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Guidelines Smaw PDF
Guidelines Smaw PDF
2018−04
Processes
Stick (SMAW) Welding
Guidelines For
Shielded Metal Arc
Welding (SMAW)
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
155095 Page 1
D Do not cut or weld on tire rims or wheels. Tires can explode if heat-
FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
Welding produces fumes and gases. Breathing D Do not weld on containers that have held combustibles, or on
these fumes and gases can be hazardous to your closed containers such as tanks, drums, or pipes unless they are
health. properly prepared according to AWS F4.1 and AWS A6.0 (see
D Keep your head out of the fumes. Do not breathe the fumes. Safety Standards).
D Ventilate the work area and/or use local forced ventilation at the arc D Do not weld where the atmosphere can contain flammable dust,
to remove welding fumes and gases. The recommended way to gas, or liquid vapors (such as gasoline).
determine adequate ventilation is to sample for the composition D Connect work cable to the work as close to the welding area as
and quantity of fumes and gases to which personnel are exposed. practical to prevent welding current from traveling long, possibly
D If ventilation is poor, wear an approved air-supplied respirator. unknown paths and causing electric shock, sparks, and fire
D Read and understand the Safety Data Sheets (SDSs) and the hazards.
manufacturer’s instructions for adhesives, coatings, cleaners, D Do not use welder to thaw frozen pipes.
consumables, coolants, degreasers, fluxes, and metals. D Remove stick electrode from holder or cut off welding wire at
D Work in a confined space only if it is well ventilated, or while contact tip when not in use.
wearing an air-supplied respirator. Always have a trained watch- D Wear body protection made from durable, flame−resistant material
person nearby. Welding fumes and gases can displace air and (leather, heavy cotton, wool). Body protection includes oil-free
lower the oxygen level causing injury or death. Be sure the breath- clothing such as leather gloves, heavy shirt, cuffless trousers, high
ing air is safe. shoes, and a cap.
D Do not weld in locations near degreasing, cleaning, or spraying op-
D Remove any combustibles, such as a butane lighter or matches,
erations. The heat and rays of the arc can react with vapors to form
from your person before doing any welding.
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or D After completion of work, inspect area to ensure it is free of sparks,
cadmium plated steel, unless the coating is removed from the weld glowing embers, and flames.
area, the area is well ventilated, and while wearing an air-supplied D Use only correct fuses or circuit breakers. Do not oversize or by-
respirator. The coatings and any metals containing these elements pass them.
can give off toxic fumes if welded. D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
ARC RAYS can burn eyes and skin. D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
Arc rays from the welding process produce intense consumables, coolants, degreasers, fluxes, and metals.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the FLYING METAL or DIRT can injure eyes.
weld.
D Wear an approved welding helmet fitted with a proper shade of D Welding, chipping, wire brushing, and grinding
filter lenses to protect your face and eyes from arc rays and cause sparks and flying metal. As welds cool,
sparks when welding or watching (see ANSI Z49.1 and Z87.1 they can throw off slag.
listed in Safety Standards). D Wear approved safety glasses with side
D Wear approved safety glasses with side shields under your shields even under your welding helmet.
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc. BUILDUP OF GAS can injure or kill.
D Wear body protection made from durable, flame−resistant mate-
rial (leather, heavy cotton, wool). Body protection includes D Shut off compressed gas supply when not in use.
oil-free clothing such as leather gloves, heavy shirt, cuffless D Always ventilate confined spaces or use
trousers, high shoes, and a cap. approved air-supplied respirator.
WELDING can cause fire or explosion. ELECTRIC AND MAGNETIC FIELDS (EMF)
Welding on closed containers, such as tanks,
can affect Implanted Medical Devices.
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot D Wearers of Pacemakers and other Implanted
workpiece, and hot equipment can cause fires and Medical Devices should keep away.
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is D Implanted Medical Device wearers should consult their doctor
safe before doing any welding. and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
operations.
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
NOISE can damage hearing.
D Be alert that welding sparks and hot materials from welding can Noise from some processes or equipment can
easily go through small cracks and openings to adjacent areas. damage hearing.
D Watch for fire, and keep a fire extinguisher nearby.
D Wear approved ear protection if noise lev-
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
el is high.
cause fire on the hidden side.
155095 Page 2
D Never weld on a pressurized cylinder − explosion will result.
CYLINDERS can explode if damaged.
D Use only correct compressed gas cylinders, regulators, hoses,
Compressed gas cylinders contain gas under high and fittings designed for the specific application; maintain them
pressure. If damaged, a cylinder can explode. Since and associated parts in good condition.
gas cylinders are normally part of the welding D Turn face away from valve outlet when opening cylinder valve. Do
process, be sure to treat them carefully. not stand in front of or behind the regulator when opening the valve.
D Protect compressed gas cylinders from excessive heat, mechani- D Keep protective cap in place over valve except when cylinder is in
cal shocks, physical damage, slag, open flames, sparks, and arcs. use or connected for use.
D Install cylinders in an upright position by securing to a stationary D Use the proper equipment, correct procedures, and sufficient
support or cylinder rack to prevent falling or tipping. number of persons to lift, move, and transport cylinders.
D Keep cylinders away from any welding or other electrical circuits. D Read and follow instructions on compressed gas cylinders,
D Never drape a welding torch over a gas cylinder. associated equipment, and Compressed Gas Association (CGA)
D Never allow a welding electrode to touch any cylinder. publication P-1 listed in Safety Standards.
155095 Page 3
H.F. RADIATION can cause interference. ARC WELDING can cause interference.
D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with
navigation, safety services, computers, and sensitive electronic equipment such as
communications equipment. computers and computer-driven equipment
such as robots.
D Have only qualified persons familiar with electronic equipment
D Be sure all equipment in the welding area is electromagnetically
perform this installation.
compatible.
D The user is responsible for having a qualified electrician prompt-
D To reduce possible interference, keep weld cables as short as
ly correct any interference problem resulting from the installa-
possible, close together, and down low, such as on the floor.
tion.
D Locate welding operation 100 meters from any sensitive elec-
D If notified by the FCC about interference, stop using the
tronic equipment.
equipment at once.
D Be sure this welding machine is installed and grounded
D Have the installation regularly checked and maintained.
according to this manual.
D Keep high-frequency source doors and panels tightly shut, keep
D If interference still occurs, the user must take extra measures
spark gaps at correct setting, and use grounding and shielding to
such as moving the welding machine, using shielded cables,
minimize the possibility of interference.
using line filters, or shielding the work area.
Shielded Metal Arc Welding (SMAW) or Stick welding is a process which melts and joins metals by heating them with
an arc between a coated metal electrode and the workpiece. The electrode outer coating, called flux, assists in creat-
ing the arc and provides the shielding gas and slag covering to protect the weld from contamination. The electrode
core provides most of the weld filler metal.
When the electrode is moved along the workpiece at the correct speed the metal deposits in a uniform layer called
a bead.
The Stick welding power source provides constant current (CC) and may be either alternating current (AC) or direct
current (DC), depending on the electrode being used. The best welding characteristics are usually obtained using DC
power sources.
The power in a welding circuit is measured in voltage and current. The voltage (Volts) is governed by the arc length
between the electrode and the workpiece and is influenced by electrode diameter. Current is a more practical measure
of the power in a weld circuit and is measured in amperes (Amps).
The amperage needed to weld depends on electrode diameter, the size and thickness of the pieces to be welded,
and the position of the welding. Thin metals require less current than thick metals, and a small electrode requires less
amperage than a large one.
It is preferable to weld on work in the flat or horizontal position. However, when forced to weld in vertical or overhead
positions it is helpful to reduce the amperage from that used when welding horizontally. Best welding results are
achieved by maintaining a short arc, moving the electrode at a uniform speed, and feeding the electrode downward
at a constant speed as it melts.
More specific information on the Stick welding procedure is provided in the following sections.
3 4
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SECTION 3 − SHIELDED METAL ARC WELDING (SMAW)
PROCEDURE
3-1. Typical Stick Welding Set-Up
151 593
155095 Page 6
3-2. Electrode And Amperage Selection Chart
PENETRATION
ELECTRODE
POSITION
AMPERAGE
USAGE
DC*
RANGE
AC
ELECTRODE
DIAMETER
150
200
250
300
350
400
450
50
155095 Page 7
3-3. Striking An Arc − Scratch Start Technique
S-0049
S-0049
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3-5. Positioning Electrode Holder
10- 30
90 90
Direction Of Welding
Fillet Welds
10- 30
45
45
Direction Of Welding
S-0660
155095 Page 9
3-6. Electrode Movement During Welding
.A single stringer bead is satisfac-
tory for most narrow groove weld
joints; however, for wide groove
weld joints or bridging across gaps,
1 a weave bead or multiple stringer
beads work better.
1 Stringer Bead − Steady Move-
ment Along Seam
2 Weave Bead − Side To Side
Movement Along Seam
3 Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode. Limit
weave width to a maximum of 2-1/2
times diameter of electrode.
S-0054-A
Notes
155095 Page 10
3-7. Conditions That Affect Weld Bead Shape
. Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal.
Electrode Angle
Correct Angle
10 - 30
Arc Length
Spatter
Travel Speed
S-0661
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3-8. Poor Weld Bead Characteristics
2 3 4
5
S-0053-A
1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During
Welding
4 No Overlap
5 Good Penetration Into Base
Metal
2 3 4 5
S-0052-B
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3-10. Typical Weld Joints
155095 Page 13
3-11. Welding Groove (Butt) Joints
S-0662
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3-12. Welding Tee Joints
1 Electrode
2 Fillet Weld
Keep arc short and move at definite
rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
1 surface.
For maximum strength weld both
sides of upright section.
3
S-0060 / S-0058-A / S-0061
1 Electrode
2 Single-Layer Fillet Weld
Move electrode in circular motion.
3 Multi-Layer Fillet Weld
Weld a second layer when a heavi-
30 er fillet is needed. Remove slag be-
Or Less fore making another weld pass.
Weld both sides of joint for maxi-
1 mum strength.
2
Single-Layer Fillet Weld
30
Or Less
3
Multi-Layer Fillet Weld
S-0063 / S-0064
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3-14. Welding Horizontal Beads And Groove (Butt) Joints
90
15
30
Direction Of
90 30°
Welding
Direction Of
Welding
Direction Of
Welding
45°
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3-15. Welding Vertical Beads And Groove (Butt) Joints
Direction Of
Welding
Whipping Up Weld vertically by carrying the
Motion weld upward or starting at the top
Direction Of
and welding down. Welding up-
Welding
ward is easier and is shown in
these illustrations.
Weave Bead
1/2 in. (12 mm) Bevel edges if warranted by ma-
Wide terial thickness (see Section
3-11). Tack weld a backing strip
to the plates to make the first
weld pass (root pass) easier.
90
Direction Of
90
1st Pass
2nd Pass
Hesitate With
Slight Up And
Direction Of
Direction Of
Down Motion. OR
Welding
Welding
Shorten Arc At
Arrowheads
When At Center
Of Weld.
3rd Pass 4th Pass
804 260
155095 Page 17
3-16. Welding Vertical Tee Joints And Lap Joints
Direction Of
Welding
Arrows Show Lifting Up
Of Electrode And Return To
Crater.
90
Shows Shows
Weaving Weaving
Motion. Motion.
Direction Of
Direction Of
Welding
Welding
OR
90 90
Shows
Weaving
Motion.
Direction Of
Welding
90
804 260
155095 Page 18
3-17. Welding Overhead Groove (Butt) Joints And Tee Joints
Direction Of Welding
1
1/2 in (12 mm) 2 3
Direction Of
Welding
1/2 in
(12 mm)
30
155095 Page 19
3-18. Weld Test
1 Vise
2 Weld Joint
3 Hammer
Strike the weld joint in the direction
shown. A good weld bends over but
does not break.
If the weld breaks, examine it to de-
termine the cause.
If the weld is porous (many holes),
the arc length was probably too
long.
If the weld contains bits of slag, the
3
arc may have been too long or the
electrode was moved incorrectly
3 which allowed molten slag to be
trapped in the weld. This may hap-
2 To 3 in. pen on a V-groove joint made in
(51-76 mm) several layers and calls for addi-
2 To 3 in. tional cleaning between layers.
(51-76 mm)
2 If the original beveled surface is vis-
1/4 in. 2 ible the material was not fully melted
(6.4 mm) 1 which is often caused by insufficient
1
heat or too fast a travel speed.
S-0057-B
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding.
155095 Page 20
4-2. Excessive Spatter
Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding.
Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.
155095 Page 21
4-5. Excessive Penetration
4-6. Burn-Through
4-8. Distortion
155095 Page 22
Notes
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ORIGINAL INSTRUCTIONS − PRINTED IN USA 2018 Miller Electric Mfg. LLC 2018−01