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Welding Symbols
Welding Symbols
15-2
July 1978 Revised May 1998 Page 1 of 12
Table of Contents
Page SCOPE .......................................................................................................................................................... 2 DEFINITIONS OF WELDING TERMS .......................................................................................................... 2 STANDARD WELDING SYMBOLS .............................................................................................................. 7 IDENTIFICATION OF COVERED ARC-WELDING ELECTRODES AND BARE ARC-WELDING RODS .. 8 ESSENTIALS FOR PROPER WELDING PROCEDURES ........................................................................... 9
List of Figures
Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. 1. 2. 3. 4. 5. 6. 7. 8. Common terms applied to a weld. .................................................................................................... 2 Shielded metal-arc welding. ................................................................................................................ 3 Types of joint (top), types of weld (center), variations of groove (bottom). ....................................... 3 Typical welding positions. ................................................................................................................... 4 Standard welding symbols. ................................................................................................................. 7 Typical applications of welding symbols. ............................................................................................ 8 Type-marked welding electrode. ......................................................................................................... 8 Location of color markings for center-grip welding electrodes. .......................................................... 8
List of Tables
Table 1. Difficulties in Metal-Arc Welding ................................................................................................... 10 Table 2. Trades Names of Electrodes and Comparable ASW-ASTM Classifications ................................ 11
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SCOPE This data sheet contains general information on the subject of electric arc-welding as it relates to the design and fabrication of boilers and unfired pressure vessels. Inspectors involved with shop inspection work, pressure vessel repairs and the certification of drawings for Code compliance should be familiar with the basic information contained herein. The term ASME Code as used in this data sheet means the ASME Boiler and Pressure Vessel Code. DEFINITIONS OF WELDING TERMS The following is an abbreviated glossary of common welding terms. Additional terms are defined in QW-492, Section IX of the ASME Code. For a complete compilation of standard welding and cutting definitions, see Section 1 of the Welding Handbook published by the American Welding Society (AWS). Arc blow. Magnetic disturbance of the arc which causes it to waver from its intended path. Arc length. The distance from the end of the electrode to the point where the arc makes contact with work surface. Arc voltage. The voltage across the welding arc. As-welded. The condition of weld metal, welded joints and weldments after welding prior to any subsequent thermal or mechanical treatment. Backing. Material (metal, weld metal, asbestos, carbon, granulated flux, etc., excluding gas) backing up the joint during welding to facilitate obtaining a sound weld at the root. May be strips, rings, welds, etc.
Back-step welding. A welding technique wherein the increments of welding are deposited opposite the direction of progression. Back weld. A weld (generally short) made to hold parts of a weldment in proper alignment until the final welds are made. Used for assembly purposes only.
Bare electrode. A filler-metal electrode, used in arc welding, consisting of a metal wire with no coating other than that incidental to the drawing of the wire. Base metal. The metal to be welded or cut (Fig. 2).
Butt weld. A weld made in the joint between two pieces of metal lying approximately in the same plane (Fig. 3).
Fig. 3. Types of joint (top), types of weld (center), variations of groove (bottom).
Covered electrode. A filler-metal electrode, used in arc welding, consisting of a metal core wire with a relatively thick covering which provides protection for the molten metal from the atmosphere, improves the properties of the weld metal and stabilizes the arc (Fig. 2). Crater. A depression at the termination of a weld (Fig. 2).
Depth of Fusion. The depth of fusion of a groove weld is the distance from the surface of the base metal to that point within the joints at which fusion ceases. Face of weld. The exposed surface of a weld, made by an arc or gas welding process, on the side from which welding was done (Fig. 1). Fillet weld. A weld of approximately triangular cross section joining two surfaces approximately at right angles to each other in a lap joint, tee joint or corner joint (Fig.3). Flat position. The position of welding wherein welding is performed from the upper side of the joint and the face of the weld is approximately horizontal - also called downhand welding (Fig. 4).
Flux. A fusible material or gas used to dissolve and/or prevent the formation of oxides, nitrides or other undesirable inclusions formed in welding. Gas metal-arc welding (GMAW). An arc welding process wherein coalescence is produced by heating with an electric arc between a filler metal (consumable) electrode and the work. Shielding is obtained from a gas, a gas mixture (which may contain an inert gas) or a mixture of a gas and a flux. (Sometimes known as MIG welding.) Flux cored arc welding (FCAW), with or without additional shielding from an externally supplied gas or gas mixture, is considered as a variation of the GMAW process. This is a gas metal-arc welding process which produces coalescence of metals by heating them with an arc between a continuous filler metal
(consumable) electrode and the work. Shielding is provided by a flux contained within the tubular electrode. Additional shielding may or may not be obtained from an externally supplied gas or gas mixture. Gas tungsten-arc welding (GTAW). An arc welding process wherein coalescence is produced by heating with an arc between a single tungsten (nonconsumable) electrode and the work. Shielding is obtained from a gas or gas mixture. Pressure may or may not be used and filler metal may or may not be used. (Sometimes known as TIG welding.) Gas pocket. A weld cavity caused by entrapped gas. Groove weld. A weld made in the groove between two members to be joined (Fig. 3). Heat-affected zone. That portion of the base metal which has not been melted, but whose mechanical properties or microstructures have been altered by the heat of welding or cutting. High carbon steel. Steel containing 0.45% carbon or more. Horizontal position. Fillet weld. The position of welding wherein welding is performed on the upper side of an approximately horizontal surface and against an approximately vertical surface (Fig. 4). Groove weld. The position of welding wherein the axis of the weld lies in an approximately horizontal plane and the face of the weld lies in an approximately vertical position (Fig. 4). Lap joint. A joint between two overlapping members (Fig. 3). Leg of a fillet weld. The distance from the root of the joint to the toe of the fillet weld (Fig. 1). Low carbon steel. Steel containing 0.30% or less carbon. Also mild steel. Melting rate. The weight or length of electrode melted in a unit of time. Open-circuit voltage. The voltage between the terminals of a power source when no current is flowing in the circuit. Overhead position. The position of welding wherein welding is performed from the underside of the joint (Fig. 4). Overlap. Protrusion of weld metal beyond the bond at the toe of the weld. Pass. A single longitudinal progression of a welding operation along a joint or weld deposit. The result of a pass is a weld bead. Peening. Mechanical working of metal by means of hammer blows or shot impingement. Penetration. The distance the fusion zone extends below the surface of the part or parts being welded (Fig. 2). Porosity. Gas pockets or voids in metal. Position of welding. See Flat, Horizontal, Overhead, and Vertical positions. Post heating. The application of heat to a weld or weldment subsequent to a welding or cutting operation. Preheating. The application of heat to the base metal immediately before a welding or cutting operation. Puddle. The portion of a weld that is molten at the place the heat is supplied. Radiography. The use of radiant energy in the form of X-rays or gamma rays for the nondestructive examination of metals. Reversed polarity. The arrangement of arc welding leads wherein the work is the negative pole and the electrode is the positive pole in the arc circuit. Root of weld. The points, as shown in cross section, at which the bottom of the weld intersects the base metal surfaces (Fig. 1). Root opening. The separation between the members to be joined, at the root of the joint. Shielded metal-arc welding (SMAW). An arc-welding process wherein coalescence is produced by heating with an electric arc between a covered metal electrode and the work. Shielding is obtained from decomposition of the electode covering. Pressure is not used and filler metal is obtained from the electrode (Fig. 2).
Submerged arc welding (SAW). An arc-welding process wherein coalescence is produced by heating with an arc or arcs between a bare metal electrode or electrodes and the work. The welding is shielded by a blanket of granular, fusible material on the work. Pressure is not used and filler metal is obtained from the electrode and sometimes from a supplementary welding rod. Size of weld. (See D. S. 15-4, Fig. 28) Groove weld. The joint penetration (depth of chamfering plus the root penetration when specified). Fillet weld. For equal leg fillet welds, the leg length of the largest isosceles right triangle which can be inscribed within the fillet-weld cross section. For unequal leg fillet welds, the leg lengths of the largest right triangle which can be inscribed within the fillet-weld cross section. Slag inclusion. Nonmetallic solid material entrapped in weld metal or between weld metal and base metal. Spatter. In arc and gas welding, the metal particles expelled during welding and which do not form a part of the weld. Straight polarity. The arrangement of arc welding leads wherein the work is the positive pole and the electrode is the negative pole of the arc circuit. Stress relief, heat treatment. The uniform heating of a structure or a portion thereof to a sufficient temperature below the critical range to relieve the major portion of the residual stresses followed by uniform cooling. String bead. A type of weld bead made without appreciable transverse oscillation. Stringer bead. Same as root pass, that is, the initial bead. Thoriated tungsten. Tungsten containing a small percentage of thorium. The electronic emission quality of the electrode is improved. Throat of a fillet weld. (See D. S. 15-4, Fig. 28) Theoretical: The distance from the beginning of the root of the joint perpendicular to the hypotenuse of the largest right triangle that can be inscribed within the fillet weld cross section. Actual: The shortest distance from the root of a fillet weld to its face. Toe of weld. The junction between the face of the weld and the base metal (Fig. 1). Tungsten electrode. A nonfiller-metal electrode, used in arc welding, consisting of a tungsten wire. Ultimate tensile strength. The maximum tensile stress which will cause a material to break (usually expressed in pounds per square inch). Underbead crack. A crack in the heat-affected zone not extending to the surface of the base metal. Undercut. A groove melted into the base metal adjacent to the toe of the weld and left unfilled by weld metal. Uphill welding. A pipe welding term indicating that the welds are made from the bottom of the pipe to the top of the pipe. The pipe is not rotated. Vertical position. The position of welding wherein the axis of the weld is approximately vertical (Fig. 4). Weaving. A technique of depositing weld metal in which the electrode is oscillated. Weld. A localized coalescence of metal wherein coalescence is produced by heating to suitable temperatures, with or without the application of pressure, and with or without the use of filler metal. The filler metal has a melting point approximately the same as the base metals. Weld metal. That portion of a weld which has been melted during welding (Fig. 2). Welding procedure. The detailed methods and practices including joint welding procedures involved in the production of a weldment. Welding rod. Filler metal, in wire or rod form, used in gas welding and brazing processes, and those arcwelding processes wherein the electrode does not furnish the filler metal. Weldment. An assembly whose constituent parts are joined by welding, or parts which contain weld deposited cladding or weld deposited hard surfacing. Whipping. A term applied to an inward and upward movement of the electrode which is employed in vertical welding to avoid undercut.
STANDARD WELDING SYMBOLS AWS welding symbols are the shorthand of welding. They enable the designer and draftsman to convey complete instructions for welding to the welder on blueprints and drawings. Use of the symbols has the following advantages: 1. Control of specific design instructions to the shop regarding weld sizes and plate edge preparation, eliminating the tendency for overwelding or underwelding (resulting in either increased production costs or unsafe fabrication) because of lack of definite information. 2. Elimination of unnecessary detail on drawings when such detail is for the sole purpose of indicating weld sizes and specifications. Welding notes are kept to a minimum. 3. Establishment of a common understanding of design intent and requirements between engineers, shop personnel, customer s representatives and Code inspection authorities. AWS welding symbols are a national standard and are, in fact, used worldwide. All inspectors involved in shop inspection work and/or checking of pressure vessel designs should be familiar with their use and interpretation. Fig. 5 shows most of the basic weld symbols and their location significance. Fig. 6 shows typical applications. For additional information on this subject, refer to Standard Welding Symbols and Rules for Their Use, published by the American Welding Society (AWS A2. 1-76).
IDENTIFICATION OF COVERED ARC-WELDING ELECTRODES AND BARE ARC-WELDING RODS Covered arc-welding electrodes are marked for identification by either of two methods: 1. By imprinting the AWS-ASTM classification number on the coating (Fig. 7). Electrodes identified in this manner are commonly referred to as type-marked.
2. By color coding in accordance with the Standard for Identification of Covered Arc-Welding Electrodes published by the National Electrical Manufacturers Association (Fig. 8). Since this method of identification has been mostly phased out in favor of type marking, no further mention will be made of it here.
The following list gives examples of covered arc-welding electrodes approved for use in the fabrication of boilers and pressure vessels under the ASME Code. See Appendix A1 of the applicable section of the ASME Code, Section II, Part C, on Welding Rods, Electrodes and Filler Metals for details of the methods of classification. 1. Mild Steel Arc-Welding Electrodes, SFA-5.1 2. Corrosion-resisting Chromium and Chromium-Nickel Steel Welding Electrodes, SFA-5.4 3. Low-Alloy Steel Arc-Welding Electrodes, SFA-5.5 4. Copper and Copper-Alloy Electrodes, SFA-5.7 5. Nickel and Nickel-Alloy Welding Electrodes, SFA-5.11 Cut-length, bare, arc-welding rods are marked for identification by one of the following methods: 1. By imprinting the AWS-ASTM classification number on the surface of the bare rod. 2. By indenting the AWS-ASTM classification number on the surface of the bare rod. 3. By attaching to the bare rod a label bearing the AWS-ASTM classification number. Regardless of the method used, at least one legible marking should be located within the space 2 12 in. (64 mm) from one end of each rod. The prefix letter E in the classification number is customarily omitted. Electrode filler metal wound on spools is identified by the AWS-ASTM classification number marked on at least one flange of the spool. ESSENTIALS FOR PROPER WELDING PROCEDURES Quality of Weld. Besides the steady frying and cracking sound that a correct arc produces, the shape of the molten pool and the movement of the metal at the rear of the pool serve as a guide in checking weld quality. In a correctly made deposit, the ripples produced on the bead will be uniform and the bead will be smooth, with no overlap or undercut. Correct Arc Length. If the arc is too long, the metal melts off the electrode in large globules which wobble from side to side as the arc wavers, giving a wide, spattered and irregular bead, with poor fusion between original metal and deposited metal. If the arc is too short, there is not enough heat to melt the base metal properly and the electrode quite often sticks to the work, giving a high, uneven bead, having irregular ripples with poor fusion and slag and gas holes. Correct Current. If current on machines is too high or too low, a poor weld is certain to result. If too high, the electrode melts too fast and the molten pool is large and irregular. If too low, there is not enough heat to melt the base metal and the molten pool will be too small, will pile up, look irregular. Correct Travel Speed. When the speed is too fast, the pool does not last long enough, impurities and gas are locked in. The bead is narrow and ripples pointed. When speed is too slow, the metal piles up, the bead is high and wide, with a rather straight ripple. Correct Electrode Size. The correct choice of electrode size involves consideration of a variety of factors, such as the type, position, and preparation of the joint, the ability of the electrode to carry high current values without injury to the weld metal or loss of deposition efficiency, the mass of work metal and its ability to maintain its original properties after welding, the characteristics of the assembly with reference to effects of strains set up by heat application, the practicability of heat treatment before and/or after welding, the specific requirements as to weld quality andthe cost of achieving the desired results. Correct Electrode Angle. The electrode angle is of particular importance in fillet welding and deep groove welding. Generally speaking, when making a fillet weld, the electrode should be held so that it bisects the angle between the plates (Fig. 9) and is perpendicular to the line of weld (Fig. 10). When undercut occurs in the vertical member, lower the angle of the arc and direct the arc toward the vertical member.
Table 1. Difficulties in Metal-Arc Welding Difficulty Incomplete Penetration Possible Causes 1. Joint design faulty 2. 3. 4. 1. 2. 3. Welding speed too rapid Insufficient welding current Too large an electrode size Current either too high or too low Improper use of electrode Faulty electrode Possible Corrections 1. Check root opening, root face dimension, included angle 2. Slow down welding speed 3. Increase welding current 4. Decrease electrode size 1. Adjust current values 2. Check welding procedure 3. Dry electrode to remove moisture; change electrode 1. Use lower current 2. Shorten arc length 3. Change angle of holding electrode so that arc force will be used to fill undercut 4. Slow down the welding speed 1. Use lower current 2. Shorten the arc length 3. See remedies for arc blow 4. Replace electrode 1. Use a-c machine 2. Counteract blow with angle of electrode 3. Rearrange or split ground clamp 4. Replace magnetic work bench 5. Use brass or copper back-up bar 1. Remove rust, scale and other foreign matter from edges 1. Proper preparation of groove before each bead is deposited. Avoid contours that are difficult to penetrate with arc 2. Use preheat and obtain higher heat input per unit 1. Slow down welding speed 2. Increase current values 3. Use low-hydrogen electrodes 4. Dry electrodes to remove moisture; replace electrodes 1. Use low-hydrogen electrodes 2. Redesign joint; use preheat and postheat; weave 3. Use slower travel or faster freezing electrode to give a more convex bead 4. Back step to fill craters 5. Preheat and/or postheat 1. Redesign to allow for expansion and contraction forces 2. Use lower current and more efficient chill bars 3. Increase the speed of the arc 4. Improve welding sequence 5. Clamp properly to chill bar 1. Use low-hydrogen or austenitic electrode 2. Use proper preheat and postheat cycles 3. Use austenitic electrodes 4. Shallow penetration by directing arc on weld puddle
Poor Appearance
Undercutting
1. Current too high 2. Arc length too long 3. Improper manipulation of the electrode 4. Welding speed too rapid 1. Current too high 2. Arc length too long 3. Excessive arc blow 4. Faulty electrode 1. Magnetic field, created when using d-c, causes the arc to wander
Excessive Spatter
Arc Blow
Porous Welds
2. High viscosity of molten metal, rapid chilling, too low a weld temperature 1. Welding speed too rapid 2. Current too low 3. High sulphur or other impurities 4. Faulty electrodes 1. Faulty electrode 2. Rigidity of joint, stressed weld 3. Shape of bead 4. Craters 5. Fast cooling rate 1. Improper design of weld 2. Overheating 3. Welding speed too slow 4. Improper welding sequence 5. Faulty clamping 1. Incorrect electrode 2. Incorrect heat treatment 3. Air-hardening deposit 4. Base metal pick-up
Cracked Welds
Brittle Welds
AWS-ASTM CLASS
HOBART
E-4510* E-4520
Sulkete
510
E-6010
10, 10-IP
610-A
E-6011
611, 335A
611
6011 60110
E-6012
12 212A 12-A
612
6012 60120
LA-6012
R62
PFA & 612P WE-9 AC-3 SM DH-6 DH-2 DH-3 DH-5 DH-27 CM-50
E-6013 LA-6014 LA-6020 LA-6024 R627 LA-7010 R70 R624 R620 R64
613
6013 60130
LA-6013
R63
14A
614
Easyarc 7014
E-6020
111
620
E-6024 7024
624
Easyarc 7024
27
627
Easyarc 6027
E-7010-A1
710
710
E-7020-A1
111 HT
DH-720
45 Series electrodes are not permitted in ASME Code construction FMELPC Apr 1978
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Page 12
AWS-ASTM CLASS ARCOS Tensilend 70 Atom-Arc 8018 DH-170 Atom-Arc 7018-MO Atom-Arc 8018-N Atom-Arc 8018 Atom-Arc 8018-CM Atom-Arc 9018 Atom-Arc 9018-CM Atom-Arc 10018-MM Atom-Arc 10018-NM Atom-Arc T Atom-Arc 12018NMV Atom-Arc 502 Atom-Arc 12018NMV 117 12018 Ductilend 110 Atom-Arc T 107 Jetweld LH-110 11018 112 10018 Speedex HTS-100 Atom-Arc 10018-MM Atom-Arc 9018-CM 190-LE Jetweld LH-90 Speedex HTS-90 Raco 9018 Raco 9018-B3 Raco 10018-D2 Raco 10018 Raco 11018 Raco 12018 SW-1018 SW-1118 1118 Atom-Arc 8018-CM 8018C2 Raco 8018-B2 Ductilend 80 P & H 108 Raco 8018-C3 Atom-Arc 8018-N 180-LE Raco 8018-C2 SW-818 Ductilend 70 MO Atom-Arc 7018-MO 170-LA-MO Raco 7018-A1 718 LH-3800 Speedex 28 Ductilend 70 LA-7018 Hyloarc 76 170-LA Jetweld LH-70 LH-71 LH-7016 7018 Speedex HTS Sureweld 7018 Raco 7018 718 SW-47 Stelco Electrode No. 716-IP LA-7016 Tensiarc 76 70LA-1, 70LA-2 1022 Pluralloy Murex HTS, HTS-18 HTS-180 Sureweld 7016 Raco 7016 SW-65 Stelco Electrode No. 716-S P&H LINCOLN MARQUETTE McKAY CO. N. C. G. SHOBER
HOBART CANADIAN HOBART ELECTRODES ALLOYS RODS CANADIAN ROCKWELL (MUREX) M &T REIDAVERY SMITHWAY DIV. P & H
AIRCO
E-6016 E-7016
&
16
#616 #716
E-6018 E-7018
&
LH-718
#718
Wiz-18
E-7028
LH-728
Easyarc 7028
E-7018-A1
LH-718-MO
E-8018-C2
LH-818-N2
E-8018-C3
LH-818-N3
Easyarc 8018
Wiz-818
E-8018-B2
LH-818-CM
E-9018-G
LH-918-M
Easyarc 9018-M
E-9018-B3
LH-918-CM
E-10018-D2
LH-1018
E-10018-G
LH-1018-M
Easyarc 10018-M
Wiz-1018 Wiz-1118
E-11018-G
LH-1118
Easyarc 11018-M
E-12018-G
LH-1218
E-502
LH-502
502-15