Weave Patterns

Circular Pattern: Used for flat position welds on butt, tee,

outside corner joints and buildup or surfacing applications.

"C", Square Pattern: Good for most flat welds, but can be
used for vertical positions.

"J" Pattern: Works well on flat lap joints, and horizontal butt
and lap welds.

"T" Pattern: Works well with fillet welds in the vertical and
overhead position.

Straight Step Pattern: Used for stringer beads, root pass

welds, and multiple pass welds in all positions.

Figure 8, Zigzag: Used as cover passes in the flat and

vertical positions.
 SMAW welding techniques

1. SMAW Welding Techniques

2. Weld Bead  A weld resulting from a pass Stringer Bead Weave Bead

3.  Weld Pass - A single progression of welding along a joint. The result of a pass is
a weld bead or layer Passes

4. Root Pass Hot Pass Fill Pass Cover Pass

5.  Stringer (drag) (whip)  Weave  Circles  crescent  zig zag  box weave 
double J Techniques

6.  Up  deeper penetration  Higher deposit rate (lb/hr)  Use near 90 degree

travel angle or slightly up  Down  faster (point to point)  less penetration for thin
metal  less dilution  Use steep grag angle Progression (vertical)

7.  Stay on the leading edge of the puddle Travel Speed

8.  Fillet/Groove - stringer or weave, split bead or wide weave Flat Position

9.  Fillet/Groove - stringers (small weave may be used in tight place)  Bead

Placement - bottom to top Horizontal

10.  Fillet/Groove - weave (or whip but not straight stringers)  Root pass 6010
whip  Root pass 7018 straight stringer or weave (open closed) Vertical

11.  Same as horizontal for Fillets  6010 open root whip for flat face and keyhole
control  7018’s stringers  OH Butt Joints can be stringers or weaves Overhead

12.  Reinforcement -ASME flush 1/16 AWS flush 1/8 discuss key holeing, metallic
backing, nonmetallic backing, partial penetration, root openings, root faces, tacking,
tack grinding, fast freeze, and fill freeze  Fill -as many as needed 1/8 per pass flat
overload 3/16 vertical  Cover -flush 1/16 high, 1/16 past edge Dimensions

13. 600 included angle Root faces Tacking Feather Tacks Butt Joint Preperation 1/16-
1/8 (Joints without backing)

14.  Use root opening to allow increase in amperage for smoother welding  Whip
backwards for penetration  Whip forwards to reduce penetration  Do Not Weave a
root pass.  Maintain a short arc gap  Stay slightly in front of the puddle at all
times. Use the keyholing technique. Open Root Technique

15. Root faces - 0 450 included angle Remove all mill scales and rust Tacking - not in
groove Tack away from coupon area. Flush on backing Butt Joint Preperation (With
Backing)

16.  Keep the root opening wide  Make the root pass in one bead  Avoid tight
areas at the weld toes Welding grooves with Backing

17. Restarts •Stagger all starts and stops or use run-on, run-off tabs •Feather all
restarts & start on top, or start in front and remelt •Don’t restart in a coupon area.
•Also stagger all beads on a single pass. •Use a longer arc length when starting a weld.
Compare interpass grinding techniques vs. techniques for no interpass grinding.

18.  Fill craters by reversing direction at the weld end  Use a short arc length to
control heat. Craters

19. Electrode Work Angles 450 300 700

20.  middle of joint  directs heat between sides  may need to direct more on
heavy plate work angle (transverse angle)

21. Transverse Angle Effects

22. Drag Angle increases Penetration Increases crown height Push Angle gives
shallow penetration, and flattens out the weld surface. Electrode Travel Angles

23. Electrode (arc) Placement Current takes the path of least resistance. Therefore, the
arc, and resulting weld, will go where the electrode end is closest to, NOT
NECESSARILY IN THE DIRECTION THE ELECTRODE IS POINTING

24. Arc Length •Longer arc lengths = increased puddle heat, flatter welds, deeper
penetration •Shorter arc lengths = less puddle heat, flatter welds, less penetration •Use
arc length to control puddle size, penetration, and burn through. •Normal arc length is
1/16” - 1/8” •Use a slightly longer arc length during a start or restart.

25. Helpful Tips •Clean your Welding Hood lens •Drape the cable over your shoulder
or knee •Get Comfortable •Watch the puddle, not the arc •Concentrate on steady
travel speed and arc length

26. SMAW Machine Setup • DCEP (also called Direct Current Reverse Polarity) • 77
- 150 Amp Range • #5 fine amperage setting (approximately 110 amps) • Connect
work lead • Set for Constant Current (Variable Voltage)

27. Amperage Calculations Range: 77 - 150 Fine tune dial: 0 - 10 Desired amperage:
105 amps 150 - 77 = 73 73 / 10 = 7.3 7.3 x 6 = 43.8 43.8 + 77 = 120.8 150 - 77 = 73
73 / 10 = 7.3 105 - 77 = 28 28 / 7.3 = 3.836 Range: 77 - 150 fine tune dial: 0 - 10 dial
set at: 6

28. Do SMAW Pipe Welding Techniques Lecture Now

 Stick Welding Examples Diagram

Poor weld bead characteristics include large spatter deposits, use of the wrong arc,
higher/lower amperage levels than recommended and poor penetration.

Operation
Starting the Arc

Scratch Start Technique:

To strike the electric arc when starting a SMAW operation, the electrode is brought into contact with
the workpiece, dragged like lighting a match, and then pulled away slightly.If the arc lights and then
goes out, that means the electrode was pulled too far away from the base metal. If the electrode sticks
to the metal, give a twist and it should come free.

Tapping Technique:
Move the electrode straight down to the base metal. Then lift slightly. The arc should start. If the arc
goes out, that means it was lifted too high off the workpiece.

Five Steps To Improving Your Stick Welding

Technique
Print Article

Paying attention to the five basic elements of Stick welding technique—Current setting, Length of arc,
Angle of electrode, Manipulation of electrode and Speed of travel (CLAMS)—can significantly improve
your Stick welding results. This illustrated technical article provides five steps to improve your stick
welding technique, including helpful photographs demonstrating correct and incorrect Stick technique.
For many people, especially to those who are new to it or perhaps who don’t weld every day, Stick
(SMAW—shielded metal arc welding) is one of the more difficult processes to learn. Experienced welders
who can pick up a stinger, pop an electrode in and lay down great welds time after time can inspire great
awe in the rest of us. They make it look easy.

The rest of us may struggle with it, though. And we don’t have to, not if we pay attention to five basic
elements of our technique: Current setting, Length of arc, Angle of electrode, Manipulation of electrode
and Speed of travel—or CLAMS, for short. Properly addressing these five basic areas can improve your
results.

Prepare

While Stick welding may be the most forgiving process on dirty or rusty metal, don’t use that as an excuse
for not properly cleaning the material. Use a wire brush or grinder to remove dirt, grime or rust from the
area to be welded. If you don’t, you’re hurting your chances to make a good weld the first time. Unclean
conditions can lead to cracking, porosity, lack of fusion or inclusions. While you’re at it, make sure you
have a clean spot for the work clamp. A good, solid electrical connection is important to maintain arc
quality.

Then position yourself so you have good view of the weld puddle. For the best view, keep your head off to
the side and out of the smoke so you can be sure you’re welding in the joint and keeping the arc on the
leading edge of the puddle. Make sure your stance will allow you to comfortably support and manipulate
the electrode.

CLAMS

Bringing all the CLAMS points (Current setting, Length of arc, Angle of electrode, Manipulation of the
electrode, and Speed of travel) together may seem like a lot to think about while welding, but it becomes
second nature with practice. Don’t get discouraged! There is a learning curve with Stick welding, which
many believe got its name because when learning how to weld, everyone sticks the electrode to the
workpiece.

Current setting: The electrode you select will determine whether your machine should be set up in DC
positive, DC negative or AC. Make sure you have it set correctly for your application. (Electrode positive
provides about 10 percent more penetration at a given amperage than AC, while DC straight polarity,
electrode negative, welds thinner metals better.) The correct amperage setting primarily depends on the
diameter and type of electrode you select. The electrode manufacturer usually indicates the electrodes
operating ranges on the box or enclosed materials. Select your amperage based on the electrode (a
general rule of thumb is 1 amp for each .001 inch of electrode diameter, see FIG 1.) welding position
(about 15-percent less heat for overhead work compared to a flat weld), and visual inspection of the
finished weld. Adjust your welder by 5 to 10 amps at a time, until the ideal setting is reached.

FIG. 1. Unless the electrode manufacturer states otherwise, use 1 amp for each .001-in. of electrode
diameter. Here a 1/8-in. (.125 in.) electrode is used, so the operator starts at 125 amps. He’ll then adjust
in 5 to 10-amp increments, if necessary, to find the optimal setting for his technique and application.

If your amperage is too low, your electrode will be especially sticky when striking an arc, your arc will
keep going out while maintaining the correct arc length or the arc will stutter. (See FIG. 2)

[FIG 2] Too little current. If you’re welding with amperage set too low, your electrode will be especially
sticky when striking an arc, the arc will keep going out while maintaining the correct arc length or the arc
will stutter.

Once you get an arc going, if the puddle is excessively fluid and hard to control, your electrode chars
when it’s only half gone or the arc sounds louder than normal, your amperage might be set too high. Too
much heat can also negatively affect the electrode’s flux properties. (See FIG. 3)
[FIG 3.] Too much current. When the amperage is set too high, the puddle will be excessively fluid and
hard to control. This can lead to excess spatter and higher potential for undercut. In addition, the
electrode will become hot—perhaps hot enough to glow [See FIG. 3A.] toward the end of the weld—which
can adversely affect the shielding properties of the flux.

[FIG. 3A.] A sign of too much current is when the electrode becomes hot enough to glow.

Length of arc: The correct arc length varies with each electrode and application. As a good starting point,
arc length should not exceed the diameter of the metal portion (core) of the electrode, e.g. an 1/8-in. 6010
electrode is held about 1/8 in. off the base material.
[FIG. 4] Length of arc: The optimal arc length, or distance between electrode and puddle, is the same as
the diameter of the electrode (the actual metal part within the flux covering). Holding the electrode too
closely to the joint decreases welding voltage, which creates an erratic arc that may extinguish itself or
cause the electrode to freeze faster and produces a weld bead with a high crown. (See FIG. 5)

FIG. 5. An arc length that is too short will create greater potential for the electrode sticking to the base
material.

Excessively long arcs (too much voltage) produce spatter, low deposition rates, undercuts and often
leaves porosity. (See FIG. 6.)

FIG. 6. Too long of an arc length will create excess spatter in the weld joint. There is also a high potential
for undercut.

When first attempting to Stick weld, it seems natural to use too long of an arc, possibly to help get a better
view of the arc and puddle. If you have trouble seeing, move your head, don’t lengthen the arc. Start by
finding a good body position that gives you an adequate view of the puddle, while also allowing you to
stabilize and manipulate the electrode. A little practice will show you that a tight, controlled arc length
improves bead appearance, creates a narrower bead, and minimizes spatter.
Angle of travel: Stick welding in the flat, horizontal and overhead position uses a “drag” or “backhand”
welding technique. Hold the electrode perpendicular to the joint, and then tilt the top in the direction of
travel approximately 5 to 15 degrees. For welding vertical up, use a “push” or “forehand” technique and tilt
the top of the electrode 0 to 15 degrees away from the direction of travel. (See FIG. 7.)

FIG 7. Angle of travel. When welding from left to right, maintain a 0- to 15-degree angle tilted towards the
direction of travel. This is known as the “drag” or “backhand” technique.

Manipulation of Electrode: Each welder manipulates the electrode a little differently than the next.
Develop your own style by observing others, practicing and noting which techniques produce the best
results. Note that on material 1/4 in. and thinner, weaving the electrode is typically not necessary because
the bead will be wider than necessary. In many instances a straight bead is all that’s needed.

To create a wider bead on thicker material, manipulate the electrode from side to side, creating a
continuous series of partially overlapping circles in a “Z,” semi-circle or stutter-step pattern. Limit side-to-
side motion to 2_ times the diameter of the electrode core. To cover a wider area, make multiple passes
or use “stringer beads.”
FIG. 8. Here the welder uses a semi-circular motion to create a wider bead with a “stacked dimes”
appearance. For thinner welds, a straight line bead may be sufficient.

When welding vertical up, if you focus on welding the sides of the joint, the middle will take care of itself.
Move across the middle of the joint slowly enough so that the weld puddle can catch up, pause slightly at
the sides to ensure solid “tie-in” to the sidewall. If your weld looks like fish scales, you moved forward too
quickly and didn’t hold long enough on the sides.

Speed of travel: Your travel speed should allow you to keep the arc in the leading one-third of the weld
pool.

FIG 9.. To establish the optimal travel speed, first establish a weld puddle of the desired diameter, and
then move at a speed that keeps you in the leading one-third of the puddle. If you travel too slowly, the
heat will be directed into the puddle and not into the weld, leading to cold lap or poor fusion.

Traveling too slowly produces a wide, convex bead with shallow penetration and the possibility of “cold-
lapping,” where the weld appears to be simply sitting on the surface of the material. (See FIG. 10.)
FIG. 10. Too slow of a travel speed will create a bead that has too much weld deposit, which can lead to
“cold-lap.” This can result in insufficient penetration in those areas. Traveling too slowly can also focus the
heat into the puddle and not into the base material.

Excessively fast travel speeds also decrease penetration, create a narrower and/or highly crowned bead,
and possibly underfill or undercut, which is when the area outside of the weld is concave or recessed.
Note towards the end of the bead in FIG. 11 how the bead appears inconsistent as if the puddle were
trying to keep up. (See FIG 11.)

FIG. 11. Traveling too fast will create a thinner/undersized bead that will have more of a “V”- shaped
ripple effect in the puddle rather than a nice “U” shaped, or “stacked dimes” effect.

These tips, along with practice and patience, will get you headed in the right direction. For more welding
tips, visit MillerWelds.com.

- See more at: https://www.millerwelds.com/resources/article-library/five-steps-to-improving-your-stick-

welding-technique#sthash.jMXlKxTR.dpuf
 A B
AC or Alternating Current Electricity that reverses it's direction
of electron flow in regular intervals
Acetylene Gas composed to two parts carbon
and two parts hydogen, when burned
with oxygen, produces on of the
highest flame temperatures
obtainable
Acetylene Regulator Device used to control flow of
acetylene. Tegulartor reduces
acetylene cylinder pressures to torch
pressures and keeps pressures
constant
Actual Throat shortest distance from root of weld
to face of weld
Adhesion Act of sticking or clinging
Alloy Pure metal that has additional metal
or nonmetal elements added while
molton.
Ampere Unit of electrical current.
Arc Flow of electricity through gaseous
space or air gap
Arc blow wanderign of an electric arc from its
normal path due to magnetic forces
Axis of weld Imaginary line through the center of
the weld metal from the beginning to
end of weld
Backfire 'Pop' of torch flame followed by
extinguishing the flame or continued
burning of gases
Base Metal metal to be welded, cut or brazed
Bead appearance of the finished weld
Bevel angle cut on edge of base metal in
weld to create a groove
Buildup The amount that the weld face
extends above the surface of the
base metal
Butt Joint Two pieces are joined in the same
plane, with the edge of one touching
the edge of the other
Capillary Action Property of liquid to move into small
spaces if it has the abiity to 'wet'
those surfaces
Coalescence Intermixing or growing together of
materials into one body while being
welded
Cohesion Sticking together through attraction
of molecules
Concave weld face A weld with the center of its face
below the weld edges
Conductivity The ability of a conductor to carry a
current
Conductor Supstance capable of readily
transmitting electricity or heat
Cone Inner visible flame shape of a neutral
or nearly neutral flame
Convex weld A weld with the face above the weld
edges
Covered electrode Metal rod used in arc welding,
covering materials aid in arc welding
Crown The curved or convex surface of a
finished weld
DC or Direct Current Electric current that flows only in one
direction
Depth of fusion Depth to which base metal is melted
during welding
Diffusion Spreading of an element throughout
a gas, liquid, or solid, so that all of it
has the same composition
Discontinuity Any abrupt change or break (crack,
seams, laps, bumps or changes in
density) in the shape or structure of
a part. The usefulness of that part
may or may not be affected
Distortion Warping of a part of a structure
Drag The offset distance between the
 actual and theoretical exit points of
the cutting oxygen stream,
measured on the exit side of that
material
Ductility The ability of a material to be
changed in shape without cracking
or breaking
Edge joint A joint between the edges of two or
more parallel parts
Effective throat On a fillet weld: the least distance
from the root of a weld to the weld
face
Electrode Terminal point to which elecctricity
os brought in the welding operation
from which the arc is produced to do
the welding. Usually melted and
becomes part of the weld
Electron One of the fundamental parts of an
atom that has a small negative
electrical charge
Face of a weld Exposed surace of the weld
Feed rate Speed material moves through
welding gun in a unit of time (MIG)
Filler metal Metal added when making a welded,
brazed or soldered joint
Fillet weld Metal fused into a corner formed by
two pieces of metal which are about
90 degrees to each other
Filter plate Optical material that protects eyes
from ultraviolet, infrared and visible
radiation
Flash Impact of eletric arc rays against
himan eyes
Flashback burning ack of gases into oxyfuel gas
torch, hoses and possibly into
regulator and cylinder: VERY
DANGEROUS SITUATION
Flashback arrestor Check valve installed between torch
and welding hose to prevent flow of
burning gas and oxygen ack into
 hoses and regulators
Flay position weld Horizontal weld on upper side of a
horizontal surface
Flux Material used to prevent, dissolve, or
help remove oxides and other
undesirable surface substances
Front view The view on a working drawing that
shows the greatest amount of detail
about an object's shape and size
Fusion Intimate mizing or combining of
molten metals
Fusion Face The surface of the base metal which
is melted during welding
GMAW Arc welding using a continuously fed
comsumable electrode and a
shielding gas
GTAW Arc welding using electrode and a
shileding gas. The filler metal is
added using a welding rod
Groove joint Joint that has one or both edges cut
or machined to form a bevel. V, U, or
J groove
Heat conductivity speed and efficiency of heat energy
movement through a substance
Heat Molecular energy of motion
Helmet Protective hood that fits welder's
head with filtering lens through
which welder can see arc safely
Incomplete Fushion Less-than-complete fusion of weld
material with the ase metal or with
the preceding bead
Inert gas A gas which does not normally
combine chmically wiht the base
metal or filler metal
Interface Surface forms a common boundary
between two bodies
Joint Line or area where two peices are
joined in an assembly
Joint penetration Depth of weld metal and base metal
 fusion in welded joint
Lap Joint Joint in whcih the edges of the two
metal to be joined overlap
Neutral flame Flame resulting from combustion of
perfect proportions of oxygen and
welding gas.
Overhead position Weld made on the underside of joint
with the face of the weld in a
horizontal position
Penetration Extent to which the weld metal
combines with the base metal, as
measured from surface of the base
metal
Plasma Temporary physical condistion of a
gas after it has been exposed to and
has reacted to an extremely high
temperature
PAC Mettal cutting process that uses an
electric arc and fast flowing ionized
gases (plasma arc cutting)
Polarity Direction of flow of electrons in a
closed direct current welding circuit
Purging Passing the proper gas through a
system to ensure that there is no air
or fereign sustances in the system
Root of weld That part of the farthest from the
sources of weld heat and/or from the
side where filler metal is added
SMAW Arc weldig process that melts and
fuses metals using the heat of an arc
between a covered electrode and
base metal.
Short arc Arc process that uses a low voltage
Spray arc GMAW process with an arc voltage
high enough to continuously transfer
the electrode metal across the arc in
small globules
Tack weld Small weld used to temporarily hold
components together
T-Joint Joint formed by placing on metal
against another to form a T
Toe of weld Junction between the face of the
weld and the base metal
Undercut Depression at the toe of the weld
that is below the surface of the base
metal
Vertical Position Type of weld in which the welding is
done in a vertical seam on a vertical
surface

7 Effective Ways to Prevent Weld Undercutting

?

Undercut is an imperfection which is characterized by a groove formation at the weld toe

due to overheating at the free edges of base metal or weld metal (of previous run). This
happens when a welder tries to make weld either with high welding current or with fast
travel speed. Also the use of incorrect angle, directs the arc towards thinner edges where
overheating can burn the metal. See what are the angles which help to eliminate welding
defects? Moreover the incorrect usage of gas shielding, wrong welding technique and
position, are other primary causes of undercut imperfection.

Undercutting always has been a serious concern in steel welding industries and efforts have
been made to resolve this problem in recent years. Following are the preventions that
effectively assist, in reducing the concentration of undercutting in your weld.
1. Correct Heat Input
One of the major causes of undercut in weld, is high heat settings while making a run near
to the free edges. This may lead to the overheating and melting of near parent metal or
previous weld metal. In order to prevent this, one must take great care of weld heat by
reducing the current, when approaching to thinner and free edges.

2. Correct Electrode Angle

As we know welding angles always play a vital role in producing defects free runs. If one
makes a run with an incorrect angle which directs more heat to free edges, here in this case
weld is more prone to undercuts. For this one must use correct angles (lead, work,
electrode, travel, and slope) in order to direct more heat towards thicker components as
compared to the free edges.

3. Moderate Travel Pace

Making a weld with high travel pace, is another big cause of weld undercutting. In doing so,
some portion of parent metal is drained into the molten metal and never came back due to
fast solidification, leaving a depression along the edges. It is recommended to travel a weld
run with moderate pace because too slow travel also does not give satisfactory results.

4. Right Selection of Gas Shielding

In case of MAG (metal active gas) process, wrong selection of gas shielding is also one
major cause of undercuts in a weld. Welding associates must ensure the correct
composition of gas according to the requirement of material type and thickness. Use
of Carbon dioxide in conjunction with inert gases, provides quality results in welding of
carbon steels.

5. Correct welding Technique

Problem of undercut also arises when a welder endeavors to make a weld run with
excessive weaving style. Codes and standards call for the recommended width of weaving
according to the electrode size. Size of weaving should not be exceeded to acceptable limit,
otherwise weld may prone to undercut grooves. In order to prevent this one must endeavor
either to reduce the size of weaving or to produce weld with multipass technique.

6. Correct Welding position

Sometimes making a fillet weld in horizontal-vertical position, also results in weld undercuts.
In this case a depression is formed due to inadequate metal filling along the joint edges. In
order to prevent this, try to weld in flat position to ensure the adequate electrode
consumption.

7. Use of multi-run technique

This one is the best option to adopt, in order to reduce the level of undercuts in welding.
Multi-run technique supports all above mentioned preventions and helps to produce fine
welds with improved mechanical properties.