Guidelines For Shielded Metal Arc Welding (SMAW)TABLE OF CONTENTS SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage 1-2. Are Welding Hazards 1-3, Additonal Symbols For Insalaton, Operation, And Maintenance 1-4. Calforia Proposton 65 Warnings 1-5. Principal Safety Standards 1-8. EMF Information ‘SECTION 2 - PRINCIPLES OF SHIELDED METAL ARC WELDING (SMAW) SECTION 3- SHIELDED METAL ARC WELDING (SMAW) PROCEDURE. 3-1. Typical Stick Welding Set-Up 3-2. Electrode And Amperage Selection Chart 8.8. Stiking An Arc ~ Scratch Start Technique 8-4. Stiking An Are ~ Tapping Technique 3-5. Postoning Electode Holder 2-6. Electrode Movement During Welding 3-7. Conditions That Affect Weld Bead Shape 1" 2-8. Poot Weld Bead Characteristics 2 3-8 Good Weld Bead Characteristics 12 2-10, Typical Weld Joints 3 3-11, Welding Groove (But Joints aon 8 8:12, Welding Tee Joints 16 5413, Welding Lap Joints... cine 218 3-14, Welding Horizontal Beads And Groove (But) Joins 16 2-15, Welding Verical Beads And Groove (But) Joints 7 8-16, Welding Verical Toe Joints Ard Lap Joints 8 3-17, Welaing Overneas Groove (But) Joints And Tee Jowts cine 19 2-18, Weld Test 20 ‘SECTION 4 - WELDING TROUBLESHOOTING. 41. Porosity 20 4-2. Excessive Spator 2 43. Incomplete Fusion 2 44 Lack Of Penetration 2 45. Excessive Penetration 2 46. Bum-Through 22 47. Waviness Of Bead 22 48. Distorion 2SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING &. Protect yourselt and others trom injury — read, follow, and save these important safely precautions and operating instructions, 1-1, Symbol Usage Aa DANGER! - Indicates a hazardous situation which, i not avoided, will result in death or serlous injury. The possible hazards are shown in the adjoining symbole ‘r explained inthe text. Indicates a hazardous situation which, if not avoided, ‘could result in death or serious injury. The possib hazards aro shown In the adjoining symbols or Plainedin the text NOTICE - indicates statements not related to persona iy. 1-2. Arc Welding Hazards The symbots shown below are used throughout this manus {0 call attention to and identity possible hazards. When you ‘06 the symbol, watch out, and follow the related inst { avoid the hazard, The safety information given ‘only a summary of the more complete safety information {ound in the Safty Standards listed in Section 1-5. Reed and follow al Safety Standards. & only quatiies persons should instal, operate, maintain, and repairthis equipment. A qualfed person is defined as one ‘whe, by possession ofa recognized degree, ceriicate, oF professional standing, or who by extensive knowledge, Ing and experience, as succesfully demonstrated ably fo Solve ot resolve problems relating to the subject matt ‘work or the project and has received safety Waning to recog. nize and avoid tho hazarde involved. &. during operation, keop everybody, especialy children, awa Le 2X, | Touching ve electrical parts can cause fatal shocks Jor severe burns. The Slectrode and workecreut is electrically Ive whenever te output ison, The put Sawer eeu and machine infernal crcl are also SR. eeschanachel naemesbasce ators fang a metal parts touetung tha welding wire are F elecrealy ive Ineotoctly installed or Improperly ELECTRIC SHOCK can kill [sounded equipment sa hazard ‘© Donottouch Ive electrical pas. ‘© Wear dry, nole-ee insulating gloves and body protection «Insulate yourset rom work and ground using dry insulating mats ‘or covers big enough to prevent ary psical contact with the work crground, Donat use AC weld output in dam, wet, or confined spaces, or there's a danger of fling, ‘© Use AC ouput ONLY if required forthe welding process, ' IFAC outputs require, use remete output contalf present on uni ‘© Adctionalsafaty precautions are requied when any ofthe follow. ing electicaly hazardous condtions are present: In damp locations or wile wearing wet clothing; on metal structures such as floors, gratings, of scaolds; when In cramped postions such as siting, sneeing. or Wing: erwnen tere is high fk of unavod: floor accidental contact with the workplace or ground. For hese Conaltons, use the folowing equipment inorder presented: 1) a SemiautomatcDC constant vatage (wire) welder, 2) @ OC manual {etek} welder or3) an AC welder wih reduced open-cicul vo lage. inmost stations, use o 2, constant valage wie welder is recommended, And, do not work alone! ‘© Disconnect Input power or stop engine betore installing or servicing this equfpment LockoutRagout input power according to (OSHA 29 CFR 1910.147 (eve Salely Siandarés). 1 Indicates special instructions. awa ‘This group of symbole means Warsing! Watch Out! ELECTRIC SHOCK. MOVING PARTS, and HOT PARTS hazards, Consult sym- bole and related inetrutions blow for necessary actions to avoid the azards ‘+ Propety instal, round, and operate this equipment according to it Onmers Manual and national, slate, and local codes, ‘© Always vert the supply ground - check and be sure that input power cor groune wire is properly connected to ground terminal in Ssconnect Box or that cord plug Is connected to a properly grounded receptacle oute ‘+ When making input connectons, attach proper grounding conduc: tor first ~ double-sneck connections, ‘© Koop cords dry, oe of ol and grease, and potectod fom hot meta and sparks. ‘© Frequently inspect input power cord and ground conductr fr damage or bare wiing—roplace immetiataly i damaged — bare wiring can ki. “Tur off all equipment whan natin use. Do not use worn, damaged, undersized, or repaired cables. Do not drape cables over your body. earth grounding ofthe workpiece is required, ground It racy witha separate cable. '* Donsttouch elecvode if you are in contact wit the work, ground, ‘or another electrode trom a diferent machine ‘© Do nat touch electrode holders connected to two wolcing ma- chines atthe same te since double open-crclt votiage wil be present ‘+ Use only wel-maintained equipment. Repair or replace damaged parts al once Maintain unt according fo manual ‘© Wear a safely hatnass if working above flor level ‘* Koop all panals and covers securely in place. ‘¢ Clamp work cable with good metato-metal contact to worksiece tor workable as near the weld as practical ‘© Insulate work clamp when not connected to workplace to prevent contact with any metal object ‘© Donat connect more than one electrode or work cable to any Single weld output terminal, Disconnect cable for process notin ‘+ Use GFOI protection when operating auxilary equipmentin damp or wat locations, SIGNIFICANT DC VOLTAGE exists in inverter weld- ing power sources AFTER removal of input power. ‘¢ Turmoff un, sconnec input power, and cischarge input capac tors according instructions in Manual before touching ary pats, HOT PARTS can burn. ‘© Donottouch hot parts bare handed ‘© Allow cooling period before working on ‘equipment. "To andle hot parts, use proper tools andlor weer heavy, nsu- lated welaing gloves and clothing fo prevent bums. 185096 Page 1FUMES AND GASES can be hazardous, SYR yoors cots ures sr gn, sean Aa > operate mies coeretens seri se etn aoe eos rewomna sce ap mr a Emery oes rene ce eosin eterna. ee Besmtno ce rh wn seman wee ae ann oe Sees ARC RAYS can burn eyes and skin. PB cc ta wa neta pcos prensa 2&2 BR) Ssvielana inva (amawoit and are) rays that san um eyes and stn Spas ty of rom he wel ‘© Wear an approved welding helmet ted with a proper shade of fiter lenses to protect your face and eyes ftom arc rays and “sparks wnen welding of watching (ee ANSI 248.1 and 287.1 lstedin Safety Standards) ‘© Wear approved safely glasses with side shields under your helmet ‘© Use protective soreens or barter to protect others from flash, dare and sparks, wan oers not o watch the arc ‘+ Wear body protection made from durable, fame-resstart mate fal eather, heavy cotton, wod). Body protection includes aitee clothing such as leather gloves, heavy shin, cuTless, ‘wousers, high shoes, and a cap, Belz] WELDING can cause tre or explosion. Welding on closed contaners, such as tanks, Srums, or pipes, can cause them to blow up. Sparks tan of rom the welding arc. The fying sparks, hot Workpiace, and hot equipment can cause tres and bums, Accidental conta! of electrode te mela objects can cause ‘Sparks, explosion, overheating, or re. Check and sie the areas ‘Sle bolore dong any welaing, ‘© lomove all tammables within 35 (10.7 m) ofthe woking are It ths isnot possi, tghy cover them with approved covers. ‘Do not weld where ying sparks can stike flammable materal. Protect yourself and cers ‘tom fying sparks and hot metal Be alert that welding sparks and not materials rom welding can fel go trough small cracks and openings to acjacent areas Witch for fr, ana keep a fre extinguisher nearby. © Be aware that welding ona cain, floor, buktead, cr partion can ‘2080 re onthe hidden sce. 195096 Page 2 ‘© Donot cut or weld on te ris or wheels. Tres can explode i heat- fed, Repaired rims and wheels can fal, Sea OSHA 23 CFR 4910.177 listed in Safety Standards, ‘© Do not weld on containrs that have held combustibles, of on closed contalners such as tanks, drums, o pipes uniess Poy are properly prepared according to AWS Fi.1 and AWS AG. (soe Safety Standarés). ‘© Dorot weld where the atmosphere can contain flammable dust, 125, or Iquid vapors (such as gasone) ‘© Connect work cable fo the work as close to the welding area as practical prevent welding curant from traveling long, possibly Unknown paths and causing elece shock, sparks, and fre hazards Do nat use welder to thaw trzen pines. Remove slick electrode from holder or cutoff welding wire at contact tp when net in use ‘Wear body prctection made from durable, tame-resistant mateal (leather neavy cotton, woo!) Body protection includes oltre flothing suchas safer gloves, heavy shir, cules trousers, righ shoes, ard a cap, Remave any combustibles, such as a butane lighter or matches, ‘rom your person before doing any welding ‘Alter completion of work, inspec area to ensure tis ae of spars, slowing embers, ard fames. Use only correc uses occu breakers. Do not oversize or by- pass them. Follow requitements in OSHA 1910,252 (a) (2) (v) and NEPA S18 for hat work and have a fe walcner and extinguisher nearby. FReae and understand the Safely Data Sheets (SDSs) and the manutacture’sInsttuctions for adhesives, coatings, cleaners, Consumables, coolants, degreasers, uses, and metals FLYING METAL or DIRT can injure eyes. rm) «vn. cp we big n ng AP) * wore ctnen wn nary sete they can throw of sia. ‘© Wear approved safety glasses wih side Shields even under your weling helmet BUILDUP OF GAS can injure or kill. ‘© Shutof compressed gas supply when notin use. ‘© Always ventiate confined spaces or use approved air-suppled respratr. ELECTRIC AND MAGNETIC FIELDS (EMF) ‘can affect Implanted Medical Devices. "© Implanted Medical Device wearers should consul thelr doctor andthe device manufacturer bore going near arc welding, spet ‘welding, gouging, plasma are cuting, or Induction heating poration, NOISE can damage hearing. Noise from some processes or equipment can damage nearing ‘© Wear approved ea protection # nose lev. alisnighCYLINDERS can explode if damaged. Compressed gas cylinders contain gas under high pressure. damaged, acynder can explode. Since fs cylinders are normally part of the welding process, be sure o teal thom caret. "© Protect compressed gas cyindes from excessive hea, mechan cal shocks, physical damage slag, open ames, sparks, anc aes. ‘© Insalleyinders in an upright poston by securing toa stationary ‘suppor or cylinder rack to prevent alin oF tipping. 1 Keep oyinders away from any welding or other electrical crc. 1 Never drape a welding torch over a gas oyinder. ‘© Never allow a welding electrode to touch any cylinder. ‘© Never weld on apressutized cyinder - explosion wil rest '© Use only corect compressed gas cyinders, regulators, hoses, and fitings designed for the specific application; maintain thom ‘and associated paris in good conciton, © Turn face away from valve outlet when opening oyinder valve. Do not stand in fore a or behind the regulator when opening the valve ‘© Keep protective cap in place over valve except when cylinder isin se o¢ connected for use ‘© Use the proper equipment, correct procedures, and sufficient ‘umber of persons taf, move, and Wanspor cylinders, ‘© Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P- ste in Safely Standards 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. & 4) © Do not instal or place unt on, over, or near combustioesurtaces, 7 Gaaioyinio gn ages epee Prensa setae erento A) geese ‘© fusing it forks to move unt, be sue forks are long enough to extend beyond opposite side of unit. '¢ Koop equipment (cables and cords) away from moving vehicles when working rom an aera location, '* Folow the guidelines in the Applications Manual forthe Revised NIOSH Lifing Equation (Publication No. 94-110) when mani aly iting heavy parts or equipment, aR sr Ba] FLYING SPARKS can injure. ‘© Wear face shield to protect eyes and fae, ze '© Shape tungsten electrode only on grinder with proper guards ina safe locaton wearing proper face, hand, and body protection. ‘© ‘Sparks can cause fies — keop flammables away. ral STATIC (ESD) can damage PC boards. FALLING EQUIPMENT can injure. Use liting eye to it unit only, NOT running ‘ear, gas cynders, or any oer accessories. OVERUSE can cause OVERHEATING '© Allow cooing period follow rated duy cyte. ‘© Rloduce current or reduce duty cyte before starting to weld again © Do.not block or fier aio to un. Bax! | + Futon guna wit sap BEFORE handing k SS boards or pats P| « Use oper sate rt bags and bores to sore, move, or ship PC boards. MOVING PARTS can injure. ern «Keep amey ton ror pate, © Keep away from pinch points such as drive WELDING WIRE can injure. + Do not press gun tigger unt instructed to do # Do not pint gun toward any past ofthe body, other people, oF any metal when threading welding wir, BATTERY EXPLOSION can injure. ‘© Do not use welder to charge batteries or jump stan vehicles unless ithas a battery charging feature designed for ths purpose. w © Koep away from moving pats suchas fans, 1 Koop all doors, panels, covers, and guards closed and securely in place.

Aways wear appropriate personal protective clothing 1 Wotkpiece Make sure workpiece is clean betore welding, 2 Work Clamp Place as close tothe weld as possible, 8 Electrode BBofore stiking an are, insert an electrode Inthe electrode holder.A smal ameter clectrode requires less current than a large one. Falow recommendations of the electrode manufacturer when sting ‘Wold amporage (see Secton 32) 4 Insulated Electrode Holder 5 Elecrode Holder Postion 6 Arc Length {Are lengths the distance from the elec trode tothe workpiece. A short are with correct amperage wil give a. sharp, ‘racing souna, Corec ac length Iso Iatedto electrode dameter Examine the weld ado eterine f the are longth IS correc ‘Are length for 1/18 and 332 In. dlametor flectrodes should be about 1/6in. (1.6 nm); ae engi fr 1/8 and 5132n. oc trodes should be about 1/8 in. @ mm). Tools Needed: N 7 Slag sea chpoing harm and ie brush to xem ‘omavo slag. Remove slag and chock ‘wold Bead Bette making anathor wold u pass Sy 195095 Page 63-2. Electrode And Amperage Selection Chart ely a @ 155095 Page 73-3. Striking An Are - Scratch Start Technique B weiaing current starts as Soon as olectrode touches the workpiece ayn IF The scratch start technique is preteredtor ac welding. 1 Electrode 2 Workpiace 3 Ae Drag slectrode across workplace Ike stiking a match; immediately If slectrede sightly “after. touching Work If are goes out, electrode was ited too high. If electrode sticks to workpiace, use a quick Ws to oo 3-4. Striking An Arc - Tapping Technique B wetsing curent starts as 000 as electrode touches the workpiece. 1 Electrode 2 Workoiece 3 Ae Bring electrode straight down to ‘workplace: then Ht slighty to start are. I are goos oul, elecitode was lites too high. I electrode sticks to workpiece, use a quck twist fee. 135095 Page 83-5. Positioning Electrode Holder is a» a trode, willbe hela ve / oD SS End View Of Work Angle ‘Side View Of Electrode Angle Fillet Welds / Direction Of Welding End View Of Work Angle Side View OF Electrode Angle ‘Ar learning to start and hole an far, practice running beads of weld metal on fat plates using af elec- Hold the electrode nearly perpen Geular othe work, ahough ting Teaheaa (in the direction of travel) CF To produce the best results, Grvove Weide hola short ar, travel at aunt. form speed, and food tho eloe trode dovnward ata constant rae as tml. 155095 Page ¢3-6. Electrode Movement During Welding [7A single stinger bead is satisfac: tory for mast narrow groove weld joints; however, for wide groove ‘weld jon or bridging across gaps, ‘a weave bead or multe singer beads work bettr ‘Stringer Bead - Steady Move- ‘ment Along Seam 2 Weave Sead ~ Side To Side Movement Along Seam 3. Weave Patterns Use weave pattems to cover a wide areain one pass of the electrode. Lint ‘weave wath to a maximums of 21/2 times dameter of electrode A Notes Work like a Pro! Pros weld and cut safely, Read the safety rules at \ the beginning of this manual. ING | asap 03-7. Conditions That Affect Weld Bead Shape -F Wold bead shape is affected by electrode angle, ac length, travel speed, and thickness of base meta ob ea Ay sm Electrode Angle ll Coreect Angle 10° - 20° 4, 7 Co ——_ Ange Too Sma —— preg ‘Angle Too Large ‘Are Length LI sate £ é 3 a c= Too Short Nomal Too tong “raval Speed os a Teo Siow Norma Too Fast 155096 Page 113-8. Poor Weld Bead Characteristics Large Spatter Deposis| 2 Rough, Uneven Bead 3 Slight Crater Durng welding 4 Bad Overton 5 Poor Penetration 3-9. Good Weld Bead Characteristics ys Fine Spater 2. Uniform Bead 3 Moderate Ctator During Welding No Overlap 5 Good Penetration Into Base Metal 188085 Page 123-10. Typical Weld Joints Groove (But) Join SLO Lap Joint “Tee doin OE Fiat Position Welds Lap Joint Groove (But) Joint Tee Joint a SEZ Horizontal Position Welds Groove (But) Joint Lap Joint Tee Joint Vertical Position Welds Groove (But) Joint Too Jolt Overead Position Welds 155095 Page 133-11. Welding Groove (Butt) Joints A Oye 4k so 1i6in = em ( + ee) ‘Types Of Groove (Butt) Joint Welds 1 Tack Welds Prevent buttjont dstorton by tack welding {ha materials in poston beter final woe \Werkpiece distortion occurs when heat ‘pplieclocally toa joint One de of amet alplat wil "cur up toward the wold, Dis tortion vl also cause the edges ofa butt Jolnto pull ogetner ahead ofthe elecrode 28 the weld cook, 2 Square Groove Weld 3 Single Groove Weld 4 Double V-Groove Weld Materials upto 116 in. (6 mr) thick can ttn De welded without special prepara tion using the square groove weld. Howev- fe winen welding thicker materiais may be necessary to prepare the edges (V grove) of but itso ensure good welds. The single or double V-groove weld is good for materals 316 ~ 32 (5-19 me) trek General the single V-groove is used on ‘materials up to 4 in. (19 mm) thick and wien, regardless of thickness, you ean weld rom one side ony. Create 3.30 do- tee bevel with oxyacetylene or plasma futtng equipment. Remove scale trom ‘materialafter cuting. A ginder can also be sede prepare bevels. Groove (But Joint Training Procedure Practice welding but joints on 1/8 in. (2 rm) or ticker materia. (void thinner ma- terials since they require greater ski) ‘Sopatatthe squared edges of tho male al about 1/1 in. (16 mm) and make abut ‘weld all he way tough wih a 18 in. elec- trode. (You may need to adjust the weld current and travel speed te obtain he do- ‘red weld) Perform a similar exercise on 114i (6 mm) materia, ceposing a bead con each side of the jin and fusing one fo the anether (no bovel needed), Practice making a single Vgroove weld on 18. (6m) plate beveled 0°. Star wth 1B in. slocrede forthe fst oad and tr isn wih a 5/32 in. (4 mn) electrode. Be Ssureto penetrate about 1/32in. (tm be- yond the batom ofthe V" or aot Perm 2 simlar exercise on thicker materials. Generally deposi a bead for eacn 17 in. {Gm of material thickness, cleaning the [ain between layers. On heavier plates, * ‘may be necessary fo weave the top layers foil tne groove After completing the practice welds, test tham as described In Seaton 218, 138085 Page 143-12. Welding Tee Joints Aas 1 Electrode 2 FiletWela Keep are short and move at defiite fate of speed. Hold electrode as Shown t0 provide fusion into the comet. Square edge of te wala surace. For maximum strangth weld both se of upaight section 3. Muti-Layer Deposits Weld second layer when a heavy or filet is needed. Use any of the weaving pattems shown in Section 355. Remove slag before making another weld pass 3-13. Welding Lap Joints RL a5 AAS Muti-Layor Filet Weld + Elecrode 2 Single-Layer Filet Weld Move electrode in circular moton, 3 Mut-Layer Filet Weld Weld second layer when a heavy lorfietis needed, Remove slag be fore making anotner weld pass. ‘Wed beth sides of ln for max mum stengih 155095 Page 153-14, Welding Horizontal Beads And Groove (Butt) Joints We i an 2 [7 When welding horizontal, a gray may distort the me fen metal LEP This teahnique is not Single Pass Bead Weld stable for al electrodes. 1 Electrode ——— es) 2 Seawestip Tit Electrode 15° : ‘Teward Direction Bevel edges warranted by mar terial thickness (600 Secton 3-11). Tack weld a backing stip { to the plates to make the first | Wold pass (oot pass) easier EOE Drecton ofWelding oF Welang. | Single Pass Horizontal Groove (Butt) Joint Weld Or First Pass Of Multi-Layer Deposit Diedion OF ‘Welding = Direction or Weld 2 TH Elecrode 15° n rection OF Travel Make First Weld Pass (Root Pass) Make Second Weld Pass \y Make Third Wels Pass. Completed Weld. 188085 Page 163-15. Welding Vertical Beads And Groove (Butt) Joints Es Single Pass Bead Weld Single Pass Vertical Groove (Butt) Joint ‘Weld Or Firet Pass Of Mult-Layer Deposit Brecon OF Wielding EF When welding vertical gravity may distort the mo fon motal This technique is not _suitabi for al lecrodes. 1 Electrode 2 Backing Stio Weld vericaly by carrying the ‘ele upmard or startng a Top land welding down, Welding up ‘ward is easier ard is shown in these listatons, Bovel gest warranted by ma- tecal thickness (see. Secton 5-19) Tack weld basking sip to the alates to make the frst weld pass (oot pass) easier. Arrows Show Ling Up } of Eleevose Ana Return To Crater, L tare 2nd Pass estate Wan | Siento ana _| = |4 5 Dommbeton t= |B srotenarcat |S] § Recuneade: |C=\ |] $8 when kt enter |] | £5 rot Wela. \ = oon \ortcal Groove (But) Joint Weld Subsequent Layors 155095 Page 173-16. Welding Vertical Tee Joints And Lap Joints PEN [Ey When welding vericaly, gravity may distort the ma fon metal Too Joint Weld ‘Arrows Show Litng Up Of Electrode An turn To [This tochniqu is not suitable fora lecrodes, For maximum strength, weld both sides of ont. ‘Subsequent Weld Passos Lap Joint Weld 188085 Page 183-17. Welding Overhead Groove (Butt) Joints And Tee Joints OB Groove (Butt) Joint Weld Srecion of | welding =| | ae iste Electrode Positon \ Direstion OF => XG CE Welding Patios \ 12in (12mm) Directon ot“ IF | ~braw are out and away | trem eater tole weld | puddle satay. J Toe Joint Weld ein ma _§//| 13 7) Fo “| f ww be [x When welding overhead, gravity may distort the mot fen meta, [This technique isnot suitable for al electrodes, 1 Electrode 2 Backing Stio Welding overneadis te most t= ficult welding ski fo master, When welding overhead, use a welding motion that draws are fut and slightly away trom the ‘rater to allow wel puddle oso lity. When weaving is necessary use the pattem shown, Bovel edges if warranted by ma fal thickness. (see. Section "), Tack wold a backing tip to the plates to make te frst ‘Weld pass (rot pass) easier 155095 Page 193-18. Weld Test 2T3im (5-76 mm) t » 2teain T G76 mm) 1 Vise 2 Weld Joint 3 Hammer ‘Strice the weld joint inthe drecton shown. A geod weld bonds over but oes nat break tne weld breaks, examine itt de- termine the cause. tthe weld is porous (many holes), the are length was probably Too Tong, the weld contains bs of slag, the fre may have been too long ore Slectroge was moved Incorecty hich allowed molten slag to De| ‘tappedin the weld. This may hap-| eran a Vegroowe joint made in Several laye's and calls for add ‘ional leaning between layers 1 tye orignal beveled sutaco is s- Tole tho material was net uly mates which s often caused by insuficent heat orto fata travel speed SECTION 4 - WELDING TROUBLESHOOTING 4-1. Porosity Porosity ~ small cavities or holes Fesuting fom gas pockets in ld rata Possible Causes Corrective Actions ‘Ac length t00 long Reduce ar length Workiece dity Damp electro 188085 Page 20 Remove all grease, el moisture, rus, pant, coatings, sag, and dit rom work surface before welding, Use dy slectode,4-2. Excessive Spatter Excessive Spatter - scattering of molten metal particles that cool fo Sold form near weld bead, Possible Causes Corrective Actions “Arsperage to high fr slectrode ‘Ac length too long oF veiage toohigh Decrease amperage or selectargor electrode Reduce ae length or votage 4-3. Incomplete Fusion Possible Insuficient heat input. Improper welding technique, Workpioce diy Incomplete Fusion ~ fare of weld ‘otal to fuse completely wth base ‘metal or a preceeding wel bead, Corrective Actions Increase amperage. Select larger electrode and increase amperage. Place stinger bead in proper location(s) at joint during welding ‘Adjust work angle or widen groove o access bottom during welaing, Momentary holé are on groove side walls when using weaving technique. Koop are on leacing edge of weld puddle. Remove all groase, el, moisture, rust, part, coatings, slag, and dit rom work surface before welding, 4-4, Lack Of Penetration CPO Lack of Penetration Lack Of Penetration — shallow fusion between weld metal and base metal Good Penetration Possible Causes Improper aint preparation, Corrective Actions: "Materia too thick, Joint preparation and design must provide access to botom of groove Improper weld technique, Insufficient het pu Keep are on leading edge of weld puddle Reduce travel speed, Increase amperage. Select larger eletode and increase amperage 155095 Page 214-5. Excessive Penetration Excessive Penetration - weld metal meling through base metal and hhangingunderneath wold Ce Excessive Penetration Good Penetation Possible Causes Corrective Actions Excessive heat input Select lower amperage. Use smaler elactrode. Improper weld technique. | Adjust tavel speed 4-6. Burn-Through ‘Bum-Through - weld metal molting completely through ‘base. metal Fesufingit holes whore no rea re- Possible Causes Corrective Actions Excessive heat nput Select lower amperage. Use smal electrode, Increase andor maintain steady travel speed. 4-7. Waviness Of Bead ‘Waviness OfBead - wel metal that is not parallel and dows not cover jaint formed by base metal [[Pessibe Causes Corrective tions Usted Fare Use we ands. racic 4-8. Distortion Distortion - contraction of weld met al during welding that forces base metalto move, Base metal moves inthe orecton of he weld bese, Possible Causes Corrective Actions: ‘Excessive heat Input Use restraint (lamp) to hold base meta in poston. Mako tack welds along jin botora starting welding operation Predict anticipated weld distention and precamber base metal Select lower amperage for electrode. Increase travel speed. Weld in small segments and allow cooing between welds. 188085 Page 22Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in.) 22 Gauge (031 in) 20 Gauge (.037 in.) 18 Gauge (.050 in}) 16 Gauge (063 in}) 14 Gauge (.078 in) 1/8 in. (125 in.) 3/16 in. (.188 in) 414 in. (25 in) 5/16 in. (313 in) 3/8 in. (375 in.)Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.Notes HOBART INSTITUT) . | OF WELDING TECHNOLOGY . Start Your Professional oy 4,4 Square East, Troy, Ohio 45373 Over 80,000 trained Welding Career Now! —.300-332-9848 www.nelding.org since 1930!iy