Welding Processes Book

DELTA SCHOOL OF TRADES
5418 PULASKI HIGHWAY

BALTIMORE, MARYLAND 21205
410-485-3449
WWW.DELTASCOOLOFTRADES.COM
WELDING HANDBOOK
CONTENTS
CHAPTER PAGES
SAFETY FOR WELDERS 3...17
SMAW STICK 18...31
SMAW ESSENTIAL VARIABLES 32...42
GMAW MIG 43...58
GTAW TIG 59…71
CERTIFICATION 72…80
BASIC JOINTS 81…88
WELDING SYMBOLS ___ 89…102
PRACTICES_____________ __ ___103..140
THIS TEXT WRITTEN AND PUBLISHED BY;
NORMAN J. ASHLEY
First printing January 2000

Latest Printing March 2005
Revised September 1st, 2007
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CHAPTER ONE
SAFETY FOR WELDING
SAFETY FIRST
CLOTHING FOR WELDING
WELDERS UNIFORM FOR DELTA SCHOOL OF TRADES
WELDING MACHINE SAFETY
SHOP AND WELDING ENVIRONMENT SAFETY
HANDLEING GAS CYLINDERS
GENERAL SAFETY
STUDENT OBJECTIVES
STUDENTS WILL BE ABLE TO:
1. List and describe the type of clothing appropriate for safely welding.
2. List and describe the 8 items that make up the welders uniform used at Delta
School of Trades.
3. Describe the safety guidelines relevant to working with welding machines at
Delta School of Trades.
4. Describe safety rules relevant to the welding shop and environment.
5. Discuss safety issues relevant to using gas cylinders in the welding industry.
6. List and describe 4 items related to safely picking up loads in the shop
7. List and describe safety concerns for using hand grinders at Delta School of
Trades.
3
SAFETY FOR WELDERS
SAFETY FIRST
Safety should be the first consideration when beginning any Trade. Welding is an Industrial trade
and as such has many hazards that can cause injury if the proper safety guidelines are not
followed.
In addition to the safety guidelines for welding training there are many safety rules that apply to
the welding field in general and to the particular company you will work for. Students and
employees should continue to take an active interest in safety throughout their careers.
CLOTHING FOR WELDING

Since welding produces intense heat and hot sparks that may cause serious burns, it is important
to wear the proper work clothes. The following describes the type of clothing appropriate for
welding operations.
WORK SHIRTS
Shirts should be made of thick heavy materials such as heavy cotton or denim that is not easily
burned.
The shirts must be long sleeved and should not have pockets unless they have button flaps on
them. Open pockets may trap hot sparks or globules of hot metal that could burn the skin.
The shirt should not have frayed edges that sparks from welding can easily ignite.
The work shirt should not have any torn areas that allow hot sparks to penetrate.
Matches, lighters, or paper materials should never be carried in shirt or pants pockets when
welding.
WORK PANTS
The pants should be close fitting and made of a heavy material such as work jeans. Overalls are
appropriate if other clothing is worn under them.
The pants should be long enough to cover the top of the boots and have no cuffs that may trap
sparks or hot slag.
Like the shirts the pants should have no frayed edges or torn areas in them.
It is advisable not to have metal keys or other devices dangling from the pants that could arc
against the work surface.
BOOTS
High top leather boots are required for welding and general shop use. Canvas boots or dress shoes
should not be worn.
The boots should fasten all the way up to prevent sparks falling into them. Leather laces that will
not easily burn or smolder should be used.
Wear heavy work socks not nylon or thinner socks for added protection against sparks.
Safety boots with steel toe caps are advisable for welding shops and work to protect the feet.
Spats or leggings are leather pieces that fit over the top of the boot to prevent sparks falling into
the boots and are available at welding supply stores.
4
CAPS
A cap or some form of head covering should be used for welding, especially in other than the flat
position. The cap must be compatible with the welding head gear called the welding helmet.
Welder’s caps or welders beanies (cap with no peaks) are available from welding supply stores.
WELDERS UNIFORM FOR DELTA SCHOOL OF TRADES
Students or welders at the School need to have the proper welding protection equipment in
addition to wearing the proper welding work clothes.
The protection equipment is used to safely view the arc and make the practice welds at the school.
It is the same type of personal equipment all welders use on the job.
The Welding Uniform is the individuals’ choice of manufacturers and styles, for the following
items:
1. THE WELDING HELMET

(WITH SUPPLY OF LENSES)
2. LEATHER WELDING GLOVES
3. LEATHER JACKET
OR CAPE SLEEVES AND BIB
4. SAFETY GLASSES
5. WELDING CAP
6. SLAG (CHIPPING) HAMMER
7. WIRE BRUSH
8. PLIERS
1. THE WELDING HELMET

The welding helmet is designed to protect the welders face and head from the ultraviolet and
infrared rays of the welding arc, while allowing the welder to view the molten weld pool or puddle.
There are a variety of welding helmets and styles available, among them are the flip front, the
wide lens, and the auto-darkening lens.
The flip front allows the welder to view the weld area through a clear lens, while still wearing the
helmet, to safely slag the work or use a grinder.
5
The wide lens helmet offers a wider view of the weld area.
(Approximately 4 X 5 instead of 2 X 4) A flip front model of the wide lens helmet is also available.
The Auto darkening helmets have a lens that is clear to allow the welder to see the joint before
striking the arc. As soon as the welder strikes the arc, the lens darkens to the normal view of the
welding puddle.
The auto darkening lenses are very useful for; production welding where small
welds can be made without constantly lifting the hood; for precise restarting of the weld; for
striking the arc without hitting the surrounding area or other parts; for grinding and oxy-fuel
cutting.
Auto darkening lenses may also be purchased to fit into a standard helmet. The auto darkening
style of helmet is a lot more expensive than the standard welding helmet and is not essential for
use at the school.
The welding helmet usually comes with a filter plate (dark plate) and a clear lens on the outer side.
The filter lens should be shade number 10 for most welding. Check the documentation that comes
with the helmet for information about the other lens shades that are available.
6
If you use a second clear lens on the inside of the helmet it protects the filter plate when the helmet
is laid down.
It is critical to clean welding lenses daily and change the outer lens when it gets pitted or
scratched, about weekly at the school. If the inner clear lens is in good condition simply swap it for
the front clear lens and place a new lens on the inside.
The dark filter plate, if protected by the cheaper clear lenses should not need to be changed.
Filter lenses and clear lenses are available as plastic or glass. I prefer a Glass filter lens for better
viewing and plastic clear lens.
Make sure you have an ample supply of clear lenses.
2. LEATHER WELDING GLOVES

The welding gloves required for welding are the gauntlet type gloves that cover the forearms.
Work gloves are not appropriate for arc welding.
Lightweight gloves designed for TIG (Healy Arc) give the welder a better feel for manipulating the
TIG torch and adding filler wire. The TIG gloves are not designed for STICK or MIG.
Gloves that are used to handle hot metal may become hard and brittle and crack. Use only pliers
to handle hot weld coupons.
Wet or damp gloves should never be used for electric arc welding.
Gloves that develop even small holes should be discarded and replaced before continuing to weld.
The less expensive work gloves may be used for general shop work, but should not be used for
welding.
3. LEATHER JACKET, OR CAPE SLEEVES AND BIB

The leather jacket, worn like a coat, offers the best upper body and neck protection from sparks
and hot metal globules typical of welding positions other than flat. Most jackets have an inside
pocket and snap all the way up to the collar.
7
A lighter jacket made of fire retardant material may also be used in welding shops. Some of these
jackets have leather sleeves. These jackets are good for light welding, but will wear and develop
holes when doing a lot of vertical and overhead position welding.
The Cape Sleeves and Bib outfit may be made of all leather or the fire retardant material shown
above. You can select either just the sleeves or the cape and sleeves or the cape and sleeves with a
front bib.
Although open in the back, the all leather cape sleeves and bib are a good less expensive substitute
for the full leather jacket, and is practical for all welding positions.
Note: the bib may be sold separately
4. SAFETY GLASSES
Safety glasses are mandatory for all industrial applications, and recommended eye protection for
many hobby or home projects.
In the welding environment Safety glasses further protect the eyes from the intense ultraviolet and
infrared rays of the welding arc.
Welders may get a condition known as an eye flash, either from striking an arc without the helmet
in place, or more likely, from other welders working in the area.
People that work around welders, are also vulnerable to eye flash without the proper protection.
The safety glasses must have side shields to protect the corner of the eye when welders are
working close by.
8
An eye flash occurs when the unprotected eye is burned in a similar manner to a sun burn on skin.
Painful problems from the flash usually start several hours after exposure (At Night) and may last
all night into the next day. The symptoms include: A feeling of sand or grit in the eye, an inability
to keep the eye open and focus, intense pain, redness swelling and watering, burning, and
headache.
It is my experience that the flash will clear up without long term problems if you avoid further eye
exposures. Consult a doctor if problems persist more than 48 hours.
IT IS CRUCIAL TO WEAR SAFETY GLASSES WHEN WELDING

If you wear prescription glasses, you should use side shields that slip on to the frames of glasses, to
protect the sides of the eyes from exposure. Many flashes come from other welders and can burn
the eye from the side. Goggles that fit over glasses may also be used
5. WELDING CAP
A welding cap protects the head from sparks flying over the welding helmet and from falling
sparks while welding overhead. A cap with no peak called a beanie is a popular choice for welders.
A cap with a peak worn backward may also be used.
6. SLAG HAMMER
(CHIPPING HAMMER)
A slag hammer or sometimes called a chipping hammer is used to remove the slag from the
completed stick weld. The slag hammer may have one pointed and be shaped like a chisel on the
other end or have two chisel shaped ends. The two most common types are the wire frame and the
wood handle.
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7. WIRE BRUSH
A wire brush is used to clean the weld layers between passes and to clean the completed weld.
8. PLIERS
A pair of pliers is used to handle the hot weld coupons, or other hot metal. Using only gloved
hands can result in a burn or at least shorten the life of the gloves. A simple pair of slip joint
pliers, or a pair of locking pliers, may be used.
WELDER AND EQUIPMENT
SAFETY IN THE WELDING FIELD
In addition to wearing the proper welding uniform there are a number of safety issues that
welders must be aware of, make sure you understand the safety guidelines in effect at your
company. The American Welding Society (AWS) has available several documents concerning
safety for further review. Of special interest is their safety Standard Safety in welding, Cutting and
Allied Processes ANSI/AWS Z49.1.
The following is a brief review of some of the guidelines for welding safety:
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WELDING MACHINE SAFETY
Before doing any welding read the manual for the type and manufacture of the machine you will
be using.
The welding machine is an electrical power source and should be installed by a qualified
electrician or properly trained personnel.
Wear the proper clothing and safety uniform to prevent contact with live parts of the welding
circuit that can cause severe electric shock or even death. The clothing should be dry and free of
grease or oil to prevent flash burning.
When changing electrode holders, ground clamps, or otherwise working on the electrical circuit
make sure the machine is turned off. If the power source is in a remote place use a lock-out system
or have another employee watch to ensure no one turns on the machine.
Frequently check the ground and electrode cables for bare spots or damage. Check to ensure that
insulated parts such as the electrode holder are not damaged exposing live parts. Only qualified
personnel should repair damaged cables, ground clamps or electrode holders
Always wear gloves to insert electrodes into the electrode holder. Never leave electrodes in the
electrode holder when not welding.
Never drape the welding cable over your body to weld.

Make sure the welding area is dry and do not weld in rain or wet conditions.
Other safety issues apply to Motor generators; make sure you do not work alone, in case of shock
the welding machine may need to be shut down quickly.
Do not attempt to repair welding machines unless you have been trained and qualified to do so.
SHOP AND WELDING ENVIRONMENT SAFETY
The welding environment should be well ventilated using fans and extraction devices to remove
fumes from the immediate breathing zone and welding area.
Special precautions must be followed when welding in confined space, for example; use welding
helmets with forced air or use respirators.
Keep the welding area free of containers that contain combustible materials, paper, cloth, paint
and oily or greasy materials.
In case of fire; you should know where the closest fire extinguisher is located and that it is fully
charged. In special circumstances an assistant is posted to act as a fire watch.
You should never weld on drums, tanks, or any closed containers unless properly trained and
qualified personnel have authorized their safe use.
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Be aware of where co-workers are and what they are doing, sparks from welding can travel some
distance from the welding area. Falling objects may endanger you or co-workers. Always warn co-
workers when you are about to start welding.
A hard hat may be required when welding on some applications. Welding helmets that
incorporate a hard hat are available from welding supply stores.
Some companies require employees and welders to wear ear plugs in noisy environments.
Welding curtains may be used to contain welding activities.
Make sure you are aware and understand the safety guidelines that apply to other shop equipment
such as; grinders, saws, hand tools and machinery.
When welding on galvanized or painted surfaces toxic fumes may be released. Remove the coating
by grinding prior to welding. Use a respirator in a well ventilated area or weld outdoors. Certain
types of metals also require the use of a respirator.
Keep the welding area clean and free of clutter, metal, excess welding cables and anything that
could fall or cause tripping accidents.
Know where the first aid station is located and report all accidents regardless how small. Burns
require immediate treatment to prevent infection.
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Because of the shape, contents and weight of gas cylinders used in the welding field it is important
they be handled with extreme caution and in a safe manner. The following safety guidelines are
suggested for safely handling and using gas cylinders.
Gas cylinders should never be moved by carrying, dragging or rolling them. They should only be
moved by securing them in an approved cart. The cylinders must have the metal caps in place to
protect the valve stem assembly of the cylinder before moving them.
If cylinders must be lifted they should be properly secured in an approved lifting cart or on a
platform. Chains, slings, magnets, and other devices where there may be a possibility of the
cylinder slipping and falling should never be used.
Cylinders that are transported over the road should be secured in the upright position with their
protective steel caps in place.
Oil and grease should never come into contact with the oxygen cylinders, regulators or equipment,
since a chemical reaction between the oil and the oxygen may cause a fire or explosion.
Hammers pry bars and similar tools must not be used to open a stuck cylinder valve or remove
valve caps. If the cylinder valve is damaged the force of the escaping gas may cause high pressure
cylinders to fly around uncontrolled and cause damage or serious injury.
If a cylinder is leaking gas it should be moved outdoors and the gas supplier should be notified
immediately.
Cylinders must be chained or secured in the upright position secured on a cart or fastened into a
welding machine cart. When not in use they should have the regulators removed and the caps in
place.
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Never weld on the cylinders, or allow the electrode to come into contact with them and establish
an arc.
Use only the approved cylinder wrench to attach regulators and hoses to the cylinder. The use of
loose fitting wrenches on the soft brass connections may cause excessive wear by slipping on the
connections. Excessive wear may cause the edges of the connectors to become rounded and make it
difficult to fit any wrench on them.
Use only the approved regulator and hoses for the type of gas being used and never use the same
regulator and hoses for different gas contents.
The cylinder the cylinder valve must be cleaned before attaching the regulators. Standing behind
the cylinder quickly open then close the cylinder valve to allowing the high pressure gas to blow
out trapped dirt. This action is known as cracking the cylinder. Make sure no one is in front of the
cylinder when you crack the cylinder.
Before attaching the regulator make sure the adjusting screw is backed out and loose. Since
regulators are designed to blow out the front and back if they fail, stand to the side of the
regulator when opening or pressurizing the regulator.
Fuel gas cylinders should only be opened about ¼ turn or until the gas registers on the regulator,
so they can be shut down quickly in an emergency. The high pressure cylinders like the oxygen,
argon and 75-25 have a double seating valve and should be opened all the way.
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GENERAL SAFETY
LIFTING
The following are suggestions for lifting objects in the shop:
1. For heavy items ask for help to lift and move them.
2. Use gloves when moving metal or pieces with sharp edges.
3. Use lifting devices for extremely heavy material.
4. Use the stronger knees to bend and lift not the weaker back.
GRINDERS
Metal hand grinders are used at the school for grinding edge preparations and cleaning up, or
repairing weld passes. Ask for instructions if you have never used a hand grinder.
If you purchase a grinder, read the manufacturers handbook and safety recommendations
supplied with the grinder.
The following suggestions apply to hand grinders:
• Never use a grinder that has bare wires or a damaged cord.

• Do not leave grinders plugged in and unattended on the workbench.
• Make sure the safety guard is on the grinder.
• Use the handle supplied with the grinder.
• Use the face shield and safety glasses when grinding.
• Make sure the cord or extension cords do not present a tripping hazard.
• Do not lay the grinder down until the wheel has completely stopped.
• Never attempt to repair or work on grinders other than regular maintenance.
• There are repair centers that specialize in safely repairing damaged grinders.
• Use gloves when grinding.
• Make sure the sparks from grinding do not present a hazard to co-workers or Cause a fire
threat.
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CONCLUSION
There are many and varied safety guidelines that apply to particular Industries and companies
not covered in this section. Take an active interest in safety as it applies to your job and
environment to avoid personal injury. Continually review safety guidelines and Material Safety
Data Sheets that pertain to you and your company.
Safety is everyone’s business, never compromise safety to get the job done. Many Industrial
accidents can jeopardize your career and future.
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CHAPTER ONE
SAFETY FOR WELDING
KEY POINTS
1. Safety clothing must be worn at all times regardless of personnel comfort, for
example do not remove leather protective sleeves or jacket in hot weather. Always
wear safety glasses on the job.
2. Always use clean welding lenses. They should be cleaned daily and replaced when
scratched, pitted, or approximately weekly.
3 Always seek first aid for minor burns or cuts.
4. replace defective equipment such as, gloves with holes or other equipment with
evident wear and tear.
5. Read and follow all available safety guidelines for the shop environment and
equipment you are using.
6. Take an active interest in safety on the job and the rules and guidelines at your
place of employment.
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CHAPTER TWO
SHIELDED METAL ARC WELDING

STICK
INTRODUCTION
DESCRIPTION
THE ELECTRICAL CIRCUIT FOR WELDING
THE WELDING MACHINE
TYPES OF WELDING MACHINES
ARC BLOW
18
CHAPTER TWO

STICK
STUDENT OBJECTIVES
1. Describe the Shielded metal arc welding (stick) process.

2. Describe how to start an Electrode (rod) by tapping or scratching.
3. Describe the welding machine, polarity and type of current used in Shielded
metal arc welding.
4. List and describe the 4 basic types of welding machines.
5. List and describe the controls on typical welding machines used at Delta.
6. Describe the problem of arc blow when using DC current and how to reduce the
effects.
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THE SHIELDED METAL ARC WELDING PROCESS
STICK
INTRODUCTION
The shielded Metal Arc Welding Process (SMAW) is also widely known by the shop term Stick
Welding. The term stick is a reference to the electrode used to provide the filler metal for welding
with this process.
The Shielded metal Arc Welding process is one of the oldest and most widely used methods of
joining metals by welding. The process is popular because of the simplicity of equipment involved,
its portability, reliability and adaptability to outdoor use.
The process may be used to weld a variety of metal types and shapes in any position.
DESCRIPTION
In the SMAW process, welding is done by setting up an electrical circuit using a welding machine
to produce the electricity, a welding cable with an electrode holder to hold the electrode and a
ground cable with a clamp to fasten to the work-piece to complete the circuit. The weld is made by
touching the electrode to the work-piece closing the electrical circuit and causing the electrode to
melt and form the weld.
THE ELECTRICAL CIRCUIT FOR WELDING
The electrode has a metal core with a covering referred to as the flux by welders
The metal core of the electrode is either the same as, or is compatible with, the metal being
welded.
20
The main difference between the electrodes used to weld mild steel is the composition of the flux.
Manufactures add Ingredients to the flux to influence the characteristics (the way the electrode
operates) of the electrode. These characteristics include; the current and polarity, penetration,
spatter, slag type and weld appearance.
The covering on the electrode decomposes during welding to provide a gaseous shielding that
protects the molten weld puddle from the nitrogen and oxygen in the air that can cause welds to
become brittle or have holes (porosity) in them.
The covering also aids in arc stability, cleaning (deoxidizing) the metal to be welded and forms the
protective black slag that covers the weld metal.
KEY POINTS: The slag should be removed before more welds are added to the joint when
multiple pass welding.
Electrodes are classified by the American Welding Society based on their specific requirements
and intended use.
Electrode guidebooks (available at welding supply stores) are a good source of information
regarding appropriate choices of electrodes.
To start the weld the electrode is tapped (or scratched like striking a match) on the work-piece
then immediately a small gap is held between the electrode tip and work-piece.
Since the gap creates an electrical arcing effect between the electrode tip and the work-piece, the
gap is referred to as the welding arc.
The distance from the tip of the electrode to the work-piece can be varied from lightly touching
the work-piece at an angle sufficient to maintain an arc to a distance approximately equal to the
electrode core.
When viewed through the welding helmet’s filter plate the molten metal from the melting
electrode and work-piece is known as the weld puddle.
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THE WELDING MACHINE
The welding machine (or power source) may vary in style and type but they all produce a steady
flow of electrical current with relatively low voltage to maintain a welding arc.
The type of welding machine used for stick welding is known as a constant current machine which
means the current stays relatively constant as set by the operator while the voltage varies with the
arc length.
The machine may produce either Alternating Current; Direct Current; or offer a selection of
either Alternating Current or Direct Current.
Welding machines that utilize Direct Current usually have a method of changing the direction of
current flow (polarity) in the welding circuit. Some machines have a switch to change the polarity,
while on others the welding cables must be switched from one terminal to the other. To switch the
cables it may be necessary to loosen the terminal bolts or plugs may be provided.
When the electrode cable is attached to the positive + terminal and the ground clamp is attached
to the negative – terminal the polarity is Direct Current Electrode Positive (DCEP) or sometimes
called Reverse polarity.
When the electrode cable is attached to the negative terminal and the ground cable is attached to
the positive terminal the polarity is Direct Current Electrode Negative (DCEN) or sometimes
called Straight Polarity.
KEY POINT; some electrodes are designed to work best on one polarity or the other.
Alternating Current does not have a polarity (direction of flow) since the current constantly
alternates from one direction to the other.
22
The welding machines may be further classified by input line voltage which may be single phase
or three phase for example: 230 volts 460 volts or in some cases 110.
One of the most important considerations may be the amount of amperage the machine is capable
of producing and the duty cycle. The duty cycle may be given in a percentage for example: 60%
duty cycle means the welder can run at capacity for 6 minutes out of ten. Since with stick welding
the welder must stop to change electrodes the duty cycle may not be as critical as with Mig
welding.
The size of the electrodes to be used determines the amount of amperage the machine will need to
produce.
TYPES OF WELDING MACHINES
There are four basic types of welding machines that produce the required low voltage high
amperage constant current for stick welding.
1. TRANSFORMERS.
2. TRANSFORMER – RECTIFIERS.
3. MOTOR DRIVEN GENERATORS.
4. INVERTERS
1. TRANSFORMERS.
A transformer welding machine takes the high voltage low amperage line current and transforms
it to the low voltage high amperage current suitable for stick welding. These machines are
relatively simple in construction with low power consumption and are economical to operate.
These machines produce only Alternating Current (AC).
The electrodes selection is limited to those designed to operate on AC current.
These machines are often used by home hobbyists.
AC Transformers or alternating current may be used to virtually eliminate the problems of arc
blow when using Direct Current.
(Arc blow is the deflection of the arc from its intended path caused by the magnetic effects of the
direct current.)
AN AC TRANSFORMER MACHINE
LINCOLN AC 225 AMPS

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2. TRANSFORMER – RECTIFIERS
The Transformer rectifier welding machines changes line current to suitable welding current
similar to the transformer machine except that the addition of the rectifier changes the output
current to Direct Current (DC). On some machines a switch is used to pass the current through
only the transformer to produce AC current, allowing the operator the choice of AC or DC
current.
The addition of a polarity switch allows a full range of currents from AC to DC electrode negative
or DC electrode positive.
KEY POINT: Some machines require the terminals or plugs to be switched to change polarity.
Some machines produce only DC current
TRANSFORMER RECTIFIERS MACHINE
LINCOLN IDEALARC AC DC 250 AMPS
A multi-process welding machine is one that may be used to weld with STICK, MIG or TIG, when
the necessary components are added.
MILLER MULTI – PROCESS MACHINE

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3. MOTOR DRIVEN GENERATORS
In the motor driven generator, the motor turns a generator to produce the electric current for
welding.
The motor that turns the generator may be powered by electricity or by a fuel powered internal
combustion engine driven by gasoline or diesel.
The fuel gas types are the type of welding machine commonly seen on trucks and job sites. These
machines may also have components added for multi-process welding.
MILLER TRAILBLAZER
4. INVERTERS
Relatively recent technology has allowed welding machine manufactures to take advantage of
electronics to rectify and transform line current for the welding circuit in a much smaller size
called inverters.
Inverter models are available that produce either DC current or offer a choice of AC or DC
current.
Models available provide either constant current used for STICK and TIG or Constant voltage
used for MIG or may combine both.
The great benefits of this technology include the production of a line of machines that offer
smaller more portable multiple process machines that are capable of providing a range of
amperages and are less costly than traditional machines.
The illustration below shows an invertec V 250 S which is a DC 250 amp stick welding machine
used at the Delta School Of Trades.
LICOLN INVERTEC 250 AMPS

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WELDING MACHINE CONTROLS
There are a variety of welding machines produced by manufactures for stick welding, each with
their particular arrangement of controls for selecting the variables for welding. Although controls
may differ with machine type and style, they serve the same basic functions.
Two of the welding machines used at the school are the Lincoln Invertec V250-S and the Miller
Dimension 400. These machines will be used to describe the welding machine controls.
LINCOLN INVERTEC V250-S CONTROLS
(1) ON OFF SWITCH

The on off switch is pushed upwards to turn the machine on and down to turn the machine off.
(2) THE NEGATIVE AND POSITIVE TERMINALS

The negative and positive terminals are used to change polarity between Electrode positive work
negative or Electrode Negative and work positive.
The work (ground) cable plug and the Electrode cable plug are twisted, pulled out and switched to
change from one polarity to the other.
(3) RUNNING LIGHT OR PILOT LIGHT

The pilot light is red when the machine is on and running.
(4) HOT START

The hot start Control regulates the amount of starting energy when initiating the arc in Stick
welding. The higher setting may be used for esier arc starting with some electrodes.
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(5) AMPERAGE CONTROL
The amperage control sets the amperage for Stick welding and becomes the upper limit when
using a remote control.
(6) ARC FORCE

This control is used to adjust the force of the arc. The arc is more forceful or digging at the higher
settings. Adjustments are made based on the type of electrode and the application.
(7) GTAW SMAW SETTING

This control offers a choice of GTAW SMAW SOFT OR SMAW CRISP.
The GTAW setting is used when the TIG (GTAW) equipment is attached and aids in touch
starting the arc.
The SMAW SOFT setting is used to soften the arc for Electrodes like the E-7018 and E-7028.
The SMAW CRISP setting allows a crisper arc when using Electrodes like the E-6010.
(8) THE REMOTE CONTROL

The remote control switches control of the amperage between
(9) REMOTE RECEPTACLE

The remote receptacle has a cover that can be removed to attach a remote device to control the
amperage from zero to the upper limit set on the machine. This control is often utilized for adding
a foot pedal when TIG (GTAW) welding, or when a hand operated remote control is used.
MILLER DIMENSION 400 MULTI-PROCESS WELDING MACHINE CONTROLS
(1) START SWITCH

The black push button switch starts the welding machine.
(2) RUNNING LIGHT

The running light is red when the welding machine is running.
(3) STOP SWITCH

The red push button switch is depressed to stop the welding machine.
27
(4) PROCESS SELECTOR
The process selector is used to switch from CC CONSTANT CURRENT used for Stick (SMAW)
and Tig (GTAW) welding to CV CONSTANT VOLTAGE used for Mig (GMAW) welding.
(5) ARC CONTROL

The arc control dial provides better arc starting for certain electrodes when Stick welding.
Examples: When using E-6010 Electrodes the higher range aids in striking the arc. When using E-
7018 Electrodes the lower range is used to lessen the effects of arc blow.
(6) AMPERAGE CONTROL

This control is a dial that is turned clockwise to increase the amperage when Stick welding or to
increase the voltage when Mig welding. There are two sets of numbers around the dial. The lower
numbers in white squares are read as voltage for Mig welding. The higher numbers indicate the
amperage level for stick welding.
(7) REMOTE CONTROL SWITCH

The remote control switch is a toggle switch with two settings ON or OFF. The switch position is
off for stick welding and on when using a remote control device such as a foot pedal.
(8) AMPERAGE METER

The amperage meter or AMMETER is a gauge that indicates the amount of amperage the welder
is using during welding. The Ammeter setting will fall to zero when the welder stops welding.
(9) VOLTAGE METER

The Volt meter acts in the same manner as the ammeter except it shows the voltage during
welding.
(10) THE REMOTE CONTACT SWITCH

The remote contact switch is a toggle switch with two settings ON or OFF. The switch position is
off for stick welding and on for MIG welding or Tig welding with a foot pedal attachment.
ARC BLOW
DESCRIPTION
A condition called arc blow may occur when using Direct Current (DC) to weld some joint designs
with the stick welding process. The direct current passing through the electrode and the base
metal sets up a magnetic field around the electrode. The force of this magnetic field can be strong
enough to pull the arc from its intended path causing an unstable weld puddle resulting in a poor
weld with excessive spatter. Arc blow may become very severe at the ends of a joint for example;
the top part of Vee groove or when welding the inside corners of a T joint.
Severe Arc Blow may appear to the welder as if someone is blowing the arc with an air hose.
28
REDUCING THE EFFECTS OF ARC BLOW
USE ALTERNATING CURRENT (AC)

Alternating current flow changes direction constantly and as a result the magnetic field does not
build up enough to cause severe arc blow.
When welding certain joint configurations, and arc blow prevents producing quality welds, if
possible switch from Direct Current to Alternating Current.
Although using AC current virtually eliminates the problems associated with Arc Blow it may not
be possible to switch current on the machine or use another machine. Try one or more of the
following tips to reduce the effects of Arc Blow.
WORKING WITH THE GROUND CLAMP

Arc Blow usually occurs either forward or backward along the joint being welded. If forward
Blow occurs, place the ground connection at the edge of the joint to be welded. If backward Blow
occurs, place the ground connection at the start of the joint and weld towards a heavy tack, prior
weld bead or run off tab. If you are unsure whether forward or backward Blow is occurring, try
moving the ground connection to another location.
If the ground connection is very close to the workpiece, try moving it as far from the joint as
possible.
Try adding a connection to the ground clamp so that you have one ground lead, but two ground
clamps. Place one clamp on opposite ends of the section to be welded.
Some welders wrap a short section of the ground cable around the workpiece to set up a magnetic
field to counteract the effects of the magnetic field causing the Arc Blow effect. Caution must be
used to prevent burning the ground cable.
Try uncoiling the ground cable and electrode cable and stretching them out.
SEQUENCE OF WELDING
The effect of Arc Blow may be reduced by changing the sequence of welding. Try some of the
following:
Weld the outsides of angles, channels or beams first where arc blow may not be as severe.
29
Place a weld at the opposite ends of long sections first.
Instead of welding from one end to the other, use a series of shorter welds in staggered locations to
completely weld the joint.
Weld towards a heavy tack weld or prior weld. Stop and change the direction of travel when Arc
Blow occurs.
Use a smaller diameter electrode if possible.
TECHNIQUE
A change in technique will reduce the effects of Arc Blow. Try the following:
Change the electrode angle. Slight angle changes during welding, when arc blow occurs, helps to
lessen the effects enough to finish the weld bead. Try changing the angle to follow the direction of
blowing, even if the electrode seems to burn down one side unevenly.
Use the lowest amperage setting practical, especially on root passes when welding grooves. Some
electrodes, such as the E-7018, have iron powder in the flux and are more prone to Arc Blow. If
possible use an alternative electrode, such as the E-6010, for the root or first pass before using the
E-7018 for the balance of the passes.
Maintain a short arc length and decrease the length of arc if Arc Blow occurs.
Turn the arc control settings on the machine to a lower value when welding joints that seem prone
to Arc Blow.
WELDING THE ONE INCH VEE GROOVE

One of the projects at the School is to weld a vee groove in the vertical up position. When welding
the first and second passes Arc Blow may occur at the top inch and a half. Try the following to
reduce the effects of Arc Blow:
Make sure you put a heavy weld on both sides of the backing strip in the flat position before
welding the groove.
Check the amperage is set correctly and not too high.
Use the backing strip as a run off tab. Start well below the joint on the backing strip and run the
bead out past the joint at the top.
If Arc Blow occurs on the first pass keep the arc length low and the electrode pushed against the
backing strip. Keep the electrode angle low and steep. If the electrode burns down on one side, do
not change the angle.
30
KEY POINTS
1. The stick welding electrical circuit is made up of the Welding machine, Electrode
cable, Electrode holder, Electrode, Work plate, and Ground cable.
2. The weld is started by tapping or scratching the electrode against the work piece.
3. In reverse polarity the electrode cable is attached to the positive terminal of the
welding machine and the ground cable is attached to the negative terminal.
4. In Straight polarity the electrode cable is changed to the negative terminal and
the electrode cable is changed to the positive cable.
5. The polarity in AC (alternating current) changes constantly and requires no
adjustment.
6. Learn about the type of machine you are using on the job and how to set the
controls for the specific job conditions.
7. Recognize and reduce the effects of Arc blow when using DC machines or use Ac
machine.
31
CHAPTER THREE
THE FIVE ESSENTIAL VARIABLES OF SMAW

(STICK)
INTRODUCTION
1. Current Setting.
2. Length of Arc.
3. Angle of Electrode.
4. Speed of Travel.
5. Selection of Electrode.
WELDING DISCONTINUITIES
32
CHAPTER THREE

(STICK)
STUDENT OBJECTIVES
1. List and describe the five essential variables of Shielded metal arc welding.
2. Set the correct current for a given application.
3. Maintain the proper length of arc.
4. Maintain the correct angles of electrode while welding.
5. Control the proper speed of travel while welding.
6. Select the correct electrode for a given application.
7. Recognize and correct welding discontinuities.
33
THE FIVE ESSENTIAL VARIABLES OF SMAW (STICK) WELDING
INTRODUCTION
Welding is a practical skill that requires continual practice and careful attention to the variables
that the welder controls to improve. The old golden rule “practice makes perfect” applies to
welding in that the more you do, as long as you or someone evaluates your welds, the better you
become.
The term variable as used in this text means something the welder has control of either before
welding or during welding.
Review the following five essential variables and the weld discontinuities that may result if control
is not maintained.
KEY POINT: An easy way to remember the variables is by remembering the first letter in each
one spells the word CLASS.
6. CURRENT SETTING.
7. LENGTH OF ARC.
8. ANGLE OF ELECTRODE.
9. SPEED OF TRAVEL.
10. SELECTION OF ELECTRODE.
1. CURRENT SETTING.
The welding current or amperage is essential to producing welds with good appearance and the
required strength characteristics. The welder controls the amperage variable by setting the
amperage on the welding machine prior to welding.
The amperage is set from recommended ranges according to the size of the electrode, the type of
electrode, and the type of current AC, DCEN or DCEP you are using.
KEY POINT: AC means Alternating Current, DC means direct current and can be set for Direct
Current Electrode Negative (Straight Polarity) or Direct Current Electrode Positive (Reverse
Polarity).
Some electrodes are designed to work best on a given Current and Polarity, for example an E-
6010 should be used with DCEP (direct current electrode positive).
Some electrodes are designed to work best on DCEN while others allow a selection of Current to
be used.
The chart below shows typical amperage ranges
Amperage may be referred to as the heat by some welders.
34
An excellent place to find amperage ranges, recommended current and polarity and information
on electrode applications are the Electrode Selection Guidebooks available at any welding supply
store.
The amperage range is fine tuned by the welder to the correct amperage before welding on an
actual workpiece or testpiece by running practice welds on a piece of scrap metal in the position
of welding as follows;
1. Run a practice weld at the lower recommended range setting.

2. Run a second practice weld at the higher recommended setting.
3. Compare the two welds for evidence of a well formed bead, good fusion, lack of defects,
and a smooth transition into the base metal.
4. If necessary reduce the amperage from lower to highest amperage until a satisfactory weld
bead is produced.
5. It is important to try different setting to avoid wasting time with a setting that is to low or
to high and will need to be changed later.
The chart below gives an idea of the evaluation process;

In example A the E-6010 weld made with the correct amperage appears properly formed with the
appropriate width and consistency.
In example B the weld made with amperage setting too low appears thin and stringy.
In example C the weld made with amperage setting too high appears wide and flat with excessive
spatter and evidence of undercut.
A B C
A) Amperage correct
B) Amperage too low
C) Amperage too high
35
KEY POINT: Remember conditions may change for example; if you are welding multiple passes
in the vertical position and using a weave technique you may need to increase the amperage when
weaving over a prior weld bead.
You may want to use higher setting for welding flat and horizontal than for welding in other
positions.
A setting used on one machine may need to be adjusted when using another machine, if the
machines are not calibrated the same.
One welder (operator) may prefer to use a slightly higher setting and travel faster than you, so set
the amperage for your technique.
The correct amperage is one that provides a good weld and is not based on a specific number on
the machine.
2. LENGTH OF ARC
When electricity is made to jump across a gap it is said to arc across the gap. In Shielded Metal
Arc Welding (Stick) it is this arcing effect that creates the intense heat required for melting the
electrode and the base metal together.
The Arc is the term used to describe the distance from the tip of the electrode to the base metal
and can be varied from lightly touching the metal at an angle sufficient to maintain an arc to a
distance far enough from the base metal to extinguish the arc.
If the electrode is held in contact with the work using the slight angle to maintain the arc it is
referred to as the drag technique. This technique is often used to weld in the flat and
horizontal positions, especially with larger or iron powder electrodes. If contact with the base
metal is made too quickly however; the electrode will stick or freeze to the metal.
Another method to employ is to allow a slight gap between the electrode tip and the base metal.
The length of the arc gap affects the appearance of the weld.
The welding machines used in Shielded Metal Arc Welding are known as Constant Current
machines which mean that the current stays relatively constant through changes in the voltage.
The machine increases the voltage as the arc length is increased to maintain current flow at the
amperage level set on the machine. If the voltage is increased too much the arc may become
unstable and result in a poor quality weld.
The correct arc length may vary according to the type of electrode and the position of welding.
When production welding flat or horizontal the drag method is often used for ease in welding and
faster travel speeds.
When a slight gap is maintained the force of the arc provides a weld bead with a slightly flatter
appearance with less chance of slag inclusions and better joint penetration.
36
KEY POINT: make sure you are maintaining a proper arc length before adjusting the amperage
on the welding machine. If the arc length is too long and the voltage increases it may seem as
though the amperage is too high or the sticking caused by too low an arc length with some
electrodes may seem as though the amperage is too low.
3. ANGLE OF ELECTRODE
In the Shielded Metal Arc Welding (STICK) process there are two electrode angles that the
welder must control. The first angle is the one formed between the electrode and the base metal,
called the work angle. The second angle is the angle the electrode is held at relative to the direction
of travel, called the travel angle.
The travel angle for the flat, horizontal and overhead can be either pulled or pushed and
the travel angle for the vertical can be either upward or downward.
Note: The direction of travel across the plate for both drag and push methods:
The work angle should be one that places the weld metal between the members to be welded in the
manner desired. The weld metal will be deposited in a relatively straight line from the tip of the
electrode to the work. The decision to push or pull is largely one of experience and practicality. I
believe a flatter somewhat less rounded weld can be achieved with a slight push angle when
welding flat and horizontal. When welding in the vertical upward position a more extreme angle
using the side of the electrode seems to produce a flatter weld with tighter ripples.
KEY POINT: because of the high deposition rat of an E-7018 electrode it is more difficult to weld
vertical downward.
4. SPEED OF TRAVEL
The rate of travel across the joint is controlled by the welder during welding and greatly affects
the appearance and strength characteristics of the weld.
The amount of weld metal deposited (weld deposition rate) and the travel speed may vary with the
type and size of electrode being used. The correct weld speed will result in a well formed weld
bead that shows good fusion, penetration and a gradual transition of weld metal into the corners
of the joint.
Since the travel speed is not timed in stick welding, the welder must be able to read the molten
weld pool as the electrode is manipulated across the joint. A weld speed that is too fast results in a
thin stringy weld with poor strength. A weld bead that is too slow a speed will result in a heavy
weld that has too much convexity.
5. SELECTION OF ELECTRODE
There are a variety of electrodes available for welding a wide range of metals. The electrode for a
given application must be selected carefully to provide the strength characteristics required for
the weld joint. One of the most useful tools for electrode selection is the Electrode Handbooks
available from welding supply outlets. These handbooks provide information from electrode
classification to application and usability.
37
In general the electrode weld metal must be matched to the type and composition of the base metal
being welded. Further some electrodes within the available scope are designed for specific
purposes.
Some of the most widely used Electrodes are those used for welding carbon Steel.
The following is a brief description of the most commonly used electrodes for welding Carbon
Steel.
The electrodes are classified by a letter and numbering system as follows:
The tensile strength is defined as the ability of the weld metal to withstand forces acting to pull it
apart.
The last digit indicates the type of flux or electrode covering and in turn determines the type of
current, penetration and appearance of the weld.
The following are some commonly used electrodes and their characteristics.
KEY POINTS:
The E-6010 and E-6011 Electrodes are similar with only a slight change in the electrode covering
to enable the E-6011 to be used with AC current.
These electrodes have a deep penetrating and forceful arc with quickly solidifying weld metal.
They may be used in all positions including Vertical Downward. Because of the arc characteristics
they may be used on dirty or rusty metals and for root passes in open root grooves and pipe.
These electrodes have a certain amount of moisture content to enable the forceful arc and should
not be stored in ovens.
The E-6012 and E-6013 electrodes are also similar with some variations in the electrode covering.
These electrodes have shallow to medium penetration making them useful for welding thinner
38
sections, sheet metal and for welding gaps due to poor joint fit up. Trapping slag may be a
problem when using E-6013 at lower amperages or on dirty metal surfaces.
Both the E-7018 and E-7028 electrodes are Iron powder Low hydrogen electrodes. The E-7028 is
used for flat and horizontal position only and may be used with a drag technique to produce a
smooth weld with good appearance.
The addition of Iron powder to these electrodes covering adds to the available weld metal
resulting in heavier convex welds.
These electrodes are classified as low hydrogen meaning they are low in moisture content and
should be stored in ovens or moisture free environment once the container is opened.
Because these electrodes are low hydrogen they are the choice for welding higher carbon steels.
A short arc length should be maintained especially when striking the arc to avoid surface porosity
(tiny holes).
WELDING DISCONTINUITIES
If control of these variables are not properly maintained the result may be a weld with one or
more discontinuities or defects.
KEY POINT: A discontinuity is defined as; an irregularity or imperfection in the appearance of

the weld or surrounding base metal. A defect is defined as; a single or group of discontinuities
severe enough to cause rejection or rework of the weld or assembly.
39
When the five essential variables are properly controlled the weld profile should be properly
formed and free of discontinuities.
Weld Profiles
Note: In the above diagrams the size of the fillet weld is shown in dotted lines and the throat is
from the root of the joint to the face of the weld.
40
CHART SHOWING DISCONTINUITIES IN SMAW AND THEIR CAUSES
DISCONTINUITY POSSIBLE CAUSES
Excessive Convexity Slow travel speed that allows weld metal to build up
Welding currents too low
Insufficient Throat A combination of Travel speed to fast and current too high
Improper placement of weld beads when multiple pass welding
Undercut Amperage too high

Arc length too long increasing the force of the arc so that it cuts into corners
Improper weld technique causing the corners to be left unfilled or cut into
Groove joint not completely filled and overlapped
Insufficient Leg Size Using the wrong electrode angle causing the weld to be deposited to heavily on one side
Using the wrong angle on multiple pas welds Causing the welds to overlap incorrectly
Poor Penetration Amperage too low

Travel speeds too fast
Using too large an electrode for the root of the joint
Improper electrode angle at the root of the joint
Improper weave technique
Using the wrong electrode for the desired joint penetration: (using E-6013 instead of E-
6010)
Poor Fusion Amperage too low
Travel speeds too fast
Improper electrode angle at the sides of the joint
Improper weave technique that does not allow enough time at the sides of the joint
Using the wrong electrode for the application
Overlap Amperage too low and /or travel speed too slow
Electrode too large with low currents
Porosity Dirty base metal painted or galvanized surfaces

Arc length too long especially with E-7018 Electrodes
Moisture in low hydrogen electrodes
Wind or fans strong enough to break down the shielding gas
Slag Inclusions Improper manipulation of the electrode especially with E-6013
Improper cleaning and slag removal between multiple pass welds
Cracks Using the wrong Electrode for the application

Using Excessively high amperage on some metals
Excessive Spatter Amperage too high

Electrode angle too extreme
Arc length too long
41
CHAPTER THREE

(STICK)
KEY POINTS
1. The 5 essential variables must be controlled to produce a sound weld without

discontinuities.
2. Always set the current on scrap plate before welding.
3. Make sure you maintain the correct angle of travel and work angle for the entire
weld.
4. Maintain the proper speed of travel for the entire length of the weld.
5. Always check you are using the correct electrode for the application before
welding.
6. Visually examine your welds to determine if you need to alter any of the 5
essential variables to produce better welds.
7. Use scrap metal to experiment with changes to the essential variables.
CONTROL OF THE FIVE VARIABLES CURRENT, LENGTH OF ARC, ANGLES, SPEED OF

TRAVEL, AND ELECTRODE ANGLE ARE THE KEYS TO PRODUCING A GOOD WELD.
42
CHAPTER FOUR
GAS METAL ARC WELDING

MIG
THE MIG WELDING CIRCUIT
1. THE WELDING MACHINE (POWER SOURCE)

2. THE WIRE FEED UNIT
3. WELDING GUN
4. SHIELDING GAS SUPPLY
5. FILLER WIRE (MIG WIRE)
6. THE MIG WELDING ARC
7. SHORT CIRCUITING TRANSFER
8. GLOBULAR TRANSFER
9. SPRAY TRANSFER
10. USING THE MIG WELDING PROCESS
43
CHAPTER FOUR

MIG
STUDENT OBJECTIVES
1. Describe the Gas metal arc welding (MIG) circuit.

2. List and describe the major pieces of equipment used in the MIG process.
3. Describe the controls on the MIG machine.
4. Describe the controls on the MIG wire feed unit.
5. Describe the main shielding gases used in the MIG process.
6. Describe the filler wire used in the MIG process.
7. List and describe the 3 methods of metal transfer across the MIG arc.
44
(MIG)
INTRODUCTION
The term Gas Metal Arc Welding is the American Welding Society’s preferred name for this
semi-automatic welding process that uses a wire feeder to deliver the filler metal to a hand
operated gun to produce the weld.
The process is also widely known by the shop name MIG (Metal Inert Gas). The name Metal
Inert Gas was used when the process was first developed to weld Aluminum using an inert
(chemically non reactive) gas supply. The process has evolved to become a favorite choice for
welding steel with gases that are not inert.
When compared with Stick welding, the mig welding process is faster, easier, and requires little
cleanup of welds. This makes Mig welding cost effective for production welding in fabrication
shops. The wire fed welding arc is capable of joining thin sections and bridging gaps in poor fit up
situations.
THE MIG WELDING CIRCUIT
Welding is done by using a constant voltage welding machine to supply the power, a wire feed unit
with an attached gun to feed the filler wire to the arc, and a gas supply system to shield the weld
area.
MAKING THE WELD

The voltage, wire speed and gas flow are set by the welder according to recommended ranges for
the application before welding.
After positioning the gun, the welder pulls and holds the trigger to start the gas flow and the arc.
The welder then controls the nozzle distance from the work, the angle of the gun, and rate of
travel speed across the joint. At the end of the joint the trigger is released to stop the wire feed, gas
flow, and break the arc.
45
TYPICAL MIG GUN
MAJOR EQUIPMENT FOR MIG WELDING
In addition to the safety clothing and hand tools generally used in the welding trade the major
parts of the Mig welding process are:
1. THE WELDING MACHINE (POWER SOURCE)

3. WELDING GUN
1. THE WELDING MACHINE

(POWER SOURCE)
Although there are many styles and designs of MIG welding machines produced by
manufacturers, they serve the same basic function. The welding machine is classified as a constant
voltage Machine. This means the voltage remains relatively constant as set on the machine, while
the amperage increases or decreases according to the arc length, in other words the distance of
the nozzle and wire from the work.
The Amperage in Mig welding is controlled by the wire speed setting on the wire feed unit. The
welding machine is usually set to provide DC reverse polarity current.
Some Mig machines are designed with an enclosed wire feed unit, while others have a separate
wire feed unit attached.
TYPICAL MIG MACHINE WITH WIRE FEED ENCLOSED
46
MIG MACHINE WITH WIRE FEEDER ON TOP
Smaller portable units are available for light shop work or home use. These units typically use a
small one pound wire spool.
47
The Miller Dimension 400 Combination Mig, Stick and Tig Machine used at the School is shown
below with a description of the controls used for mig welding.
CONTROLS:
1. ON: BLACK PUSH BUTTON.

This is a push button that when depressed starts the machine.
2. OFF: RED PUSH BUTTON.

This push button stops the machine.
3. CURRENT SELECTOR.
This lever selects either CC. Constant Current used for Stick and Tig Welding or CV Constant
Voltage used for Mig Welding. Make sure the lever is pushed up for CV when Mig Welding.
4. ARC CONTROL.
The Arc Control setting is not used for mig welding and is disabled when in the CV mode for
Mig Welding.
5. VOLTS OR AMPERAGE DIAL.

This Dial shows amperage intervals in regular numbers and Voltage settings in the white squares.
For example: 150 Amps or approximately 18 - 20 Volts. Remember when mig Welding to read the
numbers in the white square.
6. VOLT AND AMP METERS.
These meters show the amperage and voltage during welding.
7. REMOTE CONTACTOR SWITCH.

The remote contactor switch should be set to ON to enable the Mig Gun trigger as the remote
contactor.
48
8. REMOTE CONTROL SWITCH.
The remote control switch is used for Tig Welding with a Foot pedal, and should be in the OFF
position for Mig Welding.
9. MIG FEEDER CONNECTION.

The wire feed unit is connected to this receptacle for Mig Welding.
The wire feed unit may be placed on the machine, located close to the machine or built in to the
machine depending on manufactures style and type of machine. Although styles may differ they
serve the same basic function. The wire feed unit supplies a constant and smooth rate of filler wire
from a spool mounted on the back of the unit. A gas cylinder with attached regulators is hooked
up to the wire feed units solenoid to supply the gas shielding. The filler wire and gas are fed to the
Arc by the attached gun.
The wire feed unit used with the Dimension 400 Welding machine is the Miller model S-52 located
on the top of the machine. This unit is used to describe the controls on a typical wire feed unit.
The pictures below show the controls of the Miller S-52 wire feed unit.
49
CONROLS
1. WIRE SPOOL
The wire spool shown holds about 30 pounds of wire when full and sits on the wire spool hub at
the rear of the wire feed unit. When the gun trigger is pulled, the wire is drawn from the
underside of the spool through the guide rolls and the gun to the weld zone.
2. WIRE
The Type of wire shown, and used at the school, is classified as AWS ER-70S-6 used for welding
mild steel structural shapes. The wire size is 0.035.
3. PRESSURE SPRING
The pressure spring clamps the wire between the guide rolls to feed the wire through the gun. The
pressure can be increased or decreased using the thumb screw on the clamp bridge. Too little
pressure may cause the wire feed to slip or skip, while too much pressure may flatten the wire or
cause it to freeze up.
4. GUIDE ROLLS
The Guide Rolls, part of the wire feed system, are a set of upper and lower rollers with grooves
that pull the wire from the spool and drive it through the gun. The rollers are sized to match the
wire used. The guide rolls and wire used above are size 0.035. To change the guide rolls: The
adjusting spring is released and the gear cover flipped back to access the guide rolls retaining
screws, the screws are removed and the rolls are pulled out. Once the new rolls are installed the
retaining screws are replaced.
50
5. GUN
The gun plugs into the wire feed system to accept the wire and gas supply and deliver them to the
welding arc.
6. TRIGGER PLUG
The trigger plug is attached to the trigger receptacle to enable the gun to remotely activate the
wire feed and gas flow.
7. SLOW-FAST WIRE START SWITCH

The Slow-Fast Wire Start Switch is used to set the initial wire flow start as either a slow start or
fast start when starting the Arc. After the Arc is started the wire speed reverts to the speed set on
the Wire Speed Control.
8. GAS PURGE BUTTON

The Gas Purge Button is used to purge the gas from the gun when the gas supply has been turned
off. Pressing and holding this button allows the gas flow to be adjusted without starting the wire
flow or the arc.
9. FUSE
The Fuse protects the Wire Feed Unit from overload or an internal short.
10. BREAKER
The Breaker is a Circuit Breaker that protects the Motor of the wire feed unit from overload.
11. ON-OFF SWITCH

This Switch is used to activate the wire feed unit and turn it off at the end off the class session. The
switch must be off when switching to Constant Current mode and Stick welding to prevent the
gun from inadvertently arcing if it comes into contact with the work surface.
12. TRIGGER PLUG FRONT VIEW

Another view of the Trigger Plug attached to the trigger receptacle
13. WIRE SPEED CONTROL

The Wire Speed Control is used to set the rate of wire feed through the gun for welding. The wire
feed control is marked in graduations of ten and ranges from zero to 100. The appropriate setting
depends on; the metal thickness, size of wire, and welding position among other variables. The
Wire Speed is co-coordinated with the voltage setting to produce a smooth arc.
14. WIRE JOG BUTTON

The Wire Jog button when pressed and held advances the wire through the gun without
energizing the gas shielding. The wire jog button is often used to advance the wire when changing
wire spools.
15. REMOTE SWITCH

The remote switch has two settings Remote and Standard. For normal operations using an
attached Mig gun the switch is left in the Standard position. When a remote device is attached to
the remote receptacle the switch is in the Remote position.
51
16. REMOTE RECEPTACLE
The Remote Receptacle is used to attach certain remote devices and the remote switch located
above the receptacle is set to the remote position to activate the remote device.
17. GAS HOSE
The gas hose attached to the wire feed unit allows the shielding gas to be fed to the attached Mig
gun.
3. WELDING GUN
The welding gun is attached to the wire feed unit to deliver the filler wire and shielding gas to the
welding arc. The gun assembly is made up by the gun head, welding lead, power connector and
wire feed connector.
TYPICAL WELDING GUN
WELDING LEAD
The welding lead cable is constructed to allow electrical flow, conduct the shielding gas and feed
the filler wire through the gun to the arc. In addition to the electrical wiring, the welding lead has
a gas hose running through it to carry the gas supply and a liner to conduct the wire.
GUN LINER
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GUN HEAD AND PARTS
The typical mig gun has a handle with a trigger, a neck shaped like a goose neck, and a head
consisting of a gas diffuser, contact tip and nozzle. The gun has a power connector that plugs into
either the machine or the wire feed unit depending on style and design. In the case of the units
with a separate wire feeder, the gun also has a wire feed connection.
BERNARD MIG GUN HEAD AND PARTS
The gas is usually supplied from a high pressure cylinder chained or secured on, or close to the
welding machine. The safety rules for handling and using cylinders from the SAFETY SECTION
must be understood and followed.
The principal gases used in MIG welding either alone or in a mixture are: ARGON, HELIUM and
CARBON DIOXIDE.
ARGON
Both Argon and Helium are inert gases, which mean they are chemically inactive and do not
directly affect the Base metal or Weld metal.
Argon is 1.4 times heavier than air and blankets the weld zone to protect the weld zone from the
air.
Argon may be used when welding non-ferrous metals (metals that contain little or no iron) such
as; Aluminum, Magnesium, or copper and its alloys.
Argon is used in mixture with other gases because of its ability to stabilize the arc and reduce
spatter.
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HELIUM
Helium is used for similar applications to Argon, but since Helium is lighter than air it requires
higher flow rates than when using Argon.
Helium produces a hotter arc and may be desirable for welding applications that require a higher
heat input such as; for welding thicker sections, or for automated welding applications.
Helium provides deeper penetration characteristics than argon but with a less stable Arc. Helium
and Argon may be used in gas mixtures to combine the benefits of each component part.
CARBON DIOXIDE
Carbon Dioxide is a chemical compound of one part Carbon and two parts Oxygen. Although not
an Inert gas, Carbon Dioxide may be used for welding carbon steels when the filler wire with the
appropriate deoxidizers are used.
Carbon Dioxide is often used for its relatively low cost and good penetration characteristics. When
pure Carbon Dioxide is used as the shielding gas the welds that have a rougher appearance, more
spatter, and a less stable arc than when used in a mixture with Argon.
GAS MIXTURES
There are a variety of gas mixtures available for use with the MIG welding process that combines
the advantages of their component parts. It is critical to select the gas shielding that provides the
best weld characteristics for the metal being welded. Before welding consult Gas suppliers,
Engineering, Supervision, or shielding gas charts.
At Delta School Of Trades the MIG welding process is used to weld mild steel in all positions using
a popular gas mixture of 75% Argon and 25% Carbon Dioxide. This gas is commonly referred to
as simply 75-25.
FILLER WIRE (MIG WIRE)
The filler wire used at Delta School Of Trades is one of the series designed for welding Low
Carbon Steel and is supplied on 30 pound spools that are attached to the back of the wire feed
unit. The wire size used is 0.35 commonly referred to as just 035 (0 thirty five). The AWS
(American Welding Society) has developed a system of numbers and letters to designate filler wire
type and usage. The filler wire used for welding mild steel at the school is the AWS ER-70S-6. The
letter and number designation is as follows:
ER – 70 S 6
The E designates Electric Welding
The R designates Filler Rod
The 70 designates the Tensile Strength
The two or three numbers following the hyphen designate the Tensile Strength (the ability of the
weld metal to withstand forces acting to pull it apart) in thousands of pounds per square inch. In
the above the Tensile Strength is 70,000 pounds per square inch.
The S designates Solid Wire.
If the filler is designed for Flux Core the letter may be a T for tubular wire.
The 6 is used to designate the usability and characteristics of the wire.
This wire has good penetration and deoxidizers added among other weld metal characteristics.
Other numbers may be used in place of the 6 to designate other desirable weld metal
characteristics. In some cases a letter may be added at the end to designate other materials have
been added.
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A selection of filler wires are available to Mig weld other metals and Alloys and information
regarding their selection can be obtained from Welding Supply Outlets.
THE MIG WELDING ARC
The Mig Welding arc is usually Direct Current Electrode Positive (DCEP) or Reverse Polarity
with Constant Voltage.
Some multiple process welding machines, like the Miller Dimension 400 used at the School, have a
separate DCEP terminal marked CV for attaching a lead wire that runs from the machine to the
wire feed unit that energizes the attached Mig gun. Some machines designed for Mig welding are
set for DCEP polarity only.
METAL TRANSFER ACROSS THE ARC

There are three methods of metal transfer from the wire spool through the arc to the weld puddle
possible with the Mig welding Process.
1. SHORT CIRCUITING TRANSFER

2. GLOBULAR TRANSFER
3. SPRAY TRANSFER
SHORT CIRCUITING TRANSFER

Short circuiting transfer as the name implies creates a short circuiting effect when the energized
wire touches the workpiece and melts into the weld puddle. The short circuiting effect is a
simplified way of describing an action that happens approximately 200 times per second and is not
readily apparent to the welder.
The short circuiting transfer usually occurs when the voltage is relatively low, approximately 17v
to 21 volts. This type of transfer results in a smooth weld with shallow penetration that easily
bridges gaps or poor fit-up.
Short circuiting or short arc is used extensively for welding sheet metal or angles etc that are
fabricated and do not require a great deal of strength. For example; A welding table, window
guards, or Ladder rack.
Short Circuiting may be used in all positions and the arc makes a sound like frying bacon.
GLOBULAR TRANSFER
Globular Transfer as the name implies is a metal transfer where the tip of the wire forms globules
or large droplets that melt and are forced across the Arc into the weld puddle.
Globular Transfer occurs with higher voltage settings than Short Circuiting Transfer and results
in deeper penetration with a flatter weld bead.
Globular Transfer may be used to weld in all positions and the arc makes a hissing sound.
SPRAY TRANSFER
Spray Transfer as the name implies is a form of metal transfer that sprays small globules or
droplets of metal across the arc into the weld puddle.
Spray transfer occurs at higher voltages and above certain critical transition currents determined
by the wire size. Spray transfer usually requires the use of two percent oxygen or more for the
spraying effect to occur.
Spray Transfer results in weld beads with a minimum of spatter, deep penetration and smooth
weld beads.
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The Spray Transfer is a hotter arc and is best suited to thicker materials in the flat and horizontal
positions. The arc makes a harsh sound like high pressure water forced through a small opening.
METAL TRANSFERS
USING THE MIG WELDING PROCESS
Before using the Mig process to weld a specific application, the welding parameters must be
considered to achieve a sound weld with an acceptable appearance. In some instances
Management may inform the welder of the specific parameters or a Welding Procedure
Specification (WPS) may be provided to set the welding parameters. In other cases the Welder is
responsible for determining the welding parameters. The following should be considered when the
welder selects the welding parameters;
1. Determine the Filler Wire

The metal composition and classification must be considered when selecting the filler wire. In
general the filler wire should match or be compatible with the base metal being welded.
Filler wire guides and information for selecting the correct filler wire for a given application are
available from most welding supply stores.
Keep in mind a change in filler wire may require a change in gas shielding.
Filler wire with a T in the classification or inner shield are for FLUX CORE ARC WELDING and
may require a change in Polarity. Flux Core filler metal may or may not require a shielding gas as
a backup gas.
2. Determine the Gas Shielding

As mentioned above there are a variety of gas types and mixtures designed for specific
applications. Consult gas suppliers for recommendations for the specific welding application. Gas
flow should be carefully considered, too much gas flow may cause swirling and result in porosity
(Air Holes), too little and the weld will be of poor quality with porosity.
Welding Non-ferrous metals or applications that require a certain metal transfer may require a
change in gas supply.
3. Determine the voltage and wire speed settings

For most Mig welding applications, but not all, the current should be Direct Current Reverse
Polarity (DCEN). If you are not sure check on the box the wire spool came in for the current type
and range or contact your welding supply store.
The Mig process uses a constant voltage machine that means the voltage stays relatively while the
amperage varies with the stick out distance (gun nozzle tip to work distance).
56
The amperage is controlled by the wire speed setting. The wire speed and voltage must be
coordinated to produce a sound weld with good appearance. Changing the wire speed or voltage
changes the way the weld bead runs and looks.
To produces good welds, always set the machine by practicing setting on scrap metal in the same
configuration, thickness, and position you are going to weld.
The following are a few tips for setting the current;
Which metal transfer is taking place: Lower voltage will be Short Circuiting; Higher voltages will
be Globular; Higher voltage and 2% or more oxygen will produce a hot arc and spray transfer.
The weld bead should be well formed with a gradual transition to the base metal at the corners of
the weld.
If the wire is hitting the base metal and popping or skipping, turn down the wire speed or increase
the voltage.
If the wire is melting in blobs without forming a good weld turn up the wire speed or decrease the
voltage.
Note: Contact tips and nozzles must be cleaned of dirt and spatter frequently. A dirty tip may also
cause popping or the wire to hang up and not melt properly. Check the tip and clean the nozzle
before changing setting, especially if the setting were working.
A slight push angle with the gun will produce a smoother flatter weld bead than when using a
drag angle.
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CHAPTER FOUR

MIG
KEY POINTS
1. The MIG welding circuit is made up of the welding machine, wire feed unit
with wire spool, shielding gas supply and regulator, welding gun, ground
cable and clamp and the workpiece.
2. The gun nozzle must be cleaned frequently to prevent wire jamming or
burning into contact tip.
3. Shielding gas should be set at 20-30 psi
4. Make sure you understand all the controls on both the machine and wire feed
unit.
5. Gas mixtures may vary depending on the metal being welded and its
application.
6. Globular transfer penetrates more than short circuiting transfer. Short
circuiting transfer is used on thinner metals.
7. Spray transfer penetrates well into the base metal, but is only used when
welding flat and horizontal.
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CHAPTER FIVE
GAS TUNGSTEN ARC WELDING

TIG
1. The GTAW or TIG Torch

2. A Constant Current Welding Machine
3. A Gas Supply
4. A Foot Pedal
5. Filler Wire
59
CHAPTER FIVE

TIG
STUDENT OBJECTIVES
1. List and describe the Gas Tungsten Arc Welding (TIG) circuit.
2. List and describe the major components of the TIG process.
3. Describe how to sharpen and maintain the tungsten point for welding.
4. Describe the TIG torch and its component parts.
5. Describe the Welding machine and its controls.
6. Describe the gas cylinder and how to safely set it up for welding.
7. Describe the foot pedal and its use in TIG welding.
8. Describe the filler wire for welding mild steel with the TIG process.
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TIG WELDING
INTRODUCTION
The American Welding Society’s preferred name for this arc welding process is Gas Tungsten
Arc Welding As the name implies the process uses an external Gas supply and a Tungsten
electrode to produce an arc that melts and fuses the metal to be welded with or without the use of
a filler wire.
The term TIG WELDING is a common shop term that is derived from the name TUNGSTEN
INERT GAS WELDING. This name describes the same process and highlights the fact that a
Tungsten electrode and an external inert gas are used to produce a weld.
In this text the term GTAW (Gas Tungsten Arc Welding) will be used to discuss this process.
The Gas Tungsten Arc Welding process may be used to weld most metals and alloys in any
position with or without the use of filler wire. Because of the smaller heat zone and weld puddle
with the excellent shielding effect of the gases used, the welds produced are often stronger than
welds made with other processes.
Although GTAW is slower and produces smaller weld beads than SMAW or GMAW it is often
the process of choice for welding thinner sections, Aluminum, specialty metals and Stainless steels.
GTAW EQUIPMENT SET UP
Gas Tungsten Arc Welding is done by setting up a Torch to a Constant Current Welding Machine
and an external Gas Supply to shield the weld area. An optional Foot Pedal may be used to
remotely control the amperage during welding. Filler Wire may be added as necessary or welding
may be done by fusing the parts with the molten weld puddle.
THE WELDING CIRCUIT
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The major component parts of the welding circuit described below are:
1. THE GTAW OR TIG TORCH

2. CONSTANT CURRENT MACHINE
3. A GAS SUPPLY
4. A FOOT PEDAL
5. FILLER WIRE
1. THE GTAW TORCH

The GTAW torch is an assembly of parts that provides the heat or electric arc for welding and
delivers the shielding gas to protect the weld. The picture below shows a Typical GTAW torch
used to make the weld.
TORCH USED TO MAKE A WELD
The GTAW Torch used to establish and maintain an arc as well as direct the gas flow to the weld
zone, is made up of the Torch Body, Gas Diffuser, Collet, Tungsten Electrode and Back Cap. The
pictures below show the typical Torch Assembly.
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TUNGSTEN ELECTRODE
The Tungsten Electrode used in GTAW and shown above is different to electrodes used in SMAW
(STICK WELDING) in that it is used as the heat source to melt the base metal, but does not melt
and become a part of the weld. When additional weld metal is required it is fed into the arc in the
form of a filler wire.
There are a variety of types of tungsten electrodes used for GTAW the most common ones being
2% Thoriated for Steel and Stainless and Pure for Aluminum.
Check with your weld supply company to select the appropriate Tungsten Electrode for the given
application.
The electrodes used for steel should have a sharpened point and the pure for aluminum a balled
end. There are tools designed to form the point for welding, but a less expensive method is to use a
bench grinder and prepare the point like sharpening a pencil.
KEY POINTS
The sharper and longer the point the smaller and finer the arc puddle. A shorter point results in a
wider weld puddle and bead.
For AC Welding Aluminum prepare a small point and the heat of the arc will ball the end for
proper welding puddle.
Since the Tungsten Electrode does not melt and become filler metal it is referred to as a Non-
Consumable Electrode. The tungsten may get contaminated by touching to the weld puddle or hot
filler wire and will need to be re-sharpened.
When shaping the tungsten point, be sure the point is even or a deflection of the arc may occur.
TUNGSTEN PREPARATION
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TORCH BODY
There are a variety of styles of Torch used for GTAW. The one illustrated earlier is an Air Cooled
style that has a gas valve incorporated. The gas valve is used to start or stop gas flow when the
optional foot pedal is not used. When a foot pedal is used the flow of gas is automatically
controlled by starting or stopping the arc with the foot pedal.
Another popular style of torch is a Water Cooled torch used for welding with higher amperage.
The water circulates internally around the torch to keep it cool. When using this torch a water
cooling unit is added to the GTAW circuit.
WATER COOLED TORCHES
2 CONSTANT CURRENT WELDING MACHINE
The power source used for GTAW is a Constant Current Welding Machine. These machines
provide constant amperage as set by the welder, while the voltage rises or lowers with changes in
the arc length. If the arc length or distance from the tungsten to the work increases slightly, the
voltage increases to maintain the amperage level. Conversely if the arc length decreases the
voltage decreases to maintain the same amperage. The Constant Current classification of Welding
machines is also used for STICK welding (SMAW).
Any Stick or Multiple Process Welding Machine may be used for GTAW as well as some machines
developed especially for GTAW applications.
Machines developed with GTAW applications in mind have added features such as a built in high
frequency capability. A built in high frequency capability provides easier arc starting by allowing
the arc to be initiated by a high frequency current without striking an arc or touching the
tungsten to the work. This is especially useful when welding Aluminum that can easily
contaminate the Tungsten Electrode.
Some of these GTAW machines such as a Square wave or Synchrowave have a method of
changing the characteristics of the current to benefit from altered electrical flow.
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KEY POINTS
When the application or job requires an extensive use of the GTAW process it may pay to
research Welding Machines designed especially for GTAW.
The type of Welding current used for welding Carbon Steel and Stainless Steel is Direct Current
Electrode Negative (DCEN) also known as Direct Current Straight Polarity (DCSP).
The type of Welding Current most often used for welding Aluminum is Alternating Current (AC).
A GTAW torch may be attached to any STICK machine using the remote receptacle on the
machine or by attaching the Electrode Holder (Stinger) to the torch by the use of a special
connector as shown below:
In this set up there is no foot pedal and the weld is initiated by touch start (similar to striking the
arc in Stick). The gas is controlled by the valve on the torch. This setup may be readily assembled
for welding on job sites.
MILLER ECONOTIG AND CONTROLS

USED AT DELTA
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3 GAS SUPPLY
The two most commonly used types of gases used in the GTAW process are ARGON and
HELIUM. A mixture of Argon and Helium may be used for some GTAW applications. Both
Argon and Helium gases are considered INERT gases, meaning they are chemically inactive and
do not react with the metal being welded.
Argon gas is the most widely used gas for manual welding with the GTAW process while Helium
or a mixture may be used for heavier sections and automated welding.

Because of the shape, contents and weight of gas cylinders used in the welding field it is important
they be handled with extreme caution and in a safe manner. The following safety guidelines are
suggested for safely handling and using gas cylinders.
Gas cylinders should never be moved by carrying, dragging or rolling them. They should only be
moved by securing them in an approved cart. The cylinders must have the metal caps in place to
protect the valve stem assembly of the cylinder before moving them.
If cylinders must be lifted they should be properly secured in an approved lifting cart or on a
platform. Chains, slings, magnets, and other devices where there may be a possibility of the
cylinder slipping and falling should never be used.
Cylinders that are transported over the road should be secured in the upright position with their
protective steel caps in place.
Oil and grease should never come into contact with the oxygen cylinders, regulators or equipment,
since a chemical reaction between the oil and the oxygen may cause a fire or explosion.
Hammers pry bars and similar tools must not be used to open a stuck cylinder valve or remove
valve caps. If the cylinder valve is damaged the force of the escaping gas may cause high pressure
cylinders to fly around uncontrolled and cause damage or serious injury.
If a cylinder is leaking gas it should be moved outdoors and the gas supplier should be notified
immediately.
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Cylinders must be chained or secured in the upright position secured on a cart or fastened into a
welding machine cart. When not in use they should have the regulators removed and the caps in
place.
Never weld on the cylinders, or allow the electrode to come into contact with them and establish
an arc.
Use only the approved cylinder wrench to attach regulators and hoses to the cylinder. The use of
loose fitting wrenches on the soft brass connections may cause excessive wear by slipping on the
connections. Excessive wear may cause the edges of the connectors to become rounded and make it
difficult to fit any wrench on them.
Use only the approved regulator and hoses for the type of gas being used and never use the same
regulator and hoses for different gas contents.
The cylinder the cylinder valve must be cleaned before attaching the regulators. Standing behind
the cylinder quickly open then close the cylinder valve to allowing the high pressure gas to blow
out trapped dirt. This action is known as cracking the cylinder. Make sure no one is in front of the
cylinder when you crack the cylinder.
67
Before attaching the regulator make sure the adjusting screw is backed out and loose. Since
regulators are designed to blow out the front and back if they fail, stand to the side of the
regulator when opening or pressurizing the regulator.
Fuel gas cylinders should only be opened about ¼ turn or until the gas registers on the regulator,
so they can be shut down quickly in an emergency. The high pressure cylinders like the oxygen,
argon and 75-25 have a double seating valve and should be opened all the way.
KEY POINTS
For most applications welders will be using 100 % Argon as the shielding gas with an approximate
flow rate from 20-30 PSI.
If you are responsible for selecting the shielding gas for a given application, check with your gas
and welding supply company for information about specific advantages of the available gases.
4 FOOT PEDAL
The GTAW Foot Pedal is an optional Pedal added to the welding circuit to remotely control the
amperage and initiate the gas flow. When coupled with a Power Source that has a high frequency
capability it allows arc starting without contaminating the tungsten electrode. Contaminating the
electrode means the prepared point for welding becomes dull or has globules stuck to it causing
the arc to wander and the weld bead to be wide. If the electrode gets contaminated the point will
need to be re-sharpened for welding.
The use of a foot pedal is especially useful for welding aluminum where the heat needs to be
lowered or increased during welding to avoid blowing away the sides of the joint, or melting
through the joint.
The foot pedal works similar to the accelerator pedal in a car pressing down increases the
amperage lifting the foot slightly lowers the amperage. When the foot pedal is fully depressed the
amperage is at the setting on the machine. Lifting the foot lowers the amperage over a range until
the arc is extinguished.
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5 FILLER WIRE
Unlike Stick and Mig Welding, Tig uses a separate filler wire to add weld metal to the Joint to be
welded in a similar manner to Oxy-Acetylene or Braze Welding. Some pieces may also be welded
together by melting the edges of the joint called Fusion Welding.
Filler Wire is used to introduce more metal to the weld zone to fill the joint or increase the size of
the weld. Filler wire is available in different diameters or sizes, some of the more widely used
include 1/16th 3/32nds or 1/8th. The usual length is approximately 36 inches.
In general the filler metal or tig wire usually has the same composition as, or is compatible with
the metal to be welded, so that Carbon Steel wire is used to weld Carbon Steel, Stainless Steel wire
to weld Stainless Steel and Aluminum wire to weld Aluminum.
There is a selection of filler wire available for these and other metals using the GTAW process.
Selecting a specific filler wire depends on many factors including strength requirements, joint
design and condition of the joint surface.
When selecting an appropriate filler wire, consult filler wire guide books available at most welding
supply stores and discuss job requirements and joint configurations with engineering personnel or
experts at your local welding supply outlet.
Filler Wire used in the Gas Tungsten Arc Welding Process are classified by the American Welding
Society using a letter and numbering system. The following are some examples:
Filler Wire for welding Carbon Steel

ER 70 S – 6
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Filler wire for welding Stainless Steel
ER – 308 L
The Tensile strength of the weld metal is defined as the ability to resist forces acting to pull the
weld apart, measured in thousands of pounds per square inch.
The Classification for GTAW filler wire is similar to that of the GMAW process.
SUMMARY
GTAW is the most intricate of all the manual arc welding processes often requiring one hand to
angle the torch, one hand to consistently feed the filler wire and a foot to control the amperage.
The metal is often thin and requires heat distortion control and must be kept clean. Welds beads
are usually relatively small and flat with deep penetration.
Although GTAW produces less sparks with no slag, the intense arc produces ultraviolet and
infrared rays that make the use of welding leathers and safety equipment mandatory. The same
safety equipment used for SMAW should be used for GTAW except that the gauntlet gloves may
be changed for tig gloves that provide adequate protection while allowing a better feel for
manipulating the torch and filler wire
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CHAPTER FIVE

TIG
KEY POINTS
1. The TIG welding circuit is made up of the Welding machine, the gas supply,
foot pedal, ground cable, and TIG torch.
2. TIG welding steel and stainless steel is done using direct current electrode
negative (DCEN) or Straight Polarity.
3. TIG welding Aluminum is done using Alternating Current (AC).
4. The TIG torch is made up of the torch body, gas diffuser, collet, tungsten
electrode and back cap.
5. The tungsten electrode is the heat source and does not melt and become part
of the weld as in STICK welding. The filler wire is used to add weld metal.
6. The tungsten electrode is sharpened to a point to weld on steel or stainless
steel. The point may need to be re-sharpened if it touches the weld puddle or
filler wire.
7. The foot pedal controls the amount of amperage. Lifting the foot on the foot
pedal lowers the heat, while pushing down increases the heat.
8. Welders should understand the controls on the welding machine to produce
sound welds.
9. Always follow all safety guidelines for handling and using gas cylinders.
10. Argon gas is primarily used as the shielding gas for TIG welding.
11. Gloves made for TIG welding are recommended whenever practical.
71
CHAPTER SIX
CERTIFICATION
WHAT IS CERTIFICATION
WHO CONDUCTS CERTIFICATION
THE AWS CERTIFIED WELDER PROGRAM
WHO NEEDS TO BE CERTIFIED
WHAT DOES MY CERTIFICATION MEAN
WHAT CERTIFICATION IS
TESTING PROCEDURES
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CHAPTER SIX
CERTIFICATION
STUDENT OBJECTIVES
1. Describe what Welder Certification is and what it means to be Certified.

2. Describe who conducts Welder Certification testing.
3. Describe the most common welder certification tests.
4. Describe the American Welding Society’s (AWS) Certification Program.
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WELDER QUALIFICATION AND CERTIFICATION
WHAT IS CERTIFICATION?
The term “CERTIFICATION” as it applies to welders refers to a document that states “I or We

certify that” the indicated welder or welding operator has successfully completed a practical test
of their abilities to perform a sound weld in accordance with some predetermined standard.
The term QUALIFICATION means that a welder or welding operator has met the requirements
of a given STANDARD and is qualified to perform welds to within the scope of the STANDARD.
To become certified the Welder must posses the skills necessary to produce a sound weld that is
visually acceptable and meets the testing requirements.
KEY POINT: TO GET A JOB OR KEEP A JOB WELDERS OFTEN HAVE TO MAKE A WELD TO SHOW THEY
ARE CAPABLE WELDERS
The Testing Procedure involves the welder making a weld that is then tested by an Inspector, to
ensure the weld conforms to a particular Code, Standard, or written Welding Procedure
Specification. Testing Methods include Visual inspection, and may involve either destructive or
non-destructive testing.
CODE: Rules or laws that may have legal status and are considered mandatory especially when
language like shall, Will or Must is used.
STANDARD: A document, sample or thing that describes or shows exactly what the outcome
should be.
SPECIFICATION: A detailed description of the parts or variables to be controlled.
An example of Destructive Testing is when the inspector prepares a specimen from the weld and
bends the specimen against the weld to determine if it meets the requirements of the Standard.
An example of non destructive testing is when a completed weld joint undergoes an X ray and the
inspector reads the X ray film to determine if it meets the requirements of the standard.
In a typical welding Test or Certification, the welder must weld follow a set of written instructions
contained in the Welding Procedure Specification (WPS) to produce the Weld Specimen for
testing.
A simple test may involve the following steps;
1 Ensure the proper safety equipment and welding supplies.

2 Set the welding parameters on the welding machine.
3 Ensure the appropriate supplies are available.
4 Obtain the appropriate supplies and metal pieces to be welded.
5 Prepare and assemble the joint to be welded.
6 Place the weld in the proper welding position.
7 Follow the indicated procedure to fill the joint with Weld.
8 Prepare or help prepare the specimens to be tested.
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The Welding Inspector (Test Supervisor) will guide the preparation of the pieces, assembly, and
periodically check progress to ensure conformity to the Standard.
KEY POINT: Your weld coupons will be examined and tested to make sure they are good welds
There is no one universal test to Certify Welders to all welding conditions. Welders may have to
Cerify for each process (stick, mig, tig etc) used, and for each group of steels (mild steel, stainless,
aluminum). In addition some tests cover all positions of welding while some restrict positions.
When a welder becomes certified through a testing facility they usually receive a document called
a Welder Test Report that details the welder’s qualification range.
Delta certified Welders also receive a test report in the form of an actual certificate with all the
variables listed.
KEY POINT: You are only certified to do what you tested for; ask questions about your
qualification.
WHO CONDUCTS CERTIFICATION?
A Certification may be given by a testing facility’s Inspector or authorized personnel or by a

companies representative such as quality control personnel, supervisors, or engineers as long as
they are in accordance with the Code or Standards requirements for Qualified Testing personnel.
Some companies require certification to be specific to their needs and they maintain the records of
certification. A welder may have many certifications covering a wide range of variables.
KEY POINT: You may not see or receive any documentation if a company pays for testing
THE AWS CERTIFIED WELDER PROGRAM
The AWS (American Welding Society) has developed a program for certifying Welders to
National Standards that is recognized by many Industries and allows certifications to be
transferable or accepted by Companies without further testing. A database of currently Certified
Welders is maintained by the AWS for verification of a welders certification status.
DELTA SCHOOL OF TRADES is an accredited testing facility, listed as Delta Welding And
Engineering on the AWS list of authorized testing Facilities.
SEE OUR LINK FOR AWS CERTIFICATION
KEY POINT: YOU RECEIVE A WALLET CARD DESCRIBING YOUR CERTIFICATION AND THE
CERTIFICATION BELONGS TO YOU.
WHO NEEDS TO BE CERTIFIED?
Welders who wish to work for a company that requires Certification as part of their minimum
requirements for employment (an increasing number of companies now require welders to
demonstrate their skills and, or be Certified)
Welders currently working for companies that must show certification to their clients or general
contractors need to be certified.
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In many cases Welders that have been certified, either at another company or have not welded for
a period of time, may need to be recertified. Some welders are required to take periodic tests to
determine their continued competency.
Welders who wish to prove their abilities or further their career goals will take a certification or
additional certifications.
KEY POINT: BE PROUD TO BE A WELDER PROVE YOUR ONE OF THE BEST
WHAT DOES MY CERTIFICATION MEAN?
Certification is very specific to a particular Code, Standard or Welding Procedure and any
changes in the variables used in welding may require re-certification. Personnel familiar with the
governing document usually determines if the certification is valid for the work being performed.
Welders however; should know in general what their certification covers so they don’t mislead
clients or run into difficulty on the job. The variables used in qualification and the qualification
range of the certification is listed on the following documents;
Welder Qualification Test Report WQTR

The WQTR describes the results of the welding test, including what the welder is qualified to do.
The Welding Procedure specification WPS

The WPS describes the rules, welding parameters and details of the test, or how the pieces should
be assembled and welded. The WPS is like a Blueprint or set of written instructions for the test.
Welding Procedure Qualification Report WPQR

The WPQR documents the variables and tests that have been performed by a qualified individual
to prove the test is valid. The document and supporting information proves that the joint can be
welded and tested to meet the specific Standard or Code requirements. The document if followed
removes all variables except the skill of the welder.
This document and its variables are used to construct the WPS.
WHAT A CERTIFICATION IS NOT?
A certification is not a license to weld anything at anytime under any circumstances.

A certification is specific to a certain code and set of variables that allow repetition of
demonstrated skills.
A certification is not a guarantee that welders will not make mistakes. It certifies that the tester
has witnessed the welder demonstrate a specific skill level and produced a sound (good or
acceptable) Weld. The assumption is that the welder has the ability to reproduce results in an
actual work environment.
Certification in one Process does not extend to other welding process. For example a welder
certified in SMAW (Stick) is not certified to weld with GMAW (mig) The welder may have the
skills but he has not demonstrated them in a testing environment and is not Certified.
Certification to one code does not mean certification to all codes.
Certification is specific to variables such as; Base metal, Filler metal, Welding position, vertical
direction of travel, joint design, joint configuration and thickness of material.
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TYPICAL TESTING PROCEDURES AWS D1.1
SINGLE VEE GROOVE WITH BACKING WELDED IN THE VERTICAL UP 3G POSITION.
The one inch single Vee groove test with a backing bar is an AWS D1.1 pre-qualified joint. The
test qualifies the welder to weld fillets or grooves of unlimited thickness in the process the welder
used to weld the joint.
The completed joint is visually inspected and specimens are destructively tested by bend testing.
PREPARATION:
Under the direction of the Test Supervisor, get two pieces of 1x7x3 that have been beveled on one
side and assemble and tack weld them in the arrangement shown:
The position the test is welded in determines the positions the Welder is Qualified to weld Grooves
and Fillets. This test is often used to test welds produced with the Shielded Metal Arc Welding
(STICK) Process.
The test Supervisor will inspect the assembled joint for conformity to the Code and assist in
placing the joint in the position for Welding. The test Supervisor will ensure the proper supplies
are being used and periodically inspect the welders progress.
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INSPECTION:
The completed joint will be visually inspected according to the requirements of the Code and the
bend test coupons shall be cut from the joint.
PREPARING BEND TEST COUPNS
As the picture shows; under the direction of the test Supervisor, two pieces 1” by 3/8” are cut from
the welded test piece. The backing bar and weld face reinforcement are ground flush and the
pieces are bent to test the weld.
The Test supervisor evaluates the bent pieces for acceptability and conformance to the
requirements of the Code.
The acceptance criteria for bend tests in accordance with the AWS D1.1 are as follows;
• The convex surface of the bend test specimen shall be examined for surface discontinuities
exceeding the following dimensions:
• 1/8 inch measured in any direction on the surface.
• 3/8 inches - the sum of the greatest dimensions of all discontinuities exceeding 1/32 inch but
less than or equal to 1/8 inch.
• 1/4 inch the maximum corner crack, except when that crack resulted from visible slag
inclusion or other fusion type discontinuities, then the 1/8 inch maximum shall apply.
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FILLET WELD BREAK TEST ALL POSITION QUALIFICATION
The fillet weld break test is a simpler test that qualifies the welder to weld fillets with the process
used during the test. The welding position qualified works like the positions for grooves discussed
earlier. To qualify all positions fillet welding, the welder must pass a separate break test in the
vertical and the overhead positions.
When the welder is only welding fillet welds as is often the case with the GMAW (MIG) and
GTAW (TIG) processes, a fillet weld break test in all positions instead of a groove test may be the
only requirement for the job.
To perform the test, the welder weld a T joint on one side with a restart near the center as shown.
The piece is visually examined and a macroetch test is conducted on one end piece. The piece is
then broken to visually inspect for complete fusion and to ensure there are no discontinuities
according to the acceptance criteria of the Code.
The acceptance criteria for fillet weld break tests in accordance with the AWS D1.1 are as follows;
To pass the visual examination prior to the break test, the weld shall present a reasonably uniform
appearance and shall be free from overlap, cracks, or excessive undercut as defined by the Code.
There shall be no porosity visible on the weld surface.
The broken specimen shall pass if:
• The specimen bends flat upon itself.

• The fillet weld, if fractured, has a fracture surface showing complete fusion to the root of the
joint with no inclusion or porosity larger than 3/32 of an inch in greatest dimension.
• The sum of the greatest dimension of all inclusions shall not exceed 3/8” of an inch in the 6 inch
long specimen.
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CHAPTER SIX
CERTIFICATION
KEY POINTS
1. Certification comes from the term “I or We Certify that I or We have

witnessed this individual successfully complete a specific welding test in
accordance with a specific requirement”. This term is found on the
Certification document.
2. A certification is really a Welder qualification test of his/her practical
abilities as witnessed by a qualified person or inspector.
3. The assumption is if the welder has the skill to pass the test he possesses the
skill to repeat the level of quality on the job.
4. A specific Certification is limited to a specific process and specific variables
and does not imply the ability to weld anything anywhere. For example;
Welders certified to weld with STICK are not certified to weld TIG unless
they have taken both a STICK and TIG test.
5. When you become Certified as a Welder read the Test report to see what you
are Certified to do.
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CHAPTER SEVEN
BASIC WELDING JOINTS
1. BUTT JOINTS
2. T JOINTS
3. LAP JOINTS
4. CORNER JOINTS
5. EDGE JOINTS
6. JOINT ARRANGEMENTS AND WELD
EDGE PREPARATION
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CHAPTER SEVEN
STUDENT OBJECTIVES
1. Name and describe the five basic joint types used in welding metals.
2. Describe the typical edge preparations applied to the basic joints for welding.
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BASIC JOINTS
INTRODUCTION
Welding is one the most widely used methods of permanently joining Structural Shapes used
throughout the world. Generally engineers, supervisors and technicians are charged with joint
design and selection. Welders, however; need to be familiar with the most commonly used joint
shapes, their names, and the type of welds applied to them. Since there is a wide and varied list of
possible joints to fabricate structural shapes, this lesson will discuss only the most common joints
used in Arc Welding.
When two pieces of structural steel are to be connected by welding, the way they are prepared for
welding and placed together is known as the Weld Joint.
KEY POINT: In other words the joint is the way they are joined.
EDGE PREPARATION
Preparation or edge shaping may be applied to each piece (joint member) in the same way, or
combinations of the joint preparations may be used. The edge preparation for welding these joints
depends on the strength requirements and other design considerations. The Welder needs to be
aware of the most common edge preparations as shown below:
JOINT ARRANGEMENTS AND WELDS
The edge preparations are arranged to make the weld joint. The pieces to be welded may be
connected or a gap between the pieces to ensure penetration may be used. On most joints the gap
is at the bottom of the joint and is referred to as the root of the joint.
The term root opening or open root is used to describe this condition. For example; Open root V
groove, or V groove with an open root.
When the joint design allows, a backing strip or insert may be used for easier welding.
Some joints may have a backing weld, or back weld applied. A back weld is applied after the
groove is filled. A backing weld is applied before the groove is filled.
See examples below:
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THE FIVE BASIC JOINTS
There are five basic joints in common use for assembling metal.
1. BUTT JOINTS
2. T JOINTS
3. LAP JOINTS
4. CORNER JOINTS
5. EDGE JOINTS
1. BUTT JOINTS
A butt joint is formed when the pieces to be welded are laid side by side and it is one of the most
widely used types of joint.
KEY POINT: In other words, the pieces are butted together.
The names in the examples above are from the type of weld applied to the joint. Often the type of
weld is used to fully describe the joint. For example; this joint is a single bevel butt joint.
The V groove and bevel grooves are easier to prepare and are used more than the J or U groves.
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KEY POINT: If two imaginary lines are drawn parallel to the horizontal line in the above symbols
they show the joint shape, this is true for most of the symbols. This can be helpful to remember
since symbols on a blueprint do not show the actual joint shape or edge preparation.
2. T JOINTS
A T joint is formed when one piece of metal to be welded is placed vertically on another piece
lying horizontally, to form the shape of an inverted T.
KEY POINT: The T shape resembles an overhead position T joint.
The vertical member is usually placed at 90 deg to the horizontal member.

One of the most widely used types of weld applied to a T joint is the fillet weld. When a single pass
or multiple passes are made against the joint, the weld resembles a Triangle when viewed from the
side.
KEY POINT: Pronounce the T in fillet FILL-ET; not as FILL-AY a fish
The T joint and fillet weld are the most frequently used joint and type of weld.
In the same way the edges of the butt joint may be prepared for welding, the tee joint’s vertical
piece may be prepared using a Bevel, or J shape. The preparation allows the Welder to penetrate
into the root of the joint.
See examples below:
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3. LAP JOINTS
A Lap joint is formed when one piece to be welded is laid down and another piece is overlapped to
form an edge for fillet welding or an area to allow plug or slot welding.
Lap joints are often used when plug or slot welding thinner sections.
A plug weld is made by welding holes evenly spaced across the length of one or both sides of the
joint. A slot weld is similar except slots are made instead of holes.
Other welds may be applied to laps such as projection, or seam welding.

See examples below:
LAP JOINTS
4. CORNER JOINTS
A corner joint is formed by placing one piece to be welded on the other so that a corner is formed.
The corner may be Flush; Half Open; or Fully Open.
An edge preparation may be applied to one, or both of the pieces of the joint for penetration and
strength.
KEY POINT: The weld applied to the inside of many of the above is a fillet weld.
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5. EDGE JOINT
An Edge joint is formed when the two edges of the pieces to be welded come together. This joint
may be formed as a result of another structural shape and is not as widely used as some of the
other joints.
See examples below.
SUMMARY
Welders need to know the basic joint shapes and the type of welds most commonly applied to
them.
The five basic joints are: Butt; T; Lap: Corner; and Edge.
The edge preparation may be: Square edge; Bevel edge; Double Bevel edge; Chamfer edge; J
groove edge; and Double J groove edge.
J and U grooves are more labor intensive to prepare and may not be seen as often in production.
Butt joints may be open root, have a backing, or be welded both sides.
The weld applied to a T joint is a called a Fillet weld.
Fillet welds are the most commonly used welds.
Corner joints may be: Flush; Half open; or Full open.
Corner joints may be simple or have edge preparation to increase penetration.
Lap joints are more likely to be used when welding thinner sections, or when plug and slot
welding is called for.
Edge joints are usually seen as a result of an overall joint configuration.
The Welding symbols used are for illustration, and will be discussed fully in another lesson.
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CHAPTER SEVEN
KEY POINTS
1. The five basic joints are; Butt joint, T joint, Corner joint, Lap joint and Edge
joint.
2. The edge preparation may be; Square edge, Single Bevel edge, Double Bevel
edge, Chamfer edge, J groove edge, Double J groove edge.
3. Butt joints may be open root, have a backing or be welded both sides.
4. The most common weld applied to a T joint is called a fillet weld.
5. Corner joints may be; Flush, Half Open or Fully Open.
6. Corner joints may be welded flush or have an edge preparation applied to
them.
7. The type of joint used in basic STICK classes, MIG and TIG are typically T
joints formed by 2 pieces of angle iron. The joints used in Advanced STICK
are Single V grooves.
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CHAPTER EIGHT
WELDING SYMBOLS
THE REFERENCE LINE AND ARROW
THE FILLET WELD
1. The size of the weld.

2. The length of the weld.
3. The length and pitch of intermittent or staggered intermittent welds.
4. The contour requirements.
GROOVE WELDING SYMBOLS
GROOVE WELDING ELEMENTS
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CHAPTER EIGHT
WELDING SYMBOLS
STUDENT OBJECTIVES
1. Describe the reference line and indicate arrow side other side relevance.
2. Describe the fillet weld symbol and its elements.
3. Describe the contour requirements on a weld symbol
4. Describe the groove weld symbol and its elements
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WELDING SYMBOLS
INTRODUCTION
Welding symbols are used on blueprints and drawings to show where the weld is to be
placed and may also show the size, type of weld, number of welds, details about the weld
and even details about the joint.
Welders that fabricate or work with drawing must be able to interpret the welding symbol
to prepare the joint and apply a weld that has the required strength and soundness.
THE REFERENCE LINE AND ARROW

The reference line is one of the most important elements on the welding symbol. All the
other elements that describe the weld are on or located around this line. The reference line
has a leader and arrow that points to where the information applies. It may also have a tail
that has information about the process, specification, or other notes that do not normally
have an element that describes them. If the elements on the reference line describe the
necessary details (as it does in most cases) the tail is not used.
See the examples below:
In the above examples one of the reference lines has multiple arrows that are used to show
the same weld in three locations that are relatively close to each other. There is also a
reference line that has an arrow break. The break in the arrow is used to indicate the joint
member that is to receive the edge preparation.
KEY POINT: the arrow points to the bevel where the bevel needs to be prepared.
ARROW SIDE
One of the most important things about the reference line and the welding symbol is the top
and bottom of the horizontal line. The actual symbol that shows the type of weld and the
elements surrounding it that detail the weld can be placed on the top of the line or on the
bottom of the line.
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KEY POINTS: symbols on the bottom of the reference line mean weld the side of the joint
the arrow is touching or pointing to. Symbols on the top of the reference line mean apply
the weld to the other side of the joint, or the side opposite to where the arrow is pointing.
This method is used because sometimes the welding symbol must be drawn on the
blueprint on the other side of the joint. When symbols appear on both sides of the reference
line it means weld both sides of the joint.
If the reference line has a weld symbol on both sides of the reference line they may, or may
not be the same weld on both sides of the joint. Remember the rule to apply the right weld
to the right side.
See the examples:
OTHER ELEMENTS ON REFERENCE LINE
There are two other elements that may be seen on the reference line that provide
information about the weld. One is a circle around the place where the leader line connects
to the reference line and indicates the weld is “ALL AROUND”. This means the weld
extends all the way around the joint the arrow is pointing at.
KEY POINT: The all around element is only used when it is possible to weld all the way
around a single surface. Otherwise more than on symbol is used.
The other element seen on the reference line resembles a flag and is located where the
leader line joins the reference line. This element is called a field weld and means the weld
will be done in another location. For instance, this weld may be applied at the job site not
in the shop. Sometimes clarification will be given in the welding symbol tail or as a
specification on the print.
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THE FILLET WELD
The fillet weld symbol is one of the most widely used symbols and the shape placed on the
reference line to indicate a fillet weld is a triangle that resembles the side profile of a fillet
weld.
The examples of the weld all around and field weld above show a fillet weld symbol so that
the weld to be applied in both cases is a fillet weld.
The names of the parts of the fillet weld
KEY POINT: Fillet sounds like fill it (pronounce the T) not fillay as in fillet a fish.
The important elements added to a simple fillet weld symbol are as follows;
1. THE SIZE OF THE WELD.

2. THE LENGTH OF THE WELD.
3. THE LENGTH AND PITCH OF INTERMITTENT WELDS.
4. THE CONTOUR REQUIREMENTS.
1. THE SIZE OF THE WELD.

The size of the fillet weld is determined by the legs of the triangle shape which represent
the legs of the fillet.
A welded piece may have a different weld size on each side or they may be the same size.
Sometimes (not often) a weld of unequal legs may be required. For example: if one member
of the joint is thinner than the other.
93
If no size is shown on the fillet weld, a size for all fillets will be given on the drawing as a
note or specification.
KEY POINT: Making the fillet welds the wrong size may lead to costly rework if you are
not sure ask for clarification.
2. THE LENGTH OF THE FILLETWELD.

The length of the weld when it is not a continuous weld is shown by a number on the right
side of the fillet weld triangle. If it is not obvious the location is detailed on the drawing.
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3. THE LENGTH AND PITCH OF INTERMITTENT WELDS
An intermittent weld is one that is not continuous across the joint, but rather is a given
length of weld separated by a given space between them. This method of welding may be
used to control heat distortion or where the joint strength requirements allow. Intermittent
welding can save time and money if a long weld is not necessary.
Used more frequently than the length alone, the length and pitch are two numbers located
at the right of the fillet weld symbol.
The length appears first as before followed by a hyphen then the pitch is shown.
The pitch refers to a dimension from the center of one weld to the center of the next weld.
KEY POINT: The pitch is not the space between welds but a measurement from center to
center of the welds. To get the spacing for layout subtract the length of one weld from the
pitch.
The intermittent welds may be chain intermittent or staggered intermittent. Chain

intermittent the welds on both sides of the joint are opposite each other and resemble a
chain. Staggered intermittent the welds on the opposite side are usually started in the gap
between the welds on the first side. The welds then appear staggered.
KEY POINT: If the welds are staggered the fillet weld symbol will be staggered on the
reference line.
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4.THE CONTOUR REQUIREMENTS
Some welding symbols may show a contour finish that details how the fillet weld shape
must be finished after welding. The contour may be flat or convex and the element to
describe this is placed above the slope on the fillet weld symbol. A letter to indicate the
method of finish may be given above the finish element.
A letter U may be used to designate an unspecified finish, when the choice of finishing is
given.
SUMMARYWhen reading a fillet weld symbol always make sure you know what side of
the joint the weld is applied to. Fillet weld symbols on the bottom of the reference line mean
apply the weld to the side of the joint the arrow points to. Fillet weld symbols on the top of
the reference line mean apply the weld to the opposite side of the joint. Fillet weld symbols
on both sides of the reference line mean apply weld to both sides of the joint. This remains
the case regardless of how the break in the arrow is drawn.
The size of a fillet weld is determined by the length of the leg of the fillet weld and is shown
on the symbol to the left.
If two numbers appear in parenthesis the legs are unequal, check the drawing for
clarification.
When a length of weld is shown on a fillet weld symbol the dimension is placed on the right
side.
When two numbers appear separated by a hyphen, the length is indicated first then the
pitch. The pitch is the distance from the center of one length of weld to the center of the
next length of weld.
When finishing directions are shown they appear over the slope of the fillet weld symbol.
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GROOVE WELDING SYMBOLS
Groove welding symbols are used to show how butt joints are prepared for welding and to
detail how the weld is to be applied. When two pieces of metal, other than sheet metal or
thin sections, are butted together for welding they usually have some form of a groove to
allow the weld to penetrate into or through the joint.
The groove is formed by preparing the edges to be welded with a bevel edge, chamfer edge,
double bevel edge, J groove edge or double J groove edge.
When the butt joint has no edge preparation it is referred to as a square groove.
The typical edge preparations are shown below:
The edge preparations may be assembled as either open root, with a backing bar or by
utilizing the back weld or backing weld application.
The open root assembly allows penetration through the joint, while the backing bar is used
for easier welding. The backing bar may be removed or may be a part of the joint.
The backing weld is applied before welding and acts as a backing bar, while the back weld
is applied after welding to finish the back side of the joint. Before applying the back weld a
grinder or other method may be used to prepare a V.
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The edge preparations may be assembled in any configuration to form the groove for
welding from either one side or both sides. The most common configurations and their
basic symbols are shown below.
KEY POINT: If two imaginary lines are drawn parallel to the horizontal line in the above
symbols they show the joint shape, this is true for most of the symbols. This can be helpful
to remember since symbols on a blueprint do not show the actual joint shape or edge
preparation.
KEY POINT: The Groove welding symbols have the same placement relevance on the
reference line as the fillet weld. Symbols on the bottom of the reference line mean weld the
side of the joint the arrow is touching or pointing to, while symbols on the top of the
reference line mean weld the opposite side of where the arrow is touching or pointing to.
If it is not clear always ask someone; reworking welds is costly and time consuming.
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GROOVE WELDING ELEMENTS
GROOVE WELD SIZE

The groove weld size is given in two dimensions and like the fillet weld it is placed to the
left of the weld symbol.
The first size given is THE DEPTH OF GROOVE and is the dimension used to prepare the
edge preparation.
The depth of groove is measured from the surface of the joint to the bottom of the
preparation.
KEY PONT: The depth of groove does not include weld reinforcement or root penetration.
The second size given is the ACTUAL WELD SIZE and is enclosed in parentheses to
distinguish it from the groove size, or depth of groove.
The actual weld size is again measured from the surface of the groove through the bottom
of the groove but now includes the expected penetration of the weld. On a square groove
only the weld size is given.
The weld size does not include face reinforcement or root reinforcement.
KEY POINT: The penetration into the joint shown on the weld size is not measurable by
the naked eye but is given to provide information about the expected outcome.
ROOT OPENING AND GROOVE ANGLE

Two other important elements for preparing and welding the groove are the root opening
and the groove angle.
The root opening, when used, dimensions the space between the joint to be welded and is
placed inside the weld symbol.
The groove angle is also placed inside the weld symbol and is given in degrees.
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KEY POINT: The groove angle for a V groove is given as the INCLUDED angle so that
means the edge bevel or chamfer for each piece is 1/2 of the degrees given. For example; A
45 degree included angle means bevel each member at 22 1/2 degrees.
J grooves angles may be detailed elsewhere on the drawing.
The root opening and groove angle are separate elements and may or may not appear
together depending on the joint requirements.
On some drawings the root opening or groove angle will be covered in a note or
specification on the drawing for all similar symbols, and does not appear on the symbol.
The Welder must always read all information given on a drawing.
CONTOUR AND FINISHING

The same contour symbols that apply to fillet welds may be used with groove welding and
are placed above the weld symbol.
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BACKING BARS BACK WELDS AND SPACERS
As previously mentioned in this section some joint configurations may have a backing bar
or spacer for easier welding or may employ the back or backing weld technique.
The elements for these are placed on the bottom of the reference line opposite the weld
symbol or in the case of the spacer on the reference line.
KEY POINT: If the backing bar is to be removed the symbol will contain an R for remove
after welding.
Since the back and backing weld symbol look the same you must look for details to see
which weld applies.
Spacers may be removed before the second side is welded or they may become part of the
joint.
SUMMARY
The groove weld symbols are used to provide information for preparing and welding the
groove; however, they cannot always show every intended operation and often notes or
specifications are used on the drawing. The welder should read the entire drawing before
making a weld to avoid costly rework. Whenever you see something you are unfamiliar
with check with engineering or supervision for clarification.
It is critical to produce the right size fillet and groove weld for the application so check
sizes with weld gages.
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CHAPTER EIGHT
WELDING SYMBOLS
KEY POINTS
1. The reference line has a leader and arrowhead point to the joint to be
welded. It only has a tail whenever information is to be placed in the
tail.
2. Symbols on the bottom of the reference line always mean weld the side
of the joint the arrow is touching, while symbols on the top of the
reference line mean weld the opposite side of the joint where the arrow
is touching.
3. Symbols on both sides of the reference line mean weld both sides of the
joint.
4. The fillet weld symbol is a triangle shape on the reference line.
5. The fillet weld symbol may have a size, length, pitch, contour, and weld
all around indication added to the symbol
6. The groove symbol may be a square groove, single bevel, double bevel
single V, double V, single j, double j, single U or double U.
7. The groove symbol may have a size of groove, root opening, groove
angle, contour and depth of groove indication added.
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DELTA SCHOOL OF TRADES PRACTICES
BASIC SMAW (STICK)
00 Practice Angle
01 Flat Position E-7018
02 Horizontal Position E-7018
03 Flat Position E-6010
04 Horizontal Position E-6010
05 Vertical Downward E-6010
06 Vertical Upward weave E-6010
07 Vertical Upward stringers E-6010
08 Vertical Upward weave E-7018
09 Overhead E-6010
10 Overhead E-7018
ADVANCED SMAW (STICK)
11 Assemble Groove Weld Plates

12 Flat Position Vee Groove
13 Horizontal Position Vee Groove
14 Vertical Position Vee Groove
15 Overhead Position Vee Groove
GMAW (MIG)
16 Flat Position
17 Horizontal Position
18 Vertical Downward
19 Vertical Upward
20 Overhead
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GTAW (TIG)
21 Flat Position
22 Horizontal Position
23 Vertical Position
24 Overhead Position
PIPE PRACTICES FOR SMAW OR GTAW PROGRAM
25 Pipe Flat Position 1G

26 Pipe Horizontal Position 2G
27 Pipe Vertical Position 5G
28 Pipe Inclined 6G
ADDITIONAL INFORMATION FOR PRACTICES
Fillet weld Positions

Groove weld positions
Pipe Welding Positions
Certification Test Groove
Certification Test Fillet Weld Break
Standards
Troubleshooting Chart
104
PRACTICES ANGLE 00
PRACTICE NAME ASSEMBLE ANGLE T JOINT
PROCESS SMAW GMAW GTAW
POSITION ALL
FILLER ALL
MACHINE SETTINGS SET FOR ELECTRODE AND POSITION
Technique: assemble and tack weld two pieces of 1 ¼ angle six inches long as shown
above and run welds in the position of the practice until the angle is completely full
of weld on all sides.
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PRACTICES BASIC SMAW 01
PRACTICE NAME FILLET WELD
PROCESS SMAW
POSITION FLAT
FILLER E-7018 1/8 ELECTRODES
MACHINE SETTINGS DCRP 130-150 AMPS
Technique: Set the Amperage on DCRP 130 to 150 and using E-7018 Electrodes
place a weld between the joint. Hold the Electrode 90 degrees to the joint as shown
above. Change angle of Electrode slightly to overlap next weld beads evenly until the
joint is full of weld.
Once the arc is struck the electrode may lightly touch the metal or a slight arc
length may be maintained.
Slag each weld bead before applying the next.
Travel from left to right on all weld beads first, and then practice alternating
direction.
FOR ALL SMAW PRACTICES
BURN ALL ELECTRODES DOWN AS LOW AS POSSIBLE
106
PRACTICE NAME HORIZONTAL T JOINT
PROCESS SMAW
POSITION HORIZONTAL
FILLER E-7018
Technique: set the Amperage and weld the first bead using the angles shown above.
Adjust the angle slightly to overlap the first bead with the second and third weld
beads.
Continue to weld beads from the bottom up overlapping each bead in half until the
joint is filled.
Watch for the weld puddle to split the center of the bead under it to keep it straight
and for proper placement.
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PRACTICE NAME FILLET WELD
PROCESS SMAW
POSITION FLAT
FILLER E-6010
MACHINE SETTINGS 90-110
Technique: Set the Amperage on DCRP 90 to 110 and using E-6010 Electrodes place
a weld between the joint. Hold the Electrode 90 degrees to the joint as shown above.
Change angle of Electrode slightly to overlap next weld beads evenly until the joint
is full of weld.
Once the arc is struck the electrode may lightly touch the metal or a slight arc
length may be maintained.
Slag each weld bead before applying the next.
Travel from left to right on all weld beads first, and then practice alternating
direction.
Notice the difference in the appearance between the E-7018 Electrode and the E6010
Electrode. While the 7018 produces a thicker smoother weld bead with a heavy slag
and medium penetration, the 6010 produces a flatter weld bead with pronounced
ripples thinner slag and deep penetration.
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PRACTICE NAME HORIZONTAL T JOINT
PROCESS SMAW
POSITION HORIZONTAL
FILLER E-6010
Technique: set the Amperage and weld the first bead using the angles shown above.
Adjust the angle slightly to overlap the first bead with the second and third weld
beads.
Continue to weld beads from the bottom up overlapping each bead in half until the
joint is filled.
Watch for the weld puddle to split the center of the bead under it to keep it straight
and for proper placement.
The resulting weld bead is flatter with more pronounced ripples than those
produced with the E-7018 electrode. The E-7018 electrodes have iron powder added
to the electrode covering (Flux). The iron powder and metal available from the core
of these electrode accounts for the heavier, smoother weld bead.
The E-6010 electrode provides a hotter arc that cuts through dirty, rusty, or painted
surfaces and produces a weld with a flatter profile, lighter slag covering and deep
penetration.
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PRACTICES BASIC SMAW O5
PRACTICE NAME VERTICAL TEE JOINT 03
PROCESS SMAW
POSITION VERTICAL DOWNWARD
FILLER E-6010
Technique: Set the welding Amperage on DCRP 100-110 and starting at the top of
the joint, hold the correct travel angle, start the arc, and weld down the joint.
There should be no side to side or weave technique used and the weld bead should
be about the size of the electrode including the flux.
Change the angle slightly to overlap a series of weld beads from one side of the joint
to the other. Completely fill each side of the angle assembly.
110
PRACTICE NAME FILLET WELD T JOINT
PROCESS SMAW
POSITION VERTICAL UP WEAVE
FILLER E-6010
Technique: set the welding machine for DCRP at 90-110 amps and weld vertical
upwards from the bottom of the joint to the top using the weave technique.
The vertical up weave is similar to the vertical up stringers except each pass is
weaved from side to side and completely covers the prior weld bead.
The initial amperage (or heat) setting may need to be increased slightly when
weaving wider than the first three passes.
Pause in each corner to allow proper filling and weld formation. The weld
appearance will be flat with a pronounced ripples.
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PRACTICE NAME VERTICAL UP T JOINT
PROCESS SMAW
POSITION VERTICAL: UPWARD STRINGERS
FILLER E-6010
Technique: Set the correct amperage on the machine and weld from the bottom of
the T joint to the top.
Use a slight weave from side to side as you move up the joint. The closer the weave
pattern the better.
The weld bead width should be approximately 1 ½ times the diameter of the
electrode.
Place the second and third weld beads as shown above, keeping them the same size
and allowing them to overlap half of the prior weld bead.
The side to side weave shown should be quick enough to produce a bead of the
proper width, without being too high in the center. Pause slightly in each corner of
the weave pattern similar to the motion of a windshield wiper.
Fill each side of the angle assembly flush with weld beads.
112
PRACTICE NAME FILLET WELD T JOINT
PROCESS SMAW
POSITION VERTICAL UP WEAVE
FILLER E-7018
Technique: set the welding machine for DCRP at 125-150 amps and weld vertical
upwards from the bottom of the joint to the top using the weave technique.
The vertical up weave is similar to the vertical up stringers except each pass is
weaved from side to side and completely covers the prior weld bead.
The initial amperage (or heat) setting may need to be increased slightly when
weaving wider than the first three passes.
Pause in each corner to allow proper filling and weld formation. The weld
appearance will be flat to slightly round with a smooth appearance.
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PRACTICE NAME OVERHEAD T JOINT
PROCESS SMAW
POSITION OVERHEAD
FILLER E-6010
MACHINE SETTINGS DCRP E-6010 90-110 AMPS
Technique: Set the welding machine on DCRP 90-100 amps for E-6010 electrodes.
Weld the assembled angle joint in the overhead position using E-6010 Electrodes.
Hold the electrode as indicated and weld from one end of the joint to the other. A
slight push or drag method may be used.
In the Overhead position maintain travel speeds that result in a weld bead that is
flat and well formed. Slow travel speeds result in a large bead being deposited at is
difficult to overlap and blend in. Travel speeds that are too fast result in a thin
stringy bead with little penetration.
Continue to run stringer beads until the entire angle is filled with weld.
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PRACTICE NAME OVERHEAD T JOINT
PROCESS SMAW
POSITION OVERHEAD
FILLER E-7018
MACHINE SETTINGS E-7018 125-150 AMPS
Technique: Set the welding machine on DCRP 125-150 amps for E-7018 electrodes.
Weld the assembled angle joint in the overhead position using E-7018 Electrodes.
Hold the electrode as indicated and weld from one end of the joint to the other. A
slight push or drag method may be used.
In the Overhead position maintain travel speeds that result in a weld bead that is
flat and well formed. Slow travel speeds result in a large bead being deposited at is
difficult to overlap and blend in. Travel speeds that are too fast result in a thin
stringy bead with little penetration.
Continue to run stringer beads until the entire angle is filled with weld.
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PRACTICES ADV SMAW 11
PRACTICE NAME ASSEMBLE GROOVE WELDS
PROCESS SMAW
POSITION FLAT HORIZONTAL VERTICAL OVERHEAD
FILLER E-7018
MACHINE SETTINGS DCRP 150 – 165 AMPS
Technique: The Instructor will use the track burner to cut beveled plates then cut a
backing bar for assembling the groove.
The student will remove burning slag and grind the groove face for welding.
The instructor will assist you in aligning and assembling the groove joint and setting
it in the welding position.
Remember: we add two more beveled pieces to make 3 welded joints before
discarding
116
PRACTICE NAME FLAT POSITION VEE GROOVE
PROCESS SMAW
POSITION FLAT 1G
FILLER E-7018
Technique: Place the groove in the flat position and weld the root pass against the
backing bar, then continue welding stringers until the joint is filled. The cover
passes should not exceed 1/8 inch high or be more than 1/8 over each side of the
groove.
117
PRACTICE NAME HORIZONTAL POSITION VEE GROOVE
PROCESS SMAW
POSITION HORIZONTAL 2G
FILLER E-7018
Technique: Place the groove in the Horizontal position and weld the root pass
against the backing bar, then continue welding stringers until the joint is filled. The
cover passes should not exceed 1/8 inch high or be more than 1/8 over each side of
the groove.
118
PRACTICE NAME VERTICAL POSITION VEE GROOVE 3G
PROCESS SMAW
POSITION 3G VERTICAL UPWARD
FILLER E-7018
Technique: Place the groove weld in the Vertical up position and weld the first pass
against the backing strip using the side to side weave motion. Slag and continue
weld passes until joint is filled flush. The final cover pass should not be more than
1/8 inch high and not more than 1/8 inch over the edge of the groove.
119
PRACTICE NAME OVERHEAD POSITION VEE GROOVE
PROCESS SMAW
POSITION OVERHEAD 4G
FILLER E-7018
Technique: Place the groove in the Overhead position and weld the root pass against
the backing bar, then continue welding stringers until the joint is filled. The cover
passes should not exceed 1/8 inch high or be more than 1/8 over each side of the
groove.
120
PRACTICES GMAW 16
PRACTICE NAME GAS METAL ARC WELDING FLAT
PROCESS GAS METAL ARC WELDING
POSITION FLAT 1F
FILLER ER-70S-6
MACHINE SETTINGS 18-20 V0LTS 40 WIRE SPEED 75-25 GAS
Technique: Use a push angle as shown to weld the first pass down the center of the
joint. Angle the gun to overlap the 2nd 3rd and other passes until the joint is filled to
the top of the angle. Use the push angle on all passes.
After welding one side fill the other sides, alternating direction of travel.
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PRACTICES GMAW 17
PRACTICE NAME GAS METAL ARC WELDING HORIZONTAL
PROCESS GMAW
POSITION HORIZONTAL 2F
FILLER ER-70S-6
MACHINE SETTINGS 18-20 VOLTS 40 WIRE SPEED 75-25 GAS
Technique: Use the angles shown to weld the first pass. Overlap other passes to fill
the angle joint completely.
For each pass let the weld pool split the prior pass in half to keep the weld straight
and properly overlapped.
Overlap from passes from bottom up like stair steps.
Practice Alternating direction of travel from left to right then right to left.
Practice both push and pull angles.
122
PRACTICES GMAW 18
PRACTICE NAME GAS METAL ARC WELDING VERTICAL DOWN
PROCESS GMAW
POSITION VERTICAL DOWNWARD 3F
FILLER ER-70S-6
Technique: Use the angles shown to weld the first pass, then angle the gun to
overlap the other passes until the joint is filled with weld.
Weld only from the top of the joint down to the bottom of the joint.
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PRACTICES GMAW 19
PRACTICE NAME GAS METAL ARC WELDING VERTICAL UP
PROCESS GMAW
POSITION VERTICAL UPWARD 3F
FILLER ER-70S-6
Technique: Use the angles shown to weld the first pass then use the stringer weave
to fill the joint.
When the Instructor allows use the second technique “Weave Across” to fill the
joint.
Note: The stringer weave is still a weave pattern as shown but not as wide as the
weave across.
124
PRACTICES GMAW 20
PRACTICE NAME GAS METAL ARC WELDING OVERHEAD
PROCESS GMAW
POSITION OVERHEAD 4F
FILLER ER-70S-6
Technique: Use the Gun angles shown to weld the first pass, then continue to fill the
joint until it is flush with weld.
After 3rd weld shown place 4th weld on bottom of T to overlap 2nd weld then continue
to overlap to top of T. Continue from bottom up to top of T with weld passes.
Practice with both Push and Pull angles of travel.
Change Direction of weld: Practice moving both from left to right and from right to
left.
125
PRACTICES GTAW 21
PRACTICE NAME GAS TUNGSTEN ARC WELDING FLAT
PROCESS GTAW
POSITION FLAT 1F
FILLER ER-70S-6 3/32 FILLER
MACHINE SETTINGS DCSP 120-150 AMPS 20-30 FLOW 100 % ARGON
Technique: Using the torch angle shown and 3/32 filler wire weld the first pass as
shown.
Keep the filler metal as low as possible and feed it into the leading edge of the weld
pool.
Continue to weld overlapping passes across the joint.
126
PRACTICES GTAW 22
PRACTICE NAME GAS TUNGSTEN ARC WELDING HORIZONTAL
PROCESS GTAW
POSITION HORIZONTAL 2F
Technique: Use torch angle above and filler rod to weld the first pass in the
horizontal position as shown.
Keep filler wire low and feed into the leading edge of the weld pool.
Weld six overlapping passes across each side of the joint.
127
PRACTICES GTAW 23
PRACTICE NAME GAS TUNGSTEN ARC WELDING VERTICAL
PROCESS GTAW
POSITION VERTICAL UP 3F
Technique: using torch and filler angles shown weld the first pass, starting from the
bottom of the joint and progress to the top of the joint.
Keep filler straight and feed into weld pool as required.
Continue to overlap weld beads.
128
PRACTICES GTAW 24
PRACTICE NAME GAS TUNGSTEN ARC WELDING OVERHEAD
PROCESS GTAW
POSITION OVERHEAD 4F
Technique: using torch and filler angles as shown weld the first pass across the joint
Keeping filler flat and straight, feed into weld pool as needed.
Continue to overlap weld beads from bottom of weld to top of angle as shown by 2nd
and 3rd bead placement.
129
PRACTICES PIPE 25
PRACTICE NAME PIPE FLAT POSITION
PROCESS SMAW SCH 80 GTAW SCH 40
POSITION FLAT 1G PIPE
FILLER SMAW E-6010 E-7018 OR GTAW ER-70S-6
MACHINE SETTINGS AS REQUIRED
Technique: Set the proper amperage and tack weld two pieces of pipe with a 1/8 or
3/32nd root opening in 4 places as directed by Instructor. (Use size of electrode
without flux or use filler wire 3/32).
Weld the pipe in the flat position by rotating and welding only the top section until
the pipe is welded complete. Weld the root pass with E-6010 and the rest of the pipe
with E-7018.
The Root pass should penetrate into the pipe a minimum of flush to a maximum of
1/8.
The weld should not extent past the original groove face more than 1/8 on each side.
The weld should not be more than 1/8 high on the face of the pipe.
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PRACTICES PIPE 26
PRACTICE NAME PIPE HORIZONTAL POSITION
POSITION HORIZONTAL 2G PIPE
Weld the pipe in the Horizontal holding the indicated angle around the pipe, until
the pipe is welded complete. Weld the root pass with E-6010 then use E-7018 to weld
the rest of the pipe using the stringer bead technique. Weld beads from lower pipe
(bottom) to top pipe.
1/8.
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PRACTICES PIPE 27
PRACTICE NAME PIPE VERTICAL POSITION
POSITION VERTICAL 5G PIPE
Weld the pipe in the 5G Vertical holding the indicated angle around the pipe, until
the rest of the pipe using the weave bead technique.
1/8.
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PRACTICES PIPE 28
PRACTICE NAME 45 DEGREE INCLINED 6G PIPE POSITION
POSITION 6G PIPE
Weld the pipe in the 6G position holding the indicated angle around the pipe, until
the rest of the pipe using the weave bead technique.
1/8.
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PRACTICES: FILLET WELD POSITIONS
At Delta School we start with the flat 1F position then move to the horizontal
position 2F then to the vertical 3F position and finally the overhead 4F position.
You will practice each of these positions using both E-7018 and e-6010 Electrodes
until an acceptable weld can be made consistently before the instructor moves you
on to the next position.
In the GMAW (MIG) and GTAW (TIG) programs we use weld in each of these
positions.
NOTE: In the case of SMAW and GMAW we weld both Vertical Upward and
Vertical Downward
134
PRACTICES: GROOVE WELD POSITIONS
Practice each of these positions using E-7018 Electrodes until an acceptable weld
can be made consistently before progressing to the next position. Start with the flat
groove 1G progress to the horizontal groove 2G then to the vertical groove 3G and
finally to the overhead groove 4G. We return to the vertical groove 3G towards the
end of the program since that is the most often used test position for groove welding.
135
PRACTICES: PIPE WELDING POSITIONS
Flat position 1G
The flat position pipe is generally rolled so the weld is always on top or in the
downhand position. The weld beads may be stringers or weave patterns.
Pipe welds are essentially groove welds are often open root but may have a backing
called a chill ring that fits into the root.
Horizontal position 2G
In the 2g position the pipe is vertical and the weld is a horizontal position groove
weld. In most cases the welder moves around a fixed piece of pipe to make the weld.
Vertical position 5G
In the 5G position the pipe is horizontal and the weld is mainly vertical. At the very
bottom of the pipe it may be overhead. While at the top of the pipe it may be flat,
however; A weave technique may be used throughout for uniformity.
45 degree fixed position 6G

In the 6g position because the pipe is on a 45 degree incline the welder is welding all
positions around the Pipe. If one test in this position the welder is qualified in all
positions for Pipe Grooves and Fillets.
The weld is usually made using multiple stringer bead passes. The stringers should
be weaved slightly especially in the vertical segments for best results.
136
PRACTICES: CERTIFICATION TEST
ONE INCH VEE GROOVE 3G
Technique: The Instructor will provide you with 2 test coupons and 1 backing strip
follow directions to assemble the test joint and place in the test position for welding.
Weld the first pass and wait until the Welding Inspector checks the weld before
continuing.
Continue welding until the joint is filled with weld and the cover pass is completed.
The Welding Inspector will cut two bend test specimens from the completed weld
test coupon. Grind the cover pass and backing bar flush and break all sharp
corners. The Inspector will supervise the bend and interpret the results.
Remember:
You may use hand tools or power tools to clean each pass.
You should check your heat setting by running a practice bead if you are not
familiar with the welding machine.
There is no time limit on the test.
Be careful not to grind to much of the test specimens, have the inspector check if
you are unsure.
The cover pass should not be over 1/8 high (size of rod without flux) or 1/8 over the
side of the original bevel
137
PRACTICES: AWS FILLET WELD BREAK TEST
Technique: Use two pieces of 3/8 plate 3inches by 3 inches and tack weld only one
side where indicated.
Weld one pass from tack to tack in the position of testing.
For all position qualification weld the plates in both the vertical and overhead
positions.
138
DELTA SCHOOL OF TRADES STANDARDS
WELDING PRACTICES
The way to learn Welding or improve your skills is through practicing the welding
positions assigned over and over again until the Instructor or Inspector is satisfied
you can consistently perform the assigned welding practice. When one practice is of
acceptable quality, you will be moved on to the next practice.
The Standards for all practices at the school and in Industry are the American
Welding Society’s standards as described in the D1.1 Structural Welding Code for
Steel and their various Inspection publications.
Every Welder and Student should be aware of the Visual Inspection criteria used at
the school and described below:
1. There shall be no cracks anywhere in the weld.

2. There shall be no undercut anywhere in the weld.
3. There shall be no porosity anywhere in the weld
4. The weld profile shall conform to the weld profiles shown below:
139
TROUBLESHOOTING CHART
140
SUPPLEMENTAL INFORMATION 1
WELDING CARBON STEEL
The following information is not intended to be a guide to welding structures in Industry. It is
intended as a basic introduction to a complex subject known as Metallurgy. In many
Industrial settings the procedure to be followed when welding a given type and grade of metal
is established through testing to a specific Code or Standard or through practical experience.
However; it may be useful for the welder to understand the affects of welding on metal. One of
the most widely welded classifications of metal is the group of carbon steels.
WHY DOES THE WELDER NEED TO KNOW ANYTHING ABOUT THE STEEL HE
IS ASKED TO WELD?
In many cases the welder needs only to know the techniques of actual welding and does not
need to be concerned about the type or grade of steel being welded. This is because a large
amount of steel used in fabricating a metal structure is low Carbon or plain carbon steel
(also called mild steel). When welding these steels with any of the common arc welding
processes like Stick Mig or Tig there are generally few precautions necessary to prevent
changing the properties of the steel.
Steels that have higher amounts of Carbon or other alloys added may require special
procedures such as preheating and slow cooling, to prevent cracking or changing the
strength characteristics of the steel. The welder may be involved in following a specific
welding procedure to ensure weld metal and base metal have the desired strength
characteristics.
WHAT ARE THE TERMS USED TO DESCRIBE THE CHARACTERISTICS OF

METAL?
Before reviewing the weldability of steel we need to understand the terms used to describe
the changes that may occur due to welding the steels.
Review the definitions below as an introduction and refer back to them as necessary.
MECHANICAL PROPERTIES OF STEEL
Mechanical properties are the properties of the steel reacting to some load or mechanical
working such as bending, machining, or shaping. Mechanical properties affect how the
metal will react when fabricating a structure. While Iron is a relatively soft metal that can
be easily shaped or formed, other elements may be added to the iron to give it a specific
strength or enhanced mechanical properties.
The terms used to describe these properties are as follows:
STRESS
Stress is defined as the load per unit area and is measured in pounds per square inch.
Stress is pressure acting on a weld or metal to pull it apart, twist it, compress it, or shear it,
depending on the direction and type of load. In some cases one or more of the above loads
may be applied in varying degrees.
141
STRAIN
Strain is the resulting deformation of the applied stress. For example: If a piece has stress
acting to bend it, the amount or degree to which the piece bends is the measure of the
strain. In other words stress and strain go together, for instance; if you stress your back by
lifting or carrying a heavy load the resulting pain or damage is the strain.
ELASTICITY
Elasticity is the property of a material that when stressed or has a force applied allows the
shape to return to its original shape. In other word when the load is removed there is no
appreciable strain or deformation. Metals have a limit of elasticity and when the load
increases beyond the limit deformation or strain will occur.
PLASTICITY
Plasticity is the ability of a metal to be deformed or shaped without rupture. For example a
piece of plain carbon steel can be shaped easier then a piece of tool steel without rupturing
or breaking.
STRENGTH
Strength is the ability of a material to resist deformation. Plasticity and strength work
together since plasticity is the ability to take the applied load its strength is the ability to
withstand or resist deforming under the load. Metals with high strength will deform less
than metals with lower strength.
TENSILE STRENGTH
The tensile strength is the ability of a metal to withstand forces acting to pull it apart and is
measured in pounds per square inch. For example: the E-7018 electrode produces a weld
with a tensile strength of 70,000 pounds per square inch as shown by the first two digits of
its number.
DUCTILITY
Ductility is the ability of a metal to be easily shaped or elongated without failure or
rupture. Generally metals with high tensile strength are tougher but have lower ductility
and ductile metals are softer and have lower tensile strength. Ductility is the property that
allows metals such as aluminum and copper to be drawn into wire forms.
HARDNESS
Hardness is defined as the ability of a material to resist indentation and is a function of its
elastic and plastic properties. The harder the metal the more it is able to resist wear and
tear.
MALLEABILITY
142
Malleability is the ability of a metal to be shaped by compressive forces without rupture.
Metals with good malleability can be rolled into thin sheets. For example gold has high
malleability and can be rolled and shaped into thin sheets.
BRITTLENESS
Brittleness is basically a term used to describe the lack of plasticity or ductility. A brittle
metal cannot be easily deformed or shaped. For example: a hardened steel or cast iron may
be brittle and show very little resistance to impact or shock.
PHYSICAL PROPERTIES OF STEEL
Physical properties are related to the structure and nature of the steel or Alloy and include
density, electrical conductivity, heat conductivity, melting point, magnetic properties,
reflectivity, and coefficient of thermal expansion.
Of the above properties, one of the most important is the coefficient of thermal expansion.
Steel when heated increases in length, width, and thickness. The increase in unit length
when a metal is heated one degree is called its coefficient of thermal expansion. When
welding takes place a localized area is heated to melting temperature and begins cooling,
steel that has a high coefficient of thermal expansion such as Stainless Steel will warp or
change dimensionally more than regular steel. Distortion or warping due to welding will
be covered in a later lesson.
CARBON STEELS
WHAT IS CARBON STEEL?
Carbon Steel is principally a mixture (or Alloy) of Iron and Carbon with small amounts of
silicon, sulfur, phosphorous, and manganese. Other elements may be added to the steel to
impart a specific quality to enhance its usefulness.
An Alloy may be thought of as a recipe, similar to a recipe for chicken soup that has
ingredients to enhance the flavor, Iron has other elements or ingredients to enhance the
properties of the Iron.
In plain carbon steels it is the Carbon additive that has the greatest effect on the strength
and weldability of the steel.
The carbon is added to the Iron in varying amounts to harden or strengthen the steel. As
carbon content increases the hardness and tensile strength increases and the ductility,
plasticity, and malleability will decrease.
The reason the carbon content or carbon recipe varies is to produce a family of steels that
exhibit the desired characteristics for a given application.
HOW DOES THE AMOUNT OF CARBON AFFECT WELDABILITY OF STEELS?

In general as the carbon content increases the weldability (how easily welded) decreases. In
other words the higher the carbon content the more likely special procedures such as
preheating, interpass temperature control and postheating are necessary.
The following chart groups carbon content, typical uses and weldability.
143
Group Content Typical usage Weldability
%
Low 0.15 Welding electrodes, rivets Excellent weldability with all processes usually no
carbon Maximum and nails preheat interpass or postheat necessary
steel softer easily formed shapes.
Mild steel 0.15 to Plate, angle, and bar stock Readily weldable with all processes without preheat,
Plain 0.30 for general fabrication. interpass, or postheat except for very thick sections.
carbon Mild steel accounts for a
large segment of welded
parts of Industry where
good plasticity and ductility
is required.
Medium 0.30 to Used for Machine parts, Parts may be readily welded with all process if
carbon 0.50 gears, and where parts may preheat, interpass temperature controls, and post
steel be hardened by heat heat recommendations are followed.
treating. Use Low hydrogen Electrodes and appropriate filler
wire.
Heat treating after welding may be applied
High 0.50 To Springs, Dies, Railroad Usually require preheat interpass temperature
carbon 1.0 Track, Many tools, Band control and postheat. Special heating and cooling
steels saws, and Knives. Also used procedures in a furnace such as normalizing may be
where a sharp edge is required to restore the properties of the metal after
required. welding. High carbon Electrodes designed for
welding tool steels or the specific alloy are readily
available from welding supply companies.
Note: As carbon increases steel toughness and welding precautions increase
WHAT TOOLS DO WELDERS TYPICALLY USE WHEN PREHEATING, INTERPASS

TEMPERATURE CONTROL AND POSTHEATING RECOMMENDATIONS ARE
MADE?
When sophisticated inspection tools, ovens, and furnaces are not required or used a welder
may use an oxy-fuel torch and tempelsticks (tempilstik) to control preheating, interpass
144
temperatures, and postheat. Tempilstiks are crayon like indicators made of materials that
melt within 1% of their rated temperature. Mark the workpiece before heating begins. The
dry opaque Tempilstik mark will change to a distinct melted mark when the temperature
rating of the selected Tempilstik has been reached. Tempilstiks are available in a range of
temperatures making them useful for controlling temperature fluctuations between
multiple pass welds (interpass temperature) and for cooling parts.
To slow the cooling rate of small parts welders use methods to keep the part warm and
exclude air such as; burying in sand or some other medium, or wrapping in a fire retardant
blanket.
HOW ARE STEELS CLASSIFIED?
The American Iron and Steel Institute (AISI) and the Society Of Automotive Engineers
(SAE) use a four or five digit numbering system to classify steels by chemical composition.
The first digit indicates the type of steel, the second digit indicates the approximate
percentage of the main alloying element, and the last two or three digits indicate the
average carbon content. For example; in the case of the widely used 1020 steel, the first
digit indicates carbon steel the second digit indicates no predominant alloy other than
carbon and the last two digits indicate .20 carbon content.
The following shows some of the AISI SAE series designations of steel with xx representing
the range of carbon content for the group.
145
SERIES DESIGNATION TYPE OF STEEL
Carbon Steels
10xx Plain Carbon
11xx Machining Resulferized
12xx Machining Resulferized Phospherized
Manganese Steels
13xx Manganese 1.75
Nickel Steels
31xx Nickel 3.5
25xx Nickel 5.0
Nickel Chromium Steels
31xx Nickel 1.25 Chromium 0.60
Molybdenum Steels
40xx Molybdenum Carbon
41xx Molybdenum Chromium
43xx Molybdenum Nickel Chromium
Nickel Chromium Molybdenum Steels
43xx Nickel Chromium Molybdenum
Nickel Molybdenum Steels
46xx Nickel Molybdenum
48xx Nickel Molybdenum
Chromium Steels
50xx Chromium
51xx Chromium
As shown by the above chart the first group of steels are the Carbon steels. The other
groups of steels have additional elements ( alloys) added to enhance their properties in
some specific way.
HOW DOES THE ADDITIONAL ELEMENTS IN THE ABOVE CHART AFFECT THE
STEEL AND WELDABILITY?
Low alloy steels are Carbon steels that have additional elements added (alloyed) to produce
a classification of steel that has a specific benefit for production use. Although Carbon is
the main alloy that affects hardenability and weldability other elements also harden steel
and play a role in the weldability of steel. For example Manganese and Molybdenum aid in
hardening steels. For this reason a formula may be applied to a classification of steel to
roughly determine the hardenability and hence the weldability and need for pre-heating.
One example of a formula is shown below.
Carbon equivalent for alloy steels
CE = % C + %Mn + Ni + Cr + Mo + V
146
6 15 6 4 5
CE = Carbon Equivalent
C = Carbon
Mn = Manganese
Ni = Nickel
Cr = Chromium
Mo = Molybdenum
V = Vanadium
Manganese
Manganese is used to harden steels and increase its toughness and strength. High
manganese content coupled with increased carbon content lowers the ductility and
weldability. Consideration of preheat and or postheat techniques usually apply.
Molybdenum
May be used in conjunction with other elements to aid in hardening and provide steel with
good strength at elevated temperatures. Preheating may be required for welding and they
are often heat treated after welding.
Nickel
Nickel may be used to Increase toughness and impact strength and improve corrosion
resistance. Good strength and ductility may be obtained even with lower carbon content.
Depending on the amount added special procedures may be necessary when welding.
Chromium
Chromium helps improve the hardenability of steels and improves wear resistance, heat
resistance, and corrosion resistance. Depending on the amount added special procedures
may be necessary when welding.
Chromium and Chromium Nickel are used in the production of Stainless Steel.
The Strength and Mechanical properties of carbon and alloy steels may be changed or
shaped for a specific application by heat treating in furnaces or ovens. When two pieces of
metal are welded using any of the commonly used arc welding processes: Stick, Mig, Or
Tig the metals and filler are heated to the melting temperature under the arc and allowed
to solidify to form the weld.
HOW DOES THE WELDER KNOW HOW TO WELD A GIVEN STEEL STRUCTURE?
The best way for a welder to know how to weld a particular steel or steel classification is
through the use of a Welding Procedure Specification (WPS). A WPS is a written set of
147
instructions (specifications) detailing the welding procedure, joint preparation, filler metal,
current type and range as well as any required preheat, interpass temperature controls and
postheat treatments. Whenever possible welders request and use a Welding Procedure
Specification for the type and grade of metal they are welding.
A welding Procedure Specification is developed by engineering or inspection personnel
using qualified welders to weld a specific type of metal and joint configuration that will be
used on the job, while recording the welding parameters and variables. The completed
joint is then tested in accordance with a specific Code or Standard. The resulting
information is written on a form called a Procedure Qualification Record. The information
from the Welding Procedure Qualification Record is used to write the Welding
specification and as long as the procedure is carefully followed the resulting welded
products will have the required strength characteristics.
Some companies that do not have a formal Welding Specification have through practical
experience developed a set of instructions that the welder must follow to successfully weld
the given project.
If no Welding Procedure is provided at a minimum the welder MUST know what the base
metal is and find out if special precautions are necessary for welding.
There should always be some method of traceability for metals used to fabricate parts.
Metals sections and shapes should be stamped color coded or made from known materials.
There are ways to test unknown metals through appearance, magnetic properties or spark
testing; however, these test are subjective and may not be reliable for all cases. When you
can trace the material through purchase orders or metal identification you know or can
find out how to weld it.
WHAT IS THE HEAT AFFECTED ZONE AND HOW DOES IT AFFECT

WELDABILITY?
The heating and cooling action that occurs when welding is a form of heat treating in the
localized area of the puddle and weld joint that may result in changes to the mechanical
properties of the base metal and surrounding area. The area most affected by heating and
cooling during welding is called the HEAT AFFECTED ZONE (HAZ)
THE HEAT AFFECTED ZONE
The heating and cooling rate of welding directly under the arc is from the melting
temperature to normal temperatures and may occur relatively quickly or methods may be
used to slow the cooling rate of the joint. These methods include postheating the weld area
with an oxy-fuel torch, blanketing the weld area, or using a precise heating and cooling
method in a furnace or industrial setting.
The more expensive and precise method of using a furnace under controlled conditions
restores the mechanical properties of the weld joint and the surrounding base metal.
The area surrounding the joint is heated to various temperatures depending on the
distance from the arc, the heat input of the process and the number of weld passes. This
area is referred to as the Heat Affected Zone.
148
The grains structure in the melted weld area may form a desirable size and shape, while
the grain structure of the surrounding heat affected area may change to a less desirable
shape and size and may cause cracking when welding on medium or high carbon steels.
Often when welding a hardenable steel the heat affected area can harden to undesirable
levels, while welding an already hardened steel may result in a softened heat affected zone
with loss of desired hardness.
The heat affected zone may also have locked in stresses that can lead to problems when the
welded structure is in service. Some industries employ a heat treating process called stress
relieving to relieve residual stresses due to working or welding the structure.
It is imperative to use the correct electrode for the application so that weld metal is
compatible with the base metal and fewer changes occur due to the carbon or alloy content
of the filler wire. Electrodes are available for welding tool steels and Cast iron.
When welding thick sections, medium carbon, high carbon, and high alloy steels check the
recommended procedures for control of the heating and cooling rate
There are heat treating options such as annealing or normalizing that may be used to
restore the grain structure of the welded piece.
When welding low carbon, mild steels and most low alloy steels the heat affected area does
not change the properties of the metal enough to become a problem regardless of the
cooling rate.
The heating and cooling that occurs in the heat affected area and surrounding metal may
also lead to heat distortion of the parts being joined.
Procedures may be used before, during, and after welding to minimize distortion.
WHAT IS HEAT DISTORTION?
Steel when heated increases in length, width, and thickness. The increase in unit length
when a metal is heated one degree is called its coefficient of thermal expansion. I f a small
149
square block of steel were heated evenly under ideal conditions it would expand with the
heat and contract when cooling relatively evenly. When welding a piece of steel only the
joint and surrounding area is heated and cooled. This cause uneven expansion and cooling
and the piece begins to warp or distort. Uncontrolled Distortion may lead to a serious
dimensional defect or lead to failure of the part. Steps may be taken before, during, and
after welding to minimize or control the effects of heat distortion.
WHAT ARE SOME OF THE THINGS A WELDER CAN DO BEFORE WELDING TO

LIMIT HEAT DISTORTION?
Joint Preparation
The joint should be planned and prepared to limit the amount of weld and weld passes. For
example: Wide angle V grooves welded from one side would distort more than double V
grooves welded from both sides.
Select the proper Equipment
Higher welding speeds using iron powder electrodes (E-7018) and larger diameters may
reduce the amount and effect of heat distortion. Semi-automatic and fully automatic
welding processes limit the heat input and distortion.
Use Clamps Jigs and Fixtures

Jigs and fixtures with clamps hold parts in alignment and reduce the free movement of
parts from heat expansion. The clamps are left in place until the parts are welded and
cooled. In addition to clamps pieces called stiffeners may be temporarily added to areas
that tend to distort and removed when the part cools.
WHAT ARE SOME OF THE THINGS A WELDER CAN DO DURING WELDING TO

LIMIT HEAT DISTORTION?
Sequencing Welding
Use a skip or backstep method of welding to distribute the heat around the joint. This
involves making shorter welds at different locations of the joint then joining them together.
150
Welding the joint
If possible two welders weld opposite sides of the joint at the same time.
Use the smallest size fillet welds practical to reduce heat input.
If solid welding is not necessary for strength use intermittent welding and stagger the
sequence.
Weld flat or horizontal positions with larger size electrodes that allow for more weld
deposit at faster speeds whenever practical. Vertical positions and multiple pass welds
result in more heat input.
CONTROL OF DISTORTION AFTER WELDING
Distortion is more difficult to control after welding. Techniques like alternating heating
and cooling to remove warpage called straightening require a degree of skill and practice.
Postheating to remove stresses and warpage in controlled environments such as
151
normalizing and annealing, often involving the use of furnaces is usually done by qualified
personnel.
SUMMARY
Although the vast majority of carbon steels used in fabricating parts are mild steel or low
carbon and presents little difficulty in welding, some carbon steels that have more carbon
such as tool steels, high alloy steels and cast Iron require special procedures to prevent
cracking and weld failure. The welder should know the type of steel he is asked to weld to
prevent problems that may lead to questions of his or her ability. If you are unsure ask
questions and research the type of steel and its weldability.
152
SUPPLEMENTAL INFORMATION 2
PIPE WELDING
Welding pipe is like welding any other structural shape and welding can take place in any
of the normal positions for welding. When welding pipe flanges and some joints
configurations the weld applied may be a fillet weld. When welding pipe to pipe the joint is
similar to a vee groove and is often open root. Welding pipe to pipe requires a higher
degree of skill and is the topic of this supplement.
The pipe welding positions covered are the 1G flat and rolled position, the 2G horizontal
position, the 5G vertical position and the 6G fixed position as shown below.
PIPE WELDING EDGE PREPERATION
153
The pipe coupons for welding are cut using the pipe beveling machine. The slag is removed
and the edges are ground smooth for welding a 1/8 landing or flat is applied to the pipe.
The pictures below show the pipe beveling machine and the edge preparation.
154
PIPE ASSEMBLY
The pipe is assembled for welding by placing one piece on top of the other with a 1/8
electrode without flux on it between the pipe.
It is extremely important to set up and tack weld the pipe properly, if the pipe is not
aligned on the inside it is difficult to obtain the proper penetration through the pipe.
The root gap around the pipe must be consistent. If part of the root gap is too wide the key
hole will open up too much while welding and instead of penetration you may have burn
through (more than 1/8 reinforcement) on the inside. If part of the root gap is too narrow
you may not be able to penetrate through the pipe in those areas.
At least 4 tack welds should be placed around the pipe at 12 o’clock 6 o’clock 3 o’clock and
9 o’clock.
The tacks must be strong enough to hold alignment while welding the root pass and should
penetrate enough to become a part of the root pass. When testing the tack may be removed
using a cutting wheel to get a consistent root weld around the joint.
The picture below shows the tacks in a flat position pipe.
155
Chill ring
For some applications a chill ring may be used instead of an open root. The chill ring works
like a backing bar in groove welding and becomes a part of the welded joint. When the chill
ring is used the root opening is determined by the pins on the chill ring. After tacking the
chill ring on the inside of the pipe, the pins are removed. If a chill ring is used the root pass
may be made using E-7018 since it is not necessary to penetrate through the pipe.
PIPE WELDING IN THE FLAT 1G POSITION
156
Pipe Welding in the flat position requires that the Welder make some adjustments to the
normal angles and length of the welds during welding. In the flat position with the pipe
being rolled or rotated the push travel angle works best. Shorter lengths of weld are used
so that you do not change your travel angle by stretching out of position. The pipe is then
rotated before continuing. Stringer beads are used to weld the root, fill passes and cover
pass on six inch schedule 80 pipe.
Technique for welding the 1 G Rolled Pipe

The root pass is made using the E-6010 Electrode to penetrate through the open root pipe.
Make sure the amperage (heat) is set correctly to open and maintain the keyhole where the
root is s good fit. Use scrap metal and weld in the flat position with the amperage on
approximately 100 and adjust the heat as necessary.
The root pass should be flat to convex in appearance on the groove side of the pipe with no
holes and should be flush to 1/8 maximum reinforcement on the inside of the pipe.
157
After completing the root pass and evaluating the penetration, grind the groove side of the
weld in preparation for the fill passes.
Set the amperage for the E-7018 1/8 Electrode at approximately 120-150 amps to weld the
fill passes and the cover passes. Use the stringer bead technique for welding the fill passes
and cover passes.
158
PIPE WELDING IN THE 2G HORIZONTAL POSITION
When welding in the 2g pipe position the pipe is vertical and the weld is horizontal. The
pipe is not moved during welding and the welder must move around the fixed position pipe.
The preparation and amperage setting should be the same as for the flat position pipe with
E-6010 Electrodes used for the root and E-7018 Electrodes used for the fill and cover
passes. It is important to layer the fill passes and cover passes from the bottom pipe up to
the top pipe, while keeping the weld beads straight and properly overlapped.
159
160
PIPE WELDING IN THE VERTICAL 5G POSITION
In the 5G pipe position the pipe is horizontal and the weld axis is vertical so that the
welding is essentially a vertical weld. When welding some pipes for low pressure
applications or small diameter pipe it may be acceptable to weld vertical downward with
an electrodes like the E6010 however; most pipes are welded vertical upward with an E-
6010 root pass and E-7018 fill and cap.
When welding in the 5G pipe position the weld beads may be either stringers or weaves
depending on the job requirements.
At the Delta School Of Trades we use the E-6010 electrode for the open root pass and E-
7018 for the fill and cover passes using the vertical upward weave technique.
TECHNIQUE FOR VERTICAL 5G PIPE WELDING
AS always make sure the correct amperage is set for tacking the pieces and the root pass
using E-6010 electrodes. Check the machine setting and use an amperage from 90-110.
Use E-7018 for the fill passes and cover pass set at approximately 120-150 Amps.
Use a slight U shape technique with the E-6010 electrode to open and maintain the keyhole.
It may be necessary to ride up very slightly on the inside edge of the groove to chill the
keyhole if it opens up too much. If the keyhole is too tight, slow down and force it open with
the electrode while welding or stop and increase the amperage (heat).
Use a Z motion weave with the E-7018 Electrode keeping the ripples close together and the
weld profile flat for the fill and cover passes.
161
VERTICAL UPWARD WEAVES FOR 5G PIPE
Stringer Weaves may also be used to weld the fill passes and cover passes. This is an
important technique to learn in preparation for welding in the 6G position
PIPE WELDING IN THE 6G FIXED POSITION
In the 6G Pipe welding position the pipe is set on a 45 degree inclined angle.
The weld in this position covers all position welding because the bottom of the
pipe is an overhead weld; the top of the pipe is a flat weld and the front and
back sides are a vertical upward weld. The pipe is welded using stringer beads
except that a slight weave motion must be used to prevent the sides or vertical
upward part from sagging and lumping up in the middle of the weld bead.
162
The Electrode angle should remain the same for all passes. Use a slight push angle from
bottom to top.
CRITICAL ELEMENTS FOR WELDING THE 6G FIXED PIPE
As for all pipe welding take the time to set up the pipe properly with a consistent root gap
and 4 evenly spaced tacks.
Make sure you have set the correct amperage for the electrode type and size as mentioned
earlier.
After running the root, grind the root pass lightly before starting with the E-7018
Electrode.
Remember to use a slight weave motion with the E-7018 to prevent the weld lumping in the
middle and to get proper fusion.
Each filler pass should overlap the prior pass without leaving a depression (called wagon
tracks) and should show good fusion.
163
The 6G pipe position is the one used extensively for testing, since it qualifies the welder for
all position welding of pipe, grooves, and fillets.
When testing; it is advisable to remove the tacks instead of weld over them to ensure
penetration at the root. A wire wheel brush and grinder may be used to keep each pass
clean and prevent slag inclusions.
Although there are many Codes and Standards that govern the welding and testing of Pipe,
the one most widely used and recommended at the school is the AWS D1.1 Structural
Welding Code.
The test for SMAW is usually a 6 inch schedule 80 pipe with an open root, and is welded in
the 6G position. This test qualifies the welder for welding fillets grooves and pipe in all
positions. Also qualifies the welder for pipe sizes from 4 inches to unlimited and wall
thickness from 3/16 inch to unlimited.
An optional SMAW test on 4 inch schedule 40 pipe in the 6G position qualifies the welder
for all positions welding and pipe sizes from 3/4 to 4 inch with wall thickness from 1/8 to
3/4.
The pipe size recommended for GTAW Certification is the 4 inch sch 40 pipe.
164

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DELTA SCHOOL OF TRADES

5418 PULASKI HIGHWAY

DELTA SCHOOL OF TRADES

THIS TEXT WRITTEN AND PUBLISHED BY;

First printing January 2000

SAFETY FOR WELDING

STUDENTS WILL BE ABLE TO:

CLOTHING FOR WELDING

WELDERS UNIFORM FOR DELTA SCHOOL OF TRADES

1. THE WELDING HELMET

1. THE WELDING HELMET

2. LEATHER WELDING GLOVES

3. LEATHER JACKET, OR CAPE SLEEVES AND BIB

Note: the bib may be sold separately

IT IS CRUCIAL TO WEAR SAFETY GLASSES WHEN WELDING

WELDER AND EQUIPMENT

SAFETY IN THE WELDING FIELD

Never drape the welding cable over your body to weld.

SHOP AND WELDING ENVIRONMENT SAFETY

Welding curtains may be used to contain welding activities.

The following suggestions apply to hand grinders:

• Never use a grinder that has bare wires or a damaged cord.

SAFETY FOR WELDING

SHIELDED METAL ARC WELDING

SHIELDED METAL ARC WELDING

STUDENTS WILL BE ABLE TO:

1. Describe the Shielded metal arc welding (stick) process.

THE ELECTRICAL CIRCUIT FOR WELDING

TYPES OF WELDING MACHINES

LINCOLN AC 225 AMPS

TRANSFORMER RECTIFIERS MACHINE

LINCOLN IDEALARC AC DC 250 AMPS

MILLER MULTI – PROCESS MACHINE

LICOLN INVERTEC 250 AMPS

LINCOLN INVERTEC V250-S CONTROLS

(1) ON OFF SWITCH

(2) THE NEGATIVE AND POSITIVE TERMINALS

(3) RUNNING LIGHT OR PILOT LIGHT

(4) HOT START

(6) ARC FORCE

(7) GTAW SMAW SETTING

(8) THE REMOTE CONTROL

(9) REMOTE RECEPTACLE

MILLER DIMENSION 400 MULTI-PROCESS WELDING MACHINE CONTROLS

(1) START SWITCH

(2) RUNNING LIGHT

(3) STOP SWITCH

(5) ARC CONTROL

(6) AMPERAGE CONTROL

(7) REMOTE CONTROL SWITCH

(8) AMPERAGE METER

(9) VOLTAGE METER

(10) THE REMOTE CONTACT SWITCH

USE ALTERNATING CURRENT (AC)

WORKING WITH THE GROUND CLAMP

WELDING THE ONE INCH VEE GROOVE

THE FIVE ESSENTIAL VARIABLES OF SMAW

THE FIVE ESSENTIAL VARIABLES OF SMAW

STUDENTS WILL BE ABLE TO:

The chart below shows typical amperage ranges

Amperage may be referred to as the heat by some welders.

1. Run a practice weld at the lower recommended range setting.

The chart below gives an idea of the evaluation process;

KEY POINT: A discontinuity is defined as; an irregularity or imperfection in the appearance of