrication, and industrial

applications.
1. Importance of
Matching Strengths
Matching Yield Strength:
Strength • Definition: The amount of
stress a material can handle
of before it begins to deform
permanently.
Consuma • Significance: Ensures that the
Tensile
weld canStrength:
withstand applied
bles to • stresses without failing or
Definition:
deforming. The maximum
Metals amount of stress a material can
withstand while being
stretched or pulled before
breaking.
• Significance: Critical for
•Why It Matters:
2. Matching
•Compatibility: The consumable (filler
material) must match the strength
characteristics of the base metal to ensure a
Consumabl strong, reliable weld.
•Performance: Proper matching improves
es to Base weld quality, durability, and safety.
•Factors to Consider:
Metals •Base Metal Strength: Choose a

consumable with a yield and tensile strength
comparable to or exceeding that of the base
metal.
•Welding Process: Different processes may
require different consumables based on their
specific requirements and metal
characteristics.
Storing and Re-drying
Electrodes
•Storage for Low Hydrogen Electrodes:
• Unopened Containers: Good protection.
• Opened Containers: Store at 250-300°F (120-
150°C).
•Re-drying Procedures:
• Final Temperature: 700-800°F (370-430°C)
for specific durations.
• Moisture Issues: Can cause porosity and
cracking.
Re-drying Conditions - Low
Hydrogen Electrodes
•Conditions:
• Electrodes Exposed to Air for Less Than a
Week: Pre-dry at 650-750°F (340-400°C),
then final dry at 700-800°F (370-430°C).
• Electrodes Exposed to Water or High
Humidity: Pre-dry at 180-220°F (80-105°C),
then final dry at 700-800°F (370-430°C).
Storing and Re-drying Non-
Low Hydrogen Electrodes
•Storage Tips:
• Unopened Containers: Retain moisture
content indefinitely.
• Opened Containers: Store in heated cabinets
at 100-120°F (40-50°C).
•Re-drying Procedures:
• Different Electrode Groups: Specific
temperatures and times for re-drying.
1. AWS Numbering System
Overview
•Prefix "E":
• Meaning: Designates an arc welding
electrode.
• Usage: Applied to various types of welding
electrodes, including stick electrodes, flux-
cored wires, and others.
2. Decoding the AWS
Numbering System
•First Digits:
• Indicate Minimum Tensile Strength
• Example:
• E6010: Minimum tensile strength of 60,000 psi.
• E10018: Minimum tensile strength of 100,000 psi.
•Position and Coating:
• Position:
• Digit 3: Indicates welding position capabilities.
• 1: All positions.
• 2: Flat and horizontal positions only.
• 4: Flat, horizontal, vertical down, and overhead.
•Coating and Current:Last Digit(s):
Indicate the type of coating and
recommended current/polarity.
•Examples:
• 0: High cellulose sodium, DC+.
• 1: High cellulose potassium, AC, DC+, or DC-.
• 5: Low hydrogen sodium, DC+.
• 8: Low hydrogen potassium, iron powder, AC,
DC+ or DC-.
Example Breakdown
•Example Electrode: E7018
• E: Arc welding electrode.
• 70: Minimum tensile strength of 70,000 psi.
• 1: All positions.
• 8: Low hydrogen potassium, AC, DC+ or DC-.
• Examples:
• E6010: Deep
Common Electrodes penetration, used for
and Their Uses root beads.
• E6011: All-position AC
welding, good for rusty
or dirty metal.
• E6013: All-position AC
welding for clean sheet
metal.
• E7018: Low-hydrogen,
for high-quality welds
and hard-to-weld
metals.
• E7024: Large welds,
typically on thick plates.
•Mild Steel and Alloy
Electrode Steel: Various
Coding: applications like
pipelines, tanks,
bridges, etc.
•Applications
Summary:
•E6010, E6012, E6013,
etc.: Specific uses in
various industries.

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Prepari

Description: Advantages: Applications:

Welding Featur welding process.

(GTAW) Applica Welding of thin materials, stainless steel,

• Wire Consumable (Spool-fed)

• A continuous wire is fed from a spool

Welding Key Features:

• High Deposition Rate: Fast welding

• Automotive, fabrication, and industrial

Metals •Base Metal Strength: Choose a

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