r ~~i—AO33 ~

Sle CONSTRUCTION ENGINEERING RESEARCH LAB (ARMY) CHAMPAI—ETC 13/e

DETERMINATION OF ARC VOLTAGE , AMPERAGE. AND TRAVEL SPEED LIMITS—ETC(U)
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T DEC 76 R A W E B E R
LR4CLASSIFIED CERL—TR—M—197

U iI - -flj

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END
__________________________________________________________ DATE
F]LMCD
2—77

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MICROCOPY RESOLUTION TEST CHART

NAT
~ OP~~ L e~,~ (au OF STANDARDS — — A
 construction TECHNICA L REPO RT
/~ December 1976
Weldability of Construction Materials
engineering

research
laboratory _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

DETERMINATION OF ARC VOLTAGE, AMPERAGE,

AND TRAVEL SPEED LIMITS BY BEAD.ON-PLATE WELDING

by
It.A. Weber

DDC
c2 7 t916 11
~~~~~~~

~~~~~~~ UD L ~ L

IUN UI I

‘VP
RL
~~
A p~inw ~’tI b r public rekase disirihuliun unlimited.

~~ ‘~~~~L_ T ITI1TIIJ ~~
 — -—— ---- ,
_ n w,:
~~~~~~~~~~ ~~~~~ ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ - -

~~~~~~

he contents of this report are not to be used for advertising, publication , or

T
promotional purposes. Citation of trad e names does not constitute an
official indorsement or approval of the use of such commercial products.
The findings of this report are n ot t o be con strued as an of fici a l Depa rt m e n t
of the Army position , u nless so designated by other authorized documents.

DES TROY THIS R EPOR T WHEN ITIS NO L ONG ER NEEDED

DO NO T RE TUR N I T TO THE ORIGINA TOR

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SECURITY CLASSIFICATI oN OF THIS PAGE (Wpi.ii Deta Entered) _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

‘‘ A A READ IN STRUCTION S
i~ r U l ~ S IP ...UM
~J’ I~ I A l
~~~~ BEFORE COMPLET ING FORM
~~~~~~~ ~~~~~
LREPORT NUMBE 2. GOVT ACCESSION NO. 3. IPIENT S CATALOG NUMBER

~~~~~~~~~~
EERL-TR-M_ ~j.
~7 __________________________
J (— r mc DcmmDT A j ERIOD COVERED
,~
f ’) ~~TERMINATION OF ~~C ~9LTAGE , ~MPERAGE , AND TRAVELI FINAL
~~~~~~~~~
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SPEED LIMITS BY BEAD-ON-ELATE WELDING , ~~~~~
._ . ..J~~~~~~~~ 6.~ PERFORMING ORG.
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REPORT NUMBER
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” ~~( ) 6. CCeN T RAC’ OR GRANT NUMBER(s)
~
R. A.JWe ber ~I
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_ _ _ _
6;;) _ _

9. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM EL T. PROJECT . T A S K

A R E A & WORK U UMBERS
CONSTRUCTION ENGINEERING RESEARCH LABORATORY
P.O . Box 4005 - 4A762731AT41 7 007 ~~~~
_-

Cham paign , IL 61820 ~~~~

____________________________

/
II. CONTROLL ING OFFICE NAME AND ADDRESS k
! RFDt nT f l L T c
~ 1

DecaU~~V
13 NUMBER OF

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Unclassified
IS..

16. DISTRIBUTION STATEMENT (of this Report)

Approved for public release; distribution unl imited .

17. D I S T R I B U T I O N S T A T E M E N T (of th. abstract entered in Block 20, if d if f e r e n t from Report)

lB . SUPPLEMENTARY NOTES

Copies are obtainable from National Technical Information Service

Springfield , VA 22151
19. KEY W ORDS (Continue on reveres aid. if necessary end Identify by block number)
welding parameters
voltage limits
amperage limits
travel speed limits
\
20.
~
A BS T R (Continu, en ,e.are. aide if necee. ’y end identity by block ntenbsr )
~
This report the results of bead-on-piat tests to define limits for voltage ,
presents
amperage , and travel speed. The work was divided int u two sections: shielded metal-arc
welding (SMAW) and gas metal-arc welding (GMAW). The limits for voltage and travel
speed were de term in ed for SMAW electrodes based on limits previously determined by
the American Welding Society (Specification A5.l-69). Voltage and amperage limits for
GMAW electrodes were determined based on types of meta l transfer; travel speed limits
were based on bead appearance and shape. The results of this research are not final; .
. ___.
~~~

DO ~~~~~~~~~ 1473 EDITIOeS OF ) NOV SS IS OSSOLETE UNCLASSIFIED

—-
SECURITY CLASSI FICATION OF T HIS P A G E (PItin D.f• Entered)
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U a i u L r~ .) . J AI A L U

SECURITY CLAUIFICAT ION OF THIS PAGE(When bet. ‘~~ ‘~~~

Block 20 continued . •

further work on butt welds wi

l refine the limits. The final results will be used to prepare
recommended changes to appropriate guide specifications and technical manuals.

UNCLASSIFIED
• • Y1~ AT1PNOF TN PMI D .

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•.. ..•• •• . • • •
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 -• .• - -- -- - ---— - w ~~~~~~~~~~~~ f l?fl ~~~~~~~ . • • ‘~~~

•
FOREWORD

This work was conducted by the U.S. Army Construction Engineering Research
Laboratory (CERL) for the Directorate of Military Construction,Office of the Chief of
Engineers (OCE), under Project 4A76273 1AT4I , “Materials Research and Development
for Military Construction”; Task 17, “Application Engineering”; Work Unit 007,“Weld-
ability of Construction Materials.” The applicable OCR number is 1.06.004.

The OCE technical monitor for this project is Mr. I. A. Schwartz, DAEN-MCE.D.

CERL personnel concerned with the investigation were Mr. R. A. Weber and Mr. F.
Kisters of the Metallurgy Branch (MSM), Materials and Science Division (MS). Mr. C. E.
Jackson,professor in the Department of Welding Engineering at Ohio State University,
acted as a consultant for this project.

The Chief of MSM is Dr. A. Kumar and the Chief of MS is Dr. G. R. Williamson.
COL J. E. Hays is Commander and Director of CERL and Dr. L. R. Shaffer is Technical
Director.

W~1t~ IsstIw _E
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CON T E NTS

• DD FORM 1473 1
FOREWORD 3
LIST OF TABLES AND FIGURES

I INTRODUCTION 7
• B.ckground
Objective
Materials
Appro.ch

2 RESULTS AND DISCUSSION 8

Shielded Metal-Arc Welds
Gas Metal-Arc Welds

3 CONCLUSIONS 10

TABLES 10
FIGURES is
DISTRIBUTION

4 .

~~~~~~ ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ ~~
 “I’

TABLES

Number Page

1 Coatings and Current Designation 10

2 Materials Used in Study 10

3 We lding Parameters of Bead-on-Plate Welds 11

4 Voltage Umits 14

FIGURES

Number Page

1 Graph of Travel Speed Versus Current for 1/8-in. (3 .2 mm) Diameter

E6010 SMAW Electrode 15

2 Graph of Travel Speed Versus Current for 1/8-in. (3.2 mm) Diameter
E60 l1 SMAW Electrode 15
5~
3 Graph of Travel Speed Versus Current for 118.m. (3.2 mm) Diameter
E6013 SMAW Electrode 16

4 Graph of Travel Speed Versus Current for 118-in.(3.2 mm) Diameter

E7018 SMAW Electrode 16

S Graph of Travel Speed Versus Current for 1,8-in. (3.2 mm) Diameter
E7024 SMAW Electrode 17

6 Graph of Travel Speed Versus Current for 5/32-in. (4.0 mm) Diameter
E8018 SMAW Electrode 17

7 Graph of Travel Speed Versus Current for 1/8-in.(3.2 mm) Diameter

EllOl8SMAW Electrode 18

8 Graph of Voltage Versus Current for E7OS- 2 Electrode and

Shield Gas of Argon with 2 Percent Oxygen Addition 18

9 Graph of Voltage Versus Current for E7OS.2 Electrode and

Carbon Dioxide Shield Gas 19
• 10 Graph of Voltage Versus Current for E7OS.3 Electrode and
Shield Gas of Argon with 2 Percent Oxygen Addition 19

II Graph of Voltage Versus Current for E7OS.3 Electrode and

Carbon Dioxide Shield Gas 20

12 Graph of Voltage Versus Current for E7OS-4 Electrode and

Carbon Dioxide Shield Gas 20
 - F ig ures (confd)
Number Page
13 Graph of Voltage Versus Current for E7OS-6 Electrode and
Carbon Dioxide Shield Gas 21

14 Graph of Voltage Versus Current for El IOS Electrode and

Shield Gas of Argon with 2 Percent Oxygen Addition 21

I:

Ji~~~~~~~ ~~~~~ ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

-
~~~~~~~~~~
-
 DETERMINAT ION OF ARC VOLTAGE,
AMPERAGE, AND TRAVEL SPEED LIMITS
BY BEAD-ON-PLATE WELDING
1 INTRODUCTION
Background
Shielded metal-arc welding (SMAW) and gas meta l-arc
welding (GMAW) are the predominant forms of electric
arc welding used today . SMAW is used about twice as
often as GMAW for both field and shop fabrication.
Electrode technology has been improved to the point
where many types of electrodes are now available to
respond to a wide variety of welding problems. The
American Welding Society (AWS) has developed a
classification system for steel welding electrodes based
on some of the electrodes ’ characteristics. The SMAW
classification codes are made up of an E and four or five
numbers (EXXYZ). The E designates that the material
is an electrode. The first two numbers, XX , give the
minimum deposited weld metal tensile strength; that is,
an electrode with an E6OYZ classification would have a
mi n imu m deposited tensile strength of 60,000 psi (4.13
MPa). This tensile strength designation can be 60, 70 ,
80, 100 , or 110. The number represented by Y—either
1 or 2—designates the welding position in which the
electrode can be used. A I means that the electrode can
be used in all positions—fiat , horizontal, vertical, and
-• overhead; a 2 indicates that usage is limited to flat or
horizontal fillet welds. The last term in the classification,
Z, can be any number from 0 through 8. These numbers
indicate major coating constituents and welding current
limitations, as shown in Table 1.
The classification system for GMAW electrodes is
somewhat simpler. The first three or four characters ,
EXX or EXXX . have the same meaning as in the SMAW
code ; the only difference is that the tensile strength
designations for GMAW wires range from 70 to 110. The
next digit is either S or U. An S means that the electrode
has no coating and is a solid wire. A U means that the
solid wire has an emissive coating. The final digit can be
any number from I through 6 or the letter G. The
numbers refer to different chemical compositions, in
F particular carbon and silicon contents. The G represents a
general classification which has no chemistry restrictions
except that nickel,chromium,moiybdenum,orvanadium
cannot be intentionally added. ’
• 2”Specifications for Mild Steel Electrodes for Gas Metal-Arc
l
“Specification for Low-Alloy Steel Covered Arc-Welding
Electrodes, “A5.5-6 9 (American Welding Society, 1969).
i --
-- - I i
I i ~~~~~~~~~~~~~~~~~~~~~~ —-~
The choice of electrode is governed by the strength
level of the plate being welded , the welding process, and
the position of the weld. The quality of the welds resulting
from the large number of possible electrode/steel
combinations is related to the welding process variables—
current , voltage, and tra v el speed. To determine the
relationship and to optimize weld quality, a three-phase
study was undertaken to establish arc voltage,current .
and travel speed limits. The first phase, reported here,
involved establishing limits using bead-on-plate welds.
The second phase will define the limits based on work
with butt welds, and the final phase will determine the
crack sensitivity of weldments deposited using the limits
defined in the first two phases.
Objective
The objective of the first phase of this study was to
determine the extreme limits of arc voltage, current ,and
travel speed for steels used by the Corps of Engineers.
These limits were to be established by visual inspection
and macroexaniination of bead-on-plate welds produced
with differing arc variables.
Materials
Table 2 identifies the plate steels (by American Society
for Testing and Materials [ASTMJ code numbers) and the
electrodes (by AWS code numbers) used in this investi-
gation. Selection of the electrode types to be used within
each plate material was based on the AWS Structural
Welding Code.2
The number of plates and electrode types used was
limited by their availability. Most plate materials were
available in mill run quantities only (approximately 20
tons [18.1 metric tonsj ) and were not purchased because
of cost and storage problems. A similar situation was
encountered with the electrodes.
Two types of shielding gases were used with GMAW:
(1) a mixture of argon and oxygen and (2) carbon dioxide.
Tests with the E7OS-2 and E7OS-3 electrodes were
shielded with both of the gases, while E7OS-4 and E7OS-6
were shielded with carbon dioxide only and the El lOS
electrode was shielded with argon and 2 percent oxygen
only.
Approach
All plate material was cut to approximately 12 in. x
18 in. (0.3 m x 0.5 m) using an oxyacetylene cutting
____________
Welding,” A 5.1 8-6 9,Structural Welding Code, DI .1.75 (American
Welding Society, 1969).
-
~~~~~

_______ ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
apparatus. The surface to be welded was sandblasted and
wire-brushed to remove surface oxides and paints.
Welding was performed with manual SMAW and fully
• automatic GMAW systems using reversed polarity direct
current. Individual weld beads were deposited with preset
—
voltage, amperage, and travel speed. Each variable was
changed to find the maximum and minimum tolerable
limits. Table 3 contains the parameters for each electrode
and plate material ,
The deposited beads were visually inspected for bead
contour and shape and then sectioned for macrospecimen
examination. The macrospecimens were polished and
etched with 5 percent nital and examined for penetration,
reinforcement , undercut, and porosity. From all these
observations, limits of voltage, amperage, and travel
speed were determined,
2 RESULTS AND DISCUSSION
Shielded Metal-Arc Welds
The AWS specification AS. l-69 amperage limits for
~
SMAW electrodes, which are based on wire diameter and
coating compositon,were used in this study in establishing
the voltage and travel speed limitations. The amperage
limits are noted below for each electrode. Table 4
presents the voltage limits established for the SMAW
electrodes. Voltage, which is directly related to the arc
• length, affects both bead width and shielding character-
istics,i.e. a long arc length (highvoltage) produces a wide
bead and could produce porosity in the weld by allowing
the aspiration of air into the arc atmosphere.
Figures 1 through 7 are graphs of travel speed versus
current for the individual SMAW electrodes; the dashed
lines are the travel speed limits at various current levels.
These limits were determined by bead shape and amount
• of undercut. Undercutting is caused by a combination of
factors, but primarily by too high a rate of speed for a
given current level. A large area is melted and drawn into
the center of the bead and the arc passes by too quickly
• to allow a sufficient weld metal deposit in the welded
• area. Undercut results. Each electrode is discussed
separately below,
• E7018
3”speuficitlon lor Mild Steel Covered Arc-Welding Elec-
trudus.” A 5.l-69 , Sinwiural Welding (‘ode , Dl.l-75 (American
Welding Soc k’ty. I%9)
~~~~~~~~~~~~~~~~~~~~~~~~~
r
n - - -•• -
—
WV,
~~~~~~~~~~~~~~~~~~
E6010
The E6010 electrode is a high cellulose sodium
electrode that has many uses in welded fabrication. It
produces a forceful, spray-type arc which gives deep
penetration. The slag cover on the weld bead is thinand
easily removed.
AWS specification A5.l-69 gives an amperage range
of 75 to 125 A for this electrode. The voltage was varied
from 28 to 34 V and the travel speed used ranged from 6
to 21.7 in./min (15.2 to 55.1 cm/min).
The lower limit for voltage was determined to be 28 V
due to handlingcharacteristics and the tendency to short
circuit with lower voltages. The upper limit of 32 V was
based on visual inspection of the external surface and a
macrospecimen, and on the usability of the electrode
with long arc lengths. Figure 1 shows the limits for travel
speed determined by bead shape and amount of undercut.
E6011
The E601 1 electrode is quite similar to the E6010
electrode in arc characteristics, except that sodium is
used in place of potassium,which enables the electrode
to be used with alternating as well as direct current. The
current range for this electrode is also 75 to 125 A. At
the low end of the current range, the penetration was
minimal, and overall the penetration was less than that
of the E60l0 electrode.
The voltage was varied between 28 and 35 V. Based
on the same criteria used for the E6010 electrode,the
voltage range was determined to be 28 to 32 V. The
travel speed was varied between 6 and 11.4 in./min (15.2
and 29.0 cm/mm ). Figure 2 shows the limits of travel
speed determined by bead shape and amount of undercut.
E6013
The E60 13 electrode was originallydesigned for light
gage sheet metal, although larger electrode diameters are
used for single-pass, high-speed horizontal fillet welds.
The electrode can be used for welding sheet metal in the
vertical-down position.
The current range for this electrode is 130 to 150 A;
the voltage used ranged from 22 to 27 V. The voltage
limits determined for the E6013 electrode are 22 and
26 V. The travel speed was varied for 7.2 and 17.8
in./min (9.7 to 45.2 cm/mitt). Figure 3 shows the limits
on travel speed for this electrode.
The E70l8 electrode has a smooth, quiet arc with
small amounts of spatter and low penetration. Very high
_ _ _ _ _

_______
welding speeds can be used with this electrode. The coat-
ing contains as much as 25 to 40 percent iron powder.
This low-hydrogen electrode is used where other types
of electrodes could cause underbead cracking, which is
usually attributed to hydrogen pick-up from the arc
atmosphere.
The amperage range for this electrode is 115 to 165 A.
The test welds were made with voltages betwee n 25 and
38 V . Based on bead shape, porosity content , and usabil-
ity, the limits on voltage were determined to be 25 and
28 V . The travel speed was varied between 6.3 and 22.9
in./min (16.0 and 58.2 cm/rnin). Figure 4 shows the
travel speed limits for the E70l8 electrode,
Weld beads produced with the E7018 electrode on
the different types of steel plate showed no differences
that were related to the plate. Therefore, all welds made
with the E70l 8 electrode were grouped together to
determine the ‘ olerable limits of voltage, current , and
travel speed,as ‘ere the welds produced with the E7024
~ oxygen addition, transfer can be by large drop lets
electrode , discucsed next.
E7024
• The E7024 electrode’s heavy coating, which contains
high percentages of iron powder , ma kes up about 50
percent of the total electrode weight. E7024 , which is
manufacture d specifically for flat position and horizontal
fillet welding, has a smoot h, quiet arc with very small
amounts of spatter. This electrode generally has low
penetration and can be used with high lineal speed.
The current range for this electrode is 115 to 165 A.
W-~1d beads were produced with voltages from 26 to 42 V
and travel speeds from 7 to 26.7 in./min (17.8 to 67.8
cmi : in). The usable range for voltage was determined to
~ (0.8 mm) or O.045 in.(l.l mm). The 0.062-in, diameter
be 26 ~o 32 V. Figure 5 shows the travel speed range for
this electrode.
E8018
The E80l8 electrode ,which is used with high-strength
steel , is a low-hydrogen electrode with arc characteristics
similar to the E7018 electrode. The electrode provides
shallow penetration with a smooth, quiet arc and small
amounts of spatter.
The ..‘n erage range for this electrode is 150 to 220 A.
~~
The voltage used for this electrode ranged from 22 to
36 V , and the travel speed ranged from 8 to 20 in.fmin
(20.3 to 50.8 cm/mm ). The usable voltage range was
determined to be 22 to 28 V. Figure 6 shows the travel
speed at various current levels,
L’
•
IIT
II ~~~~ :..
~~ ~~~~~~..
~~~
- _
— --- - -
‘ •“ -—-- - - - --— - - -
~~
~~~~~ ~ ~~ ~~~~~~~~~~~~~~~~
E11018
The El 1018 electrode is alsoalow-hydrogen electrode
that is used for high-strength, low alloy steels. The arc
characteristics are similar to the E70 18 and E80 18
electrodes.
The current range for this electrode is 115 to 165 A.
The voltage used was 25 to 35 V , and the travel speed
ranged from 6.3 to 17.8 in./min (16.0 to 45.2 cm/mm ).
The voltage range for this electrode was determined to
be 25 to 30 V; above 30 V , porosity and spatter became
problems, and below 25 V ,usability dropped off because
of short circuiting problems. Figure 7 shows the travel
speed limits for the El 1018 electrode.
Gas Met al-Arc Welds
The travel speed, voltage, and current limits for the
GMAW electrodes were not as clearly delineated as those
for the SMAW electrodes. Arc voltage and current level
combinations can be adjusted to give several types of
metal transfer. With the use of argon plus 2 to 5 percent
(globular) with low power levels or by a fine spray with
high power levels. There is a clear-cut transition to spray
transfer,which is the method normally used with argon-
oxygen shielded GMAW .
With carbon dioxide shield gas ,three types of transfer—
short circuit, repelled, and projected—-can be obtained,
depending on the levels of current and voltage . The short
circuiting transfer method, which was developed for thin
materials and welding in the vertical and overhead posi-
tions, involves transfer of weld metal from the electrode
tip by repetitive short circuits through contact of the
molten electrode and the work piece. The wire diameters
recommended for short circuiting welding are 0.030 in.
(1.6 cm) wire used in this investigation_is not normally
u sed in short circuii[r~~transfer because of the higher
currents required to melt this size of electrode. Higher
currents and voltage cause formation of droplets at the
end of the electrode. As these droplets enlarge, they
begin to detach from the electrode. Forces in the center
of thc t” give the drop an initial acceleration that repels
it from the weld pool. With further increased current
levels, the electromagnetic forces pinch the drop off and
project it toward the weld pool. The projected transfer
mode is most frequently used because it gives better
pene ration and less spatter than the repelled transfer
~
mode.
Figures 8 through 14 are graphs of voltage versus
current levels for the GMAW electrodes used in this
:
~~~~~~~~~
_ ___________
_ _ _ :
. :_
_ .. :
_ .~~~~~~
 - - -

study. The lines on these graphs represent the boundaries 3 CONCLUSIONS

between types of metal transfer. In Figure 10, the two
points at the lower left are from arcs that exhibited
short circuiting characteristics but were very erratic and
had minimal usability; the settings used in these arcs are
not recommended when using shield gas of ’ argon with
2 percent oxygen addition. The spray transfer region was
established for the three electrodes that can be used with
argon-oxygen shield gas (Figures 8, 10,and 14).
The travel speed and voltage limitations for SMAW
electrodes were established using the American Welding
Society ’s current limits. The travel speed was found to be
current-dependent; that is, at low current levels slower
travel speeds are required, while at high current levels
faster travel speeds are required.

The four electrodes shielded with carbon dioxide gas—
E7OS-2 , E7OS-3 , E7OS-4 , and E7OS-6—all exhibited the
three types of weld metal transfer. Figures 9, 11, 12,and
13 show the limits of the three transfer modes.
The travel speed for each electrode ranged from S to
35 mn./min (12.7 to 88.9 cm/min). With the exception of
E7OS-2 shielded with argon with 2 percent oxygen
addition and A 36 steel,no significant undercutting was
present at the toe of the weld. Further examination of
the A 36 welds showed that the problem of undercut
was due to a cast in the weld wire which forced the arc
to one side, leaving an undercut toe on the other side.
The usable range of travel speed was 10 to 35 in./min
(25.4 to 88.9 cm/mitt). Below 10 in./min (25.4 cm/min)
the weld crown became excessively high, exceeding the
AWS’s 1/8-in. (3.2 mm) limit (AWS D1.1.75). A few
isolated weld beads other than those deposited at the
Current and voltage limits for GMAW electrodes were
determined based on the most frequently used transfer
modes through the arc. Travel speeds between 10 and
35 in./min (25.4 and 88.9 cmfmin) were found to be
acceptable for GMAW electrodes , except in special cases
of low voltages and high currents, where the weld beads
were narrow and high.
These conclusions, however , are not final. Further
refinement of the limits of voltage, current , and travel
speed is anticipated when butt joints are studied in the
second phase of this study. The third phase will de-
termine the effect of weldments deposited using the
defined limits on crack sensitivity. The f’malresults will be
used to revise and update Technical Manual TM 5-8O5-7
~
and to propose changes to guide specifications such as
CE 260.02.
~
______________

slow travel speeds exceeded the maximum. These were 4 j velding; Design, Procedures and Inspection , TM-5-805-7
attributed to short arc lengths and high current levels (Department of the Army, 1968)
• that did not allow the weld metal to spread out, thus 5 Welding, Structural
for Critical Applications, CE 260.02
resulting in tall, narrow weld beads. Further work is (Office of the Chief of Engineers,June 1968).
required to better characterize the travel speed limits
for the GMAW process. These limits should be better
defined by the butt weld stage of this study, during
which mechanical property tests will be conducted to Table 2
further refine the tolerable limits of weld variables. Materials Used in Study
Table 1 Plate Material Electrodes (AWS No.)
(ASTM No.) GMAW SMAW
Coatings and Current Designation
A 36 E7O S-2 , E7OS-3 E6 010 , E60 1 1
• Z CoatingTypes Currentlypes E7OS-4 ,E7OS-6 E6013 , E70 18
E7024
0 High cellulose sodium dc , reversed polarity
I High cellulose potassium ac or dc, reversed polarity A 242 E70S 2,E70S 3 £7018,£7024
2 High titania sodium ac or dc,st raight polarity E7OS.4 ,E70S 6
3 Fli gh titania potassium ac or dc,either polarity A 441 E7OS-2 ,E7OS-3 £7018,£70 24
4 Iron powder titania ac or dc,either polarity E70s-4 ,E7OS-6
5 Low hydrogen sodium dc,reversed polarity
6 Low hydrogen potassium ac or dc,reversed polarity A 514 Fl I0 EliOt
7 Iron powder ,iron oxide ac or dc,either polarity ** A 527 E7OS-2, E7OS-3 E70l8,£70 24
8 Iron powder . low hydrogen ac or dc,reversed polarity E7OS-4 . E7OS-6

I-;xccpt when preceded by a 2; in that case it is high iron

*
A 5 88 E7OS-2, E7OS-3 E7018,E7024
oxide,ac or dc , either polarity. OS • 0

~~ Reverse d polarity is not recommended for horironta l fillets. A 710 - £8018

10

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Table 3

Welding Parameters of Bead-on-Plate Welds

Plate Material Current,A Voltage,V Travel Speed, Plate Material Current,A Voltage,V Travel Speed,
(ASTM No.) in./min (ASTM No .) in./min
(cm/mm ) (cm/miss)
11 5 26 8.9 (22.6)
E60l0( l/8-in. 13.2 mml diameter) itS 25 12.3 (31.2)
A36 75 28 7.5 (19.1) 115 24 15.5 (39.4)
75 32 7.7 (19.6) 115 25 17.1 (43.4)
75 28 6.0 (15.21 135 26 6.7 (17.0)
10)) 29 8.3 (21.1) 135 32 7.0 (17.8)
100 29 14.1 (35.8) 140 26 12.0 (30.5)
100 34 9.8 (24.9) 140 26 8.0 (20.3)
125 30 11.7 (29.7) 140 26 18.5 (47.0)
125 28 21.7 (55.1) 150 26 7.5 (19.1)
125 38 13.3 (33.8) 150 35 8.1 (20.6)
150 32 8.5 (21.6)
E60ll (1/8-in. (3.2 mml d
iameter) 165 21 8.2 (20.8)
A 36 75 28 9.6 (24 .4) 165 36 8.7 (22.1)
75 34 8.7 (22.1) 165 33 8.6 (21.8)
75 30 8.0 (20.3) 165 26 10.4 (26.4)
75 30 6.0 (15.2) 165 26 16.6 (4 2.2)
100 28 11.4 (29.0) 165 26 22.9 (58.2)
100 28 8.0 (20.3) A 572 115 26 8.7 (22.1)
100 35 10.0 (25.4) 115 25 16.6 (42.2)
125 30 8.2 (20.8) 115 26 10.4 (26.4)
1 25 30 13.7 (34.8) 140 26 8.0 (20.3)
125 28 7.2 (18.3) 140 26 20.0 (50.8)
140 26 13.0 (33.0)
E6013 (1/8-in. (3. 2 mmj diameter) 165 29 12.0 (30.5)
A 36 130 22 8.3 (21.1) 165 28 16.0 (40.6)
130 23 16.0 (40.6) 165 27 8.7 (22 . 1)
130 27 9.6 (24 .4) A 588 11 5 26 8.0 (20.3)
150 26 10.0 (25.4) 115 25 14.6 (37.1)
150 27 17.8 (45.2) 115 26 9.8 (24.9) - 1
150 22 7.2 (18.3) 140 26 8.0 (20 31
150 24 9 .4 (23.9)
140 26 18.5 (47.0)
F70l8 (1/8-in. 13.2 mml diamet
er) 10:7

A 36 115 25 8.7 (22.1) 165 30 20.0 (50.8)

115 25 15.0 (38.1) 165 32 9.8 (229 )
115 25 8.0 (20.3)
140 26 10.2 (25.9) E7024 (1/8-in . (3.2 mml diameter)
140 25 20.0 (50.8) A 36 140 29 12.3 (3 1.2 )
140 26 8.3 (21.1) 140 30 21 .8(55.4)
165 21 12.0 (30.5) 140 30 7.7 (19.6)
165 28 15.5 (39.4) 170 31 10.7 (27.2)
165 28 7.5 (19.1) 170 32 20.0 (50. 8)
~ 242 115 26 6.5 (16.5) 170 31 7.0 (17.8)
115 25 8.4 (21.3) 190 34 12.6 (32.0)
• 115 25 12.0 (30.5) 190 34 20.9 (531)
115 25 16.6 (4 2.2) 190 32 7•8 (19.8)
140 26 8.0 (20.3)
A 24 2 140 26 22.9 (58.2)
140 27 12.0 (30.5)
140 27 12.0 (30.5)
140 26 16.0 (40.6)
140 27 8.0 (20 3)
165 28 8.0 (20.3)
170 30 19.2 (48.8)
165 ‘7 12.0 (30.5) 110 ( 3 0 5 )
170 30
165 27 17.0 (43.4)
170 30 8 3 ( 21:1)
•\ 44 l 115 25 6 .3( 16 .0) 190 32 20.9 (53.1)
11 5 38 6.4 (16.3) 190 32 12.0 (30.5)
115 28 6.7 (17 01 190 32 8.0 (20.3)

Ii

.-•-•-. • - -. —- — - —. . . - - ___________ -
~~~~~ • .- ._-~~~~~._ -_. U
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
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_ _ _ _ _ ~~~~~~~~~~~ •

Table 3 (cont’d)

Plate Material Current,A Voltage, V Travel Speed, Plate Material Current,A Voltage,V Travel Speed,
(ASTM No.) in./min (ASTM No.) in./mln
(cm/m iss) (an/mid)
—
A44 I 140 26 21.8 (55.4) 165 30 10.9 (27.7)
140 28 12.0 (30.5) 165 26 17.8 (45.2)
140 28 8.0 (20.3) 165 26 10.0 (25.4)
140 32 8.3 (2 1.1) 165 26 8.5 (12.7)
140 40 8.1 (20.6)
170 31 9.4 (23.9) E7OS-2 (1/16-in. 11.5 mmj diameter)
170 40 11.2 (28.4) (argon with 2 percent oxygen addition)
190 32 11.2 (28.4) A36 360 25 15(38.1)
190 42 11.2(28.4) 350 25 15(38.1)
190 33 22.9 (58.2) 300 26 15 (38.1)
190 33 16.0 (40.6) 400 23 15 (38.1)
A 572 140 28 10.4 (26.4) 370 20 15 ( 8.1)
~
140 30 22.9 (58.2) 315 22 15 (38.1)
140 29 8.0 (20.3) 295 22 15 (38.1)
170 29 9.8 (24.9) 270 23 15 (38.1)
170 31 20.9 (53.1) 260 25 15(38.1)
170 30 8.0 (20.3) 200 20 15 (38.1)
190 31 10.9 (27.7) 250 20 15 (38.1)
190 33 24.0 (61.0) 275 19 15(38.1)
190 32 10.4 (26.4) 310 18 15 (38. 1)
360 33 15 (38.1)
A 588 140 28 10.9 (27.7)
140 27 25.3 (64.3)
470 31 15(38:1)
140 28 7.7 (19.6)
370 24 30 7 6 2
5 . ( .)
380 24 2 63
- .)
35 0 2 20 50 8
. ( . )
350 2 1 2 4
- )
305 25 5 ( 12 7 )
190 33 24.0 (61.0)
320 18 10(25:4)
190 33 7.8 (19.8)
310 18 20 (50.8)
ESOl8 (5/32-in. [4.0 mm) diameter) 315 18 25 (63.5)
A7 10 150 22 13,0(33.0) 3 20 18 30 (76.2)
• 150 27 13.7 (34.8) 500 29 30 (76.2)
150 25 8.0 (20.3) A 242 365 25 35 (88.9)
185 26 12.0 (30.5) 365 25 25 (63.5)
185 26 19.5 (49.5) 390 25 15(38.1)
185 30 10.4 (26.4) 390 25 10(25.4)
185 26 8.0 (20.3) A44 1 360 25 35 (88.9)
220 28 12.0 (30.5) 360 25 35 (88 9)
220 36 12.0 (30.5) 385 25 15 (38.1)
220 30 20.0 (50.8) 385 25 10 (25.4)
220 29 8.2 (20.8)
A 572 365 25 15(38.1)
El 1018 (1/8-In.[3.2 mm) diameter) 380 25 25 (63.5)
A 514 11 5 25 8.0 (20.3)
380 25 35 (88.9)
115 32 8.0 (20.3) A 588 390 25 35 (88.9)
115 27 8.0 (20.3) 390 25 25 (63 5)
115 25 11.4 (29.0) 390 25 15(38.1)
115 25 6.3( 16.0) 390 25 10(25.4)
115 25 17.1 (43.4)
140 26 17.1 (43.4) E7OS-2 (1/16-in. [1.5 mmj di .meter) (carbon dioxide)
~
140 25 12.0 (30.5) A 36 300 35 10(25.4)
140 25 7.5 (19.1) 350 34 10(25.4 )
140 28 8.4 (21.3) 390 34 10(25 .4)
140 34 10.2 (25.9) 430 33 15 (3 8.1 )
165 27 10.9 (27.7) 430 32 15 (38 .1)
165 35 9.4 (23.9) 450 32 15 (38.1)

12

—. _ _ _ •. _ 6 _ _ _ _ •_ _ _ • ’ _ _ _
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——
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-

Table 3 (cont’d)

Plate Material Current , A Voltage,V Travel Speed, Plate Material Current ,A Voltage,V Travel Speed.
(ASTM No.) in./min (ASTM No.) in./min
(cm/msas ) (cm/miss )
380 25 IS (38.1) A 242 380 25 35 (88.9)
365 25 IS (38.1) 380 25 25 (63.5)
360 27 15 (38. 1) 375 25 IS (38.1)
345 26 15 (38.1) 375 25 10t25.4 )
280 27 15 (38.1)
A44 1 380 25 35 (88.9)
330 20 15(38. 1)
380 25 25 (63.5)
280 20 15 (38.1)
210 22 370 25 15 (38 I)
15(38.1)
370 25 10 (25.4)
370 25 35 (88.9)
380 25 30 (76.2) A 572 370 25 25 (63.5)
380 26 5 (12.7) 360 25 15 (38.1)
A 242 375 25 35 (88.9) A 588 370 26 35 (88.9)
375 25 25 (63.5) 370 26 25 (63.5)
360 26 15(38.1) 375 25 15(38.1)
360 26 10(25.4) 375 25 10(25.4)
A 441 360 26 35 (88.9)
360 26 25 (63.5) E70S-3 (1/16-in. [1.5 m m ) diameter) (carbon dioxide)
370 25 15 (38.1)
370 25 10 (25.4) A 36 180 22 10(25.4 )
230 21 15 (38.1)
A 572 370 25 25 (88.9)
270 20 15 (38.1)
365 25 25 (63.5)
310 19 15(38.1)
360 25 15(38.1)
300 27 15(38. 1)
A 588 360 26 35 (88.9) 325 26 15 (38.1)
360 26 25 (63.5) 350 26 15 (38.1)
360 26 15(38.1) 380 26 15(38.1)
360 26 10(25.4) 400 25 15 (38.1)
420 24 15 (38.1)
E7OS-3 (1/16-in, [1.5 mm) diameter)
365 33 15 (38.1)
(argon with 2 percent oxygenaddition)
415 32 15 (38.1)
A36 400 28 15 (38.1) 440 32 15 (38.1)
445 27 15 (38.1) 480 31 15 (38.1)
465 28 15 (38.1) 365 26 35 (88.9)
400 20 15 (38.1) 395 25 35 (88.9)
37 0 20 15 (38.1) 385 25 25 (63.5)
350 21 15(38.1) 385 25 10(25.4)
355 21 15 (38.1)
300 22 15 (38.1)
275 23 15 (38.1) A 242 370 26 35 (88.9)
150 18 15(38.1) 370 26 25 (63.~ )
230 24 15(38.1) 350 26 15(38.1)
200 17 15(38.1) 350 26 10-25 .4)
250 16 15(38.1) A44 1 350 26 3S (88.9)
340 16 15(38. 1) 350 26 25 (63.5)
280 16 15 (38.1) 360 26 15 (38.1)
285 16 25 (63.5) 360 26 10 (25.4)
280 16 30 (76.2)
280 16 20 (50.8) A 572 350 26 35 (88.9)
250 17 10(25.4) 350 26 25 (63.5)
410 27 10(25.4) 350 26 15(38 .1)
410 27 20 (50.8) 340 26 10(25.4)
410 27 25 (63.5) A 588 370 26 35 (88.9)
390 28 30 (76.2) 370 26 25 (63.5)
415 27 5( 12.7) 360 26 15 (38.1)
4 10 27 35 (88.9) 360 26 10(25.4)

13
 .,__— ~~~~~~~ -- ‘_ ‘r - ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
.•
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
—.— ~
——-,.•• — ,‘
;,,—‘——.- ‘_ -,- - -——-----.- -——- - .

Table 3 (con t’d)

Plate Material Current, A Volta ge,V Travel Speed, Plate Material Current , A Voltage,V Travel Speed,
(ASTM No.) in./m in (ASTM No.)
(ens/m iss) (an/mid )
• E7OS-4 (1/16-In. [1.5 mm) diameter) (carbon dIoxide) 315 19 15(38.1)
A 36 140 22 20 (50.8) 270 20 15 (38.1)
230 21 15 3 8 1 220 21 15(38.1)
280 20 15 (38 1 I0 . )

360 19 15 (38 I) ‘ -0
• 220 29 15 (38:1) 340 26 25 (63.5)
300 28 15(38 .1) 340 26 5(12.7)
350 26 15 (38.1) A 242 340 26 35 (88.9)
370 25 15 (38.1) 340 26 25 (63.5)
300 34 15 (38.1) 320 26 15 (38.1)
375 33 15 (38.1) 320 26 10 (25.4)
420 32 15 (38.1)
A 441 340 26 35 (88.9)
450 32 15 (38.1)
340 26 25 (63.5)
360 26 35 (88.9)
365 26 15 (38 1)
350 26 25 (63.5)
365 26 10 ‘25 4
335 26 10 (25.4)
A 242 360 26 35 (88.9) A 572 340 26 35 (88.9)
360 26 25 (63.5) 350 26 25 (63.5)
360 26 15 (38.1) 360 26 15 (38.1)
350 26 10 (25.4) 350 26 10 (25.4)
A44 1 360 26 35 (88.9) A 588 320 26 35 (88.9)
360 26 25 (63.5) 325 26 25 (63.5)
-
360 26 15 (381) 335 26 15 (38.1)
-

350 26 10(25.4)
E 1I OS (1/16-in. [1.5 mm) diameter)
A 572 340 26 35 (88.9) (argon with 2 percent oxygen addition)

.
A5 14 225 20 15 (38.1)
280 20 15 (38.1)
A 588 360 26 35 (88.9) 330 19 15(38.1)
360 26 25 (63.5) 370 18 15 (38.1)
360 26 15(38.1) 390 25 15(38.1)
360 26 10 (25.4) 425 24 15 (38.1)
E7OS-6 (1/16-in. [1.5 mm) diameter) (carbon dioxide)
A36 340 34 15(38.1) 500 30 15 (38.1)
440 32 15 (38.1) 120 15 15 (38.1)
440 32 15 (38.1) 225 14 15 (38.1)
400 25 15 (38.1) 245 14 15(38.1)
360 26 15 (38.1) 300 20 35 (88.9)
340 26 15 (38.1) 300 20 25 (63.5)
280 27 15 (38.1) 300 20 10(25.4)

Table 4

Voltage Umita

Electrode Voltage LImits,V

£6010 28 to 32
£6011 28to 32
£6013 22 to 26
£7018 25 to 28
£7024 26 to 32
£8018 22 to 28
£11018 25 to 30

14

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Figur e 1. Graph of travel speed versus current for l/8-in. (3.2 mm) diameter E6010 SMAW electrode. Dashed lines
show travel speed limits as determined by amount of undercut and bead shape.

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• I Figure 2. Graph of travel speed versus current for 1/8-in. (3.2 mm) diameter E601 I SMAW electrode . Dashed lines
show tr veI speed limits as determined by amount of undercut and bead shape.
~

15

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CURRENT ( AMPERES ) -

Figure 3. Graph of travel speed versus current for 1/8-in. (3.2 mm) diameter E6013 SMAW electrode. Dashed lines
show travel speed limits as determined by amount of undercut and bead shape.

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CURRENT (AMPERES)

Figure 4. Graph of travel speed versus current for 1/8-in. (3.2 mm) diameter E7018 SMAW electrode. Dashed lines
show trave lspeed limits as determined by amount of undercut and bead shape. -

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
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Figure 5. Graph of travel speed versus current for 1/8-in. (3.2 mm) diameter £7024 SMAW elcctrode .Dashed lines
show travel speed limits as determined by amount of undercut and bead shape.

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Figure 6. Graph of travel speed versus current for 5/32-in. (4.0 mm) diameter E80 18 SMAW electrode. Dashed lines
show travelspeed limits as determined by amount of undercut and bead shape.

17

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CURRENT (AMPERES)

Fi gure 7. Graph of travel speed versus current for 1/8-in.(3.2 mm) diamete r El 1018 SMAW electrode . Dashed lines
show travel speed limits as determined by amount of undercut and bead shape.

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Figure 8. Graph of voltage versus current for E7OS-2 electrode and shield gas of argon with 2 percent oxygen addition.

18

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FIgure 10. Graph of voltage versus current for E7OS-3 electrode and shield gas of argon with 2 percen t oxygen addition.

19

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Figure 12. Graph of voltage versus current for E70S4 electrode and carbon dioxide shield gas.

20

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CURRENT (AMPERES )

Figure 13. Graph of voltage ve rsus current for E7OS-6 electrode and carbon dioxide shield gas.

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CURRENT (AMPERES )

Figure 14. Graph of voltage versus current for Eli OS electrode and shield gas of argon with 2 percent oxygen addition.

21

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