Types of Are Welding * (FCAW) Flux Cored Are Welding * (SAW) Submemged Are Wei * (SMAW ) Shicided Metai Are Welding © GMAW g them with an are between a continuously fed filler metal electrode and the work. The process uses shiel ing from an externally supplied 2 GTAW Gas Tungsten Are Welding is a welding process performed heat of an arc established between a non-consumable tungsten electrode and the work piece. TiG welding uses a filler metal, when required, is added by hand.* SMA’ SHIELDED METAL ARC WELDING I rocess wherein coalescence iS produced by heating with an electric are nd the work. Shielding is obtained from decom- Position of the electrode covering and metal is obtained irom the eiectrode. Because of the versatility of the process and the simplicity of its equipment and operation. shielded metal arc welding is one of the world's most popular welding processes. It dominates other welding processes in the maintenance and repair industry, and though 7 is growing in popularity, SMAW continues to be used extensively in the construction of structures and in dustrial fabricatian The process is used primarily to weld ino and sicels (including stain! 1) but alr can also be welded with this method. {and <: Stick Weldin: Stick Welding is a slang term commonly used for Shielded Metal Arc Welding or “SMAW” Stick welding is the most basic and common type of welding processes used. It is also the first process leamed in any welding school. Stick is the most trouble free of all of the welding processes and is the fundamental basis for ail the skilis needed to learn how to weld, Advantages of SMAW © SMAW process is very Flexible * SMAW is very Portable process = SMAW is VersatileWhat is Welding? Welding ts not more than the ant of Dy halls, Oncks are hele togetner with 1 DY welding, Wh such a big deal is that the world’s intrastructure depends on it, Everything you touch everyday made of metal is most likely welded in one form or another. It is one of the mast valuable tw the pakes welding n ingredients which are required te + Anelectri al power source t produce an are. » Some form of shielding to protect the weld from the air. + Filler material to fill the weld joint. The ways these three ingredients work together are: ant because + Flist, the weld area needs io be shielded from any 3 oxygen and other gasses in the air make welds brite + Second, is the electricity to produce an are. An electrical are melts metal in fractions 0 second and is hot enough to melt any known metal!Voltage is the measurement of electric pressure and controls the maximum length of the are across a gap,4 group of welding proc mained by heating with an electric are OF ares, with or wit a Se a BRNIAMIN Fe RLFeedback ESSENTIALS OF WELDING \ Five Essontials of Welding Correct Electrode Size be Correct Current rect Travel Spead Correct Electrode Angle Yoo large electrode than prescribed. It can cause melt-through, end can be difficult to control in out of position joints. Poor appearance and possible defects can result, Nul enough heai to meit the base metal. Ihe ton poo! valle too small, pile up, and look irregular. Poor penetration ‘ incomplete fusion in the joint can result. ‘Yoo tong an arc length. It will cause the deposit to be coarse, rippled end flattar than normal wi 1288 in spaiter, “Travel speed too slow. It will cause the puddle to be large, wilh pile-ur . Wilh pile-up, end straight ripple. For out of position welding, slow travel speed can cause the puddle to drip out of the joint. Urag angle is when the electrode is pointing backward and the welder’s hand and electrode holder proceeds the puddle, while push angle is when the slacliode is pointing forward and the welder’s hand and electrode holder precedes the puddle,TEMPERATURE The te , miperature of arc welding is approximately 9000°F {5000°C). The exact temperaty s ‘ re depend upon the resistance to current flow which ix affected by the ar vaporize: i : aoe “ Ate are lengthens the resistance increases, thus causing rise in the arc ores : ' he shorter the are, the lower is the arc temperature produced, The amount produced is determined by the size of clectrode and the amperage setting. * *Function of Core Wire: * To carry the welding current * To serve as most of the filler metal in the finished weld = Function of Plax Covering: To provide some of the alloying elements To provide an are stabilizer To serve as an insulator © To provide a slag cover to protect the weld bead * To provide a protective gaseous shield during welding Electrode qenaie Strength “ef Completed Weld Jers Positien Sy fat, horizontal, vertical, overhead | 2eflar and horizontal only goiiat, horizontal, vertical down, overhead pes of Coating and Current Costing 6 = Geliuiose sodium 1 = Gelluiose potassium Titania sodium Tikaer iit prec rt ene Iron powder titanie Low hydrogen sodium Low hydrogen potassium tren powder iron onde + iran poweder tow hydrogen AC. DCEP, DCEN BNowsy pereeetetek ect ee cs Seer —— aa feat oe ane ore ema ee tel atoll 303, 304, 305, 308, }09-15,16 oF 01 and 202, fF E309C-15,16 electrodes Flectrodes for 309 stainless steels are used for high temperature service such as furnace parts and mufflers. All 309 electrodes can be used to weld on 309 stainless or join mild steel to any 18-8 type stainless steel 1 W ior itions For weiding plate the positions typically come in two different joint types. Fillet welds welds. Most plate welding certifications are performed in groove welds, This is ‘welding codes, grove welds will also qualify you for fillet welds, but fillet welds do not cover rove welds, Fillet welds and grove welds also vary in different postions. The positions are fat grove ‘The coding system for plate end structural welding is as ition. fo econ position. « Fis fora fillet weld. fs 3 is for the vertloal position, ‘¢ 4 is for the overhead position. ‘coding systern works isthe number stands forthe position and then the letter duis a qpeareas Tae For cxmple if you take the number 3 forthe vertical position om) ne ice weld Then you put them together like "36" then that isthe code fo Gis fo © you P 2Vertical grove weld. In the YOU WOUld get a "3F wel ao alle weld you would simply replace the G with an F, then Weld joint and that is a vertical fillet weld, 1G Welding Certification Position The 1G welding certification Position is piute in the fiat Posilion that is beveled. This Position is the most basic and only covers the welder in that position. It's the easiest test to pass and the position that is beveled. This position is a iiitie harder than the 1G test but by passing it you do not need to take the 1G test. This one test covers the 1G and 2G positions. 3G Welding Certification Position The 3.) weiss conieaivn position isa plate in the vertical position that is beveled. This position varies depending on the travel direction. The vertical welding certification can be you start on the bottom of the plate welding upward to the top. Semetimes welding vertical down meaning welding from the top down. The 3G test pos were the 16, 2G, and 10‘overhead position that is beveled. This position is dered the hardest for welding plate but in reality it's not much harder then welding flat. The 4G welding test cavers the 1G, 2G, and 4G positions, but does not cover the 3G position, 3 & 4G Combo Welding Certification Positions Whea centified for structural s y certification together. These two tests usually cover all the positions and most codes allow fillet welds . IPE WELDING POSITIONS ing pi iti i ally groove it comes to welding pipe there are four main positions and again they are typically g welds: There is also a coding system to identify the postions and joint ypes, They ae as follows: #1 is fora pipe in the horizontal position that is» F is fora fillet weld. rolled. © Gis fora grove © 2is for a pipe in the fixed vertical position. weld. uw* Sis for u pipe in the fixed horizontal position. * 61s tora pipe in a 45 degree fixed position. Remember: terms refer to the position of the pipe and not to the weld iG Pipe Welding Certification Position T w cation p a pipe in the horizontal position and the pipe is rolled when welding. This is basically welding in the flat position. The 1G pipe welding certification is rarely used. 2G Pipe Welding Certification Position The 2G pipe welding certification position is a == pipe that is standing in the vertical position. yl The weld being done is a horizontal weld and a the pipe cannot be rotated. It is in a fixed position.UE’ 5G Pipe Welding Certification Position ‘The SG pipe welding certification position is a pipe welding in the horizontal position that is fixed and cannot be moved. The welding done is overhead, vertical, and flat with a full transition of all of those positions. This position comes in two travel directions. The first is a vertical up travel and that is the most commonly used progression. The second is vertical down progression and this is commonly used for pipe line welder qualification. | Then there is the (4 pies Gene ccelassion, This isa pipe that is in standing on a 45 degree angle and cannot be moved. This test incorporates all of the positions. What makes this position so hard is there is an easy side and a hard side. This all depends if you are right handed ot left handed and the welding processes being used. This one test will qualify the welder to weld pipe and plate in all positions. This is the hardest of all welding positions and the test typically given for the higher paying jobs. If you need to get one welding certification this is the | position to go for. | Pet Ascent Ooecendant Vertes Versent Over BTYPES OF JOINTS WELD JOINTS The weld joint is Where ‘Wo or more metal Parts are joined by welding. The five basic types of weld joints are the butt, cor mer, tee, lap, and edge. A butt joint is used to in plate, sheet metal, of the variations of join two members aligned in the same plane, This joint is frequently used and pipe work. A joint of this type may be either ‘square or grooved. Some this joint are discussed later in this lesson. Gut ot - tat carts a Corner and tee joints are used to join two members located at right angles to each other, In cross section, the comer joint forms an L-shape, and the tee joint has the shape of the letter 7. Various joint designs of both types have uses in many types of metal structures, | Full inside corner joint Half-lap corner joint Corner to comer joint 14ay : Joints - Kdgo Preparation & Weld Types ses A JL ‘Saves Gece Bevel Grace Toute Revel rooee i | arose Far Gem Goow A lap joint, as the name im, ide by lapping one piece of metal over another. This is one of the strongest types of joints available; however, for maximum joint efficiency, you should overlap the metals a minimum of three times the thickness of the thinnest member you are joining. tacts, Lae 1sGE ODES + Properties of Base Metal % Position of Joints + Types of Joints ‘> Amount of Welding required Tightness of Joints fit up : Types of current available OTHER Factors to be considered when choosing electrode: Type of Electrode Surface Condition Number of Passes ‘Type of Current DistortionPower Range Type of Metal Preheat or Post heat Thickness of Metal ‘Temperature Service Weld Position Mechanical Properties Joint Design Post Welding Cleanup Quantity of Weld Shop or Field Weld WELDING TECHNIQUES ARC LENGTH or LENGTH OF ARC When an are is 100 long, the metal melts off the electrode in large globules and the are may break fre-quently. This produces a wide, spattered, and irregular deposit with insufficient fusion between the base metal and the weld (fig. 7-12, view F). When an are is foo short, it fils to generate enough heat to melt the base metal properly, causes the electrode al, and produces uneven deposits with iregular ripples. The it the base met 2 Te ot equal to the diameter of the bare end of the electrode, as recom-mended length of the arc is shown in figure 7-14. 16Edge Joints - Edge Preparation & Weid Types i to Square Groove Bevel Groove ViGreove I ro J-Groove Flare V-Groove Weld joints Mare wetas Coc CNet) fo oF ee Vee Dahle Now Ningtet tee wetas oH wv .2 0 } } C 1 Siisle bevel Double bevel S| fap weld Hae wotd Qo oS co IA RR eS Robe Viewers 2 Serio, The length of the therefore, for smal Remember: the | Are depends upon the type of electrode and the type of Welding being done; ler diameter electrodes, a shorter are is Neces-sary than for larger electrodes, Id be about equal to the diameter of the bare electrode: ELECTRODE ANGLE ‘The angle at which you hold the electrode Very Impor-tant in tillet and deep groove ‘Work angle and travel angle. Work angle isthe angle from the ho greatly affects the shape of the weld bead which ic Welding, Ine electrode angie consists ot wo positions: orizontal measured at right 7-15). Travel angle is the angle in the direction of welding pending on the welder’s choice and conditions (fi 7-16) Angles to the direction of welding (fig, and may vary from 5 10 30 degrees, d 1sr10 or Hipure 7.15. Work angle, igure 718, Ltavel angie. ‘Work angle is especially important in multiple-pass fillet welding. Normally , a small variance of the work angle will not affect the appearance or quality of a weld; however, when undercuts occur in the vertical section of a fillet weld, the angle of the arc should be lowered and the electrode directed more toward the vertical section. 18WEAVING PATTERN * Circular * Zigzag ® Slight oscillating moti © Bight seh M8 Motion TRAVEL SPEED * The speed of travel (inches per minute) is an important factor when are welding, * The best speed of travel (weldin, i speed) is determined by several factors: ® The size of the joint, © The type of electrode ‘The size of the electrode The amperage setting on the machine BD fF the electrode (cubi es per minute) "= The deposition rate of an electrode will change with the welding amperage. 19SETTING THE CURRENT * Welding rod boxes are marked with their recommended current. * Where in the range you work will depend on the position of the work, but for beginners setting the amps right in the middle of the range should rule out most faults due to incorrect amps. ‘The amount of current used during a welding operation depends primarily upon the diameter of the electrode. As a rule, higher currents and larger diameter electrodes are better for welding in the flat position than the vertical or overhead position. Manufacturers of electrodes usually specify 2 current range for each type and size of electrode; this information is normally found on se fave of ihe eiecuude euniainer. : Since most recommended current settings are only approximate, final current settings and adjustments need to be made during the welding operation. For example, when the recommended current range for an electrode is 90-100 amperes, the usual practice is to set the controls midway between the two limits, or at ¥> amperes, Atter starting the weld, make your final adjust-ments by either increasing or decreasing the current. When the current is too high, the electrode melts faster and the molten puddle will be excessively large and irregular. High current also leaves a groove in the base metal along both sides of the weld, This is called undercutting. worst, cern eo rer ae iy 100 ner roo ast roo uae vad Le a 2 c D © F Figure 712° Coouparhan chart of welds 20With current that ; at will be 100 small, 712° there i ! Snot in igure 7-12, vgs "PU is poor aye eet HE me he base metal adhe ten poo the electrode iays gn 4, tS Piling up ofmone irregular shaped deposit that piles up, as shown overlapping resuj m the Work with iten metal is called overlap. The molten metal from t to i in poor welds, "Wt Penetrating the base metal. Both undercutting and » 8S shown in figure 7-13, S228 I pe | an oo) SS es Z. = eS coon — Mo overiar wers FS end Vea rom (Pigure 713.) Cadercuts aad overtaps in welding. When the electrode, current, and polarity are correct, a good are produces a sharp, crackling sound, When any of these conditions are incorrect, the arc produces a steady, hissing sound, such as steam escaping PARTS OF WELDS Reinforcement. Leg a.Repair: Weld with sm aller el Sometimes must gou, at Metal before welding. "st be low hydrogen with preheat. — > MISALIGNMENT (ALLO) Definition: Amount A joint is out of alignment at the root Canse: Carelescness. Also di © 10 joining different thicknesses (transition thickness) kmanshi ion angles not to exceed 25 to 1. : vention: Workmanship, ‘Transition angles not te exces ide of Pipe sue Grinding. Careful On surface finish and direction of grind marks. Inside /Tube difficult. * Somet 18e first, mes my > INCOMPLETE FUSION joining weld beads. Incomplete and adjoining wel the weld metal ion ofthe base metal, 7 tion between the v paration of oe pelsk of complete integra ator technique, ea beads. and improper joint design. ‘sions caused by faulty Tack of acess to he ai i ing heat, lac! ‘ufficient welding lqnomplete Fusiot ‘ ds beyond the toe ofthe weld > OVERLAP the weld exten o} * Definition: When the fa2#er produce welds cael the Job arent, itis tnt tat YOU Become vnior with the ts ° war describe a weld, ire 3-20 SHOWS a Broove jidanda filet Weld, ‘he foe UIE eNHORES surface cya weld on the side from wich the weld was made, the toe fs the junction peweenthefaceofthe weld and the base metal - the root of a weld includes ws the points at which the back a! ofthe weld intersects the ase metal surfaces, When we took ata triangul section of a filet weld, as shown in view B, the leg is the portion of the weld from the toe to the root. The throat is the distance from the root to2 point on the face of the weld al0n6 = fine perpendicular tothe face of the weld. Theoretically, the face forms a straient ne be- “tween the toe 23E 5 XCESSIVE PENETRATION A disconti / heat, slow characterized hy an excess of weld metal on the hack side of the joint, Excessive Movement, and poor joint alignment can cause excessive penetration. > BURN THROUGH Definition: Wien an undesicabie open hiote has been completely meited through the base metal. The hole may or may not be left open. + Cause: Excessive heat input.* Definition: When the face of the weld extends beyond the toe of the weld . Proveatlon: Overlap is a contour problem, Proper welding technique will prevent this > SPATTER + Definition: Small particles of weld metal expelled from the welding operation which adhere to the base metal surface. vot. Incempk cessively thick root face in a butt weld an exe too small a root gap misplaced welds incampiete root fusion when using too iow an are energy theat) input too small a bevel angle. too Jange an electrode in MMA weldingSAFETY is not negotiable and When it comes to weldi . be welding, ipment i 1 Thi co , equipment is an Absolute Must! must be used at all times, The basics are as follows: * A nelding helmet with the proper shade lens for the process and amperage used when ing, + Safety glasses, + Leather weiding gloves that ure designed for weiding. * Fire retardant long sleeve shirt or a leather welding jacket. * Pants that are made of cotton (preferably jeans) or are fire retardant. * Leather boots that are high enough (6" or higher) for your pants to overlap thiem. ‘+ Always make sure you have proper ventilation, Personal Protective Equipment 26Titravialet rays — Hie hey nd the violet end af the visihle snectrn nm They have wave teat up to the upper limits of X-rays and it can cause sunbum on the eyes and in weldin, t ine ii ae ut wien Oecause the intensity of the ultra violet rays can cause w OUT Wo Bernesd skin in a very short time, Visible Light Rays - It can be seen by the eye when an are is struck. They reflect off walls and other objecis, causing eye problems to anyone nearby who is not wearing a oon UE Tosanee. Ut hla T inht Dave ran cance ausctrein and tamnnran hlindnece Infrared Rays - Situated beyond the red end of the visible spectrum are heat rays with wave lengths shorter than radio waves. It is also known as ULTRARED, may cause cumulative effects that may iead to cataracts or retina injuries. Infrared rays are Are Flash - It is happening when a welding flash causes are rays to come into contact with unprotected eyes. If the flash is frequent enough or severe enough the eyeball will become covered with many small water blisters. Deep Bums ‘Welding Fumes — iets fumes are a complex mixture of metallic oxides, silicates andran . < ea Ai mea, * ai Sith” © git) Ait way, “Pane ae << “li tae oe eae \ SEU ia fa. iyPREPARATION REMOVE UNNECESSARY PARTICLES AND RUST ON YOUR BASE METAL USING GRINDER OR FILE. : DS BOTH ENDS. (TACK WITH HIGHER AMPERAGE SETTINGS, APPROXIMATELY 90 AMPERES AND ABOVE DEPENDS UPON THE THICKNESS OF THE METAL BEING WELDED.) IDS TO EN 5 N WEE THIS ¥ RE ND PENETRATE TO PROVIDE STRONG BRAZE TO AVOID WARPAGE AND DISTORTION OF THE METALS. ROOT OPENING MUST BE 3/32 - 1/8 OF AN INCH. | TACK WELDS | oF \ v ROOT OPENINGFiT UP ON AND ARATI JOINT PREP SE SCALE, iF ALL LOOs ES OR SURFACES ©} DGi . CREAN THE WELD EI ATHER ror ND SMOOT TH A! i S ARE 5! iE JOINT SURFACE ENSUike THAT THI UNIFORM. :WITHAS PREPARE your pIpE W mH Noacbeds soeesieeral poigea- ee t BoctWELDING PROCESS: ay ase INCLINATION, PRIS A FIXED THIS WILL INCORPORATES ALL WELDING POSITION 3 O0°CLOCK § O’CLOCK