Date:16/06/2015

WELCOME
IN
TRAINING
PRESENTATION Prepared by :
ILiyas Mahmed Siroya
QA/QC Dept.(Alfanar Steel)
TRAINING PRESENTATION

SMAW
SHIELDED METAL ARC WELDING /
STICK WELDING
SMAW is commonly known as ‘Stick’
welding or manual arc welding also
SMAW Process :
ELECTRODE:
 Mainly uses electrode according to Standard -American Welding Society (AWS) D1.1
(1)E6013 (High Titania potassium ) –Strength and Toughness
 Describing :E6013
Electrode
Minimum Tensile Strength (6) X 10,000psi =413 Mpa

E6013
Indicates the flux coating (High titania Potassium)
Welding Position: 1 - All-Position (F,H,V,OH)
2 - Flat and Horizontal
3 - Flat Only
Advantage/Disadvantage: E6013 –Partial penetration/fusion (AC & DCEP/DCEN)

DCEN – It will puts more heat into the electrode therefore higher deposition/melting rate with less
penetration (We should use DCEN up to 5 mm Thickness)
DCEP – It will puts more heat into the work piece with best penetration
(We should use DECP more than 5mm Thickness)
ELECTRODE:
(1) E7018 (LOW HYDROGEN ELECTRODE)
 Describing :E7018
Electrode
Minimum Tensile Strength (7) X 10,000psi =482 Mpa

E7018
Indicates the coating (K, Iron powder) – High Strength and Toughness
Welding Position: 1 - All-Position (F,H,V,OH)
2 - Flat and Horizontal
3 - Flat Only
Advantage/Disadvantage: E7018 –Deep penetration/Fusion and current used (AC/DCEP Only)

 E7018 has a very good deposition rate, providing a quiet steady arc with
low spatter and medium penetration
 Weld deposits are of X-ray quality with easy slag removal, exceptional
mechanical properties and a smooth uniform bead appearance
 E7018 mainly used in shop/field welding of bridges and structural
E7018
 Electrode storage and reconditioning
 Low hydrogen electrodes are manufactured
with moisture levels below 0.07% then
packaged in hermetically sealed
containers.
 An open electrode should be stored at 100 –
1500C in portable oven.
 If needed they can be reconditioned by
baking for one hour at 3500C in mother
oven.
 Should be a common practice of baking
when using low hydrogen electrodes.
 FILLET WELDS IN PLATE — TEST POSITION

Welder Test :
 If welder Pass 1F position –Can do weld, Flat (F) position
 If welder Pass 2F Position –Can do weld, Flat (F) & Horizontal (H) position
 If welder Pass 3F Position –Can do weld, Flat (F),Horizontal (H) &Vertical (V) position
 If welder Pass 4F Position- Can do weld, Flat (F), Horizontal (H) & Overhead (O)

 When welder passed in 3F & 4F position test then qualified for all position
WELDING TECHNICAL DETAIL

 S2 is Minimum thickness
 S1 is Maximum thickness
 H is Welding LEG LENGTH
 B is Welding THROAT/THICKNESS
 When fillet weld comes single side then B (THROAT/THICKNESS) is 70% OF MINIMUM THICKNESS &
H ( LEG LENGTH ) is EQUAL OF MINIMUM THICKNESS
 When fillet weld comes double side then B (THROAT/THICKNESS) is 50% OF MINIMUM THICKNESS &
H ( LEG LENGTH ) 70% OF MINIMUM THICKNESS
Measurement of welding throat thickness
WELDING CALCULATION DETAIL

 If we use E7018 electrode on baseplate area following advantages are obtained:

 (1) Can withstand higher load (static/dynamic) without failure.
 (2) Good fusion obtained between beam & base plate.
 (3) Good mechanical/chemical properties are achieved.
WELDING CALCULATION
Defects in SMAW
(1) Porosity
Causes :
 Grease/ hydrocarbon/ water
contamination on surface
 Too high arc voltage / arc length
 Incorrect/insufficient de-oxidant in
electrode, filler or parent metal
 Damp fluxes/ corroded electrode
Prevention :
 Must clean welding area prior start the
welding
 Reduce arc voltage or arc length
 Use electrode with sufficient de-oxidation
activity
 Use dry electrodes in good condition
Defects in SMAW

(2) Slag Inclusions

Causes :
 Heavy mill scale / rust on work surface
 Incomplete slag removal (1st run) from
underlying surface of multi pass weld
 Unfused flux due to damage coating
Prevention :
 Grind surface prior welding
 Improve intern slag removal
 Use electrode in good condition
Defects in SMAWMeasured in both Length & Depth
(3) Undercut

Causes :
 Melting of top edge due too high welding
current ( especially at free edge) or high
travel speed
 Attempting an Horizontal/Vertical fillet
weld leg length >9.0 MM
 Excessive/Incorrect weaving / Incorrect
electrode angle
Prevention :
 Reduce power input , especially
approaching a free edge where
overheating can occur
 Weld in a flat position or use multirun
technique
 Direct arc towards thicker member
Defects in SMAW

(4) Spatter

Causes : Prevention :
 High arc power  Reduce arc power
 Damp electrodes  Use dry electrodes
 Wrong selection size of electrode  Must be choose electrode size as per job
Check-Point/List for welder
1 Turn power supply on
2 Connect work clamp
3 Select electrode
a. Type (E6013/E7018)
b. Diameter (Ф2.5, Ф3.2 & Ф4.0mm)
ELE.DIA E6013 E7018
4 Adjust output
2.5 mm 45 -90 Amp 70 – 100 Amp
a. Current/Polarity (DCEP/DCEN) 3.2 mm 80 – 130 Amp 115 – 165 Amp
b. Amperage Setting 4.0 mm 105 – 180 Amp 150 – 220 Amp
5 Insert electrode into electrode holder
6 Work Angle
7 Travel Angle
8 Arc Length
9 Travel Speed
10 Tools like….(1) Chipping Hammer (2) Wire brush (3) Cleaning brush (4) Chisel for metal
Thanking you all on behalf
of QA/QC Department

Alfanar steel

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