55 095 E 2013−07 Processes Stick (SMAW) Welding Guidelines For Shielded Metal Arc Welding (SMAW) Visit our website at www.MillerWelds.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 7 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. D Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1-5.
SECTION 2 − PRINCIPLES OF SHIELDED METAL ARC WELDING (SMAW) Shielded Metal Arc Welding (SMAW) or Stick welding is a process which melts and joins metals by heating them with an arc between a coated metal electrode and the workpiece. The electrode outer coating, called flux, assists in creating the arc and provides the shielding gas and slag covering to protect the weld from contamination. The electrode core provides most of the weld filler metal.
SECTION 3 − SHIELDED METAL ARC WELDING (SMAW) PROCEDURE 3-1. Typical Stick Welding Set-Up 5 ! Welding current starts as soon as electrode touches the workpiece. ! Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. . Always wear 4 2 1 appropriate personal protective clothing. Workpiece Make sure workpiece is clean before welding. 2 Work Clamp Place as close to the weld as possible.
6013 7014 7018 7024 Ni-Cl 308L DEEP ALL DEEP 6013 EP,EN ALL LOW GENERAL ALL MED SMOOTH, EASY, FAST USAGE PENETRATION ALL EP AC EP 6011 DC* 6010 ELECTRODE 450 400 350 300 AMPERAGE RANGE 250 200 150 POSITION 6010 & 6011 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 100 50 DIAMETER ELECTRODE 3-2.
3-3. Striking An Arc − Scratch Start Technique ! Welding current starts as soon as electrode touches the workpiece. . The scratch-start technique is preferred for ac welding. 1 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match; immediately lift electrode slightly after touching work. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it. 2 3 S-0049 3-4.
3-5. Positioning Electrode Holder After learning to start and hold an arc, practice running beads of weld metal on flat plates using a full electrode. Hold the electrode nearly perpendicular to the work, although tilting it ahead (in the direction of travel) will be helpful. . To produce the best results, hold a short arc, travel at a uniform speed, and feed the electrode downward at a constant rate as it melts.
3-6. Electrode Movement During Welding .A single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better. 1 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side To Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode. Limit weave width to a maximum of 2-1/2 times diameter of electrode.
3-7. Conditions That Affect Weld Bead Shape . Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal.
3-8. Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 1 2 4 3 5 S-0053-A 3-9.
3-10.
3-11. Welding Groove (Butt) Joints Types Of Groove (Butt) Joint Welds 1 Tack Welds Prevent butt joint distortion by tack welding the materials in position before final weld. Workpiece distortion occurs when heat is applied locally to a joint. One side of a metal plate will “curl” up toward the weld. Distortion will also cause the edges of a butt joint to pull together ahead of the electrode as the weld cools.
3-12. Welding Tee Joints 1 Electrode 2 Fillet Weld Keep arc short and move at definite rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface. 1 For maximum strength weld both sides of upright section. 2 45° Or Less 3 Multi-Layer Deposits Weld a second layer when a heavier fillet is needed. Use any of the weaving patterns shown in Section 3-6. Remove slag before making another weld pass. 2 1 3 S-0060 / S-0058-A / S-0061 3-13.
3-14. Welding Horizontal Beads And Groove (Butt) Joints . When welding horizontally, gravity may distort the molten metal. . This technique is not suitable for all electrodes. Single Pass Bead Weld Direction Of Welding Tilt Electrode 15° Toward Direction Of Welding. 1 1 Electrode 2 Backing Strip Bevel edges if warranted by material thickness (see Section 3-11). Tack weld a backing strip to the plates to make the first weld pass (root pass) easier.
3-15. Welding Vertical Beads And Groove (Butt) Joints . When welding vertically, gravity may distort the molten metal. Single Pass Bead Weld . This technique is not Whipping Up Motion Weave Bead 1/2 in. (12 mm) Wide Direction Of Welding 1/2 in (12 mm) Direction Of Welding suitable for all electrodes. 90° 1 1 Electrode 2 Backing Strip Weld vertically by carrying the weld upward or starting at the top and welding down. Welding upward is easier and is shown in these illustrations.
3-16. Welding Vertical Tee Joints And Lap Joints . When welding vertically, gravity may distort the molten metal. . This technique is not Tee Joint Weld suitable for all electrodes. 90° Direction Of Welding For maximum strength, weld both sides of joint. Arrows Show Lifting Up Of Electrode And Return To Crater. 90° First Weld Pass Shows Weaving Motion. Direction Of Welding Direction Of Welding Shows Weaving Motion.
3-17. Welding Overhead Groove (Butt) Joints And Tee Joints . When welding overhead, gravity may distort the molten metal. . This technique is not 2 Groove (Butt) Joint Weld suitable for all electrodes. 1 Electrode 2 Backing Strip Welding overhead is the most difficult welding skill to master. 90° When welding overhead, use a welding motion that draws arc out and slightly away from the crater to allow weld puddle to solidify.
3-18. Weld Test 1 Vise 2 Weld Joint 3 Hammer Strike the weld joint in the direction shown. A good weld bends over but does not break. If the weld breaks, examine it to determine the cause. If the weld is porous (many holes), the arc length was probably too long. If the weld contains bits of slag, the arc may have been too long or the electrode was moved incorrectly which allowed molten slag to be trapped in the weld.
4-2. Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. Possible Causes Amperage too high for electrode. Corrective Actions Decrease amperage or select larger electrode. Arc length too long or voltage Reduce arc length or voltage. too high. 4-3. Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input.
4-5. Excessive Penetration Excessive Penetration − weld metal melting through base metal and hanging underneath weld. Excessive Penetration Good Penetration Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Improper weld technique. Adjust travel speed. 4-6. Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Excessive heat input.
Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in.) 22 Gauge (.031 in.) 20 Gauge (.037 in.) 18 Gauge (.050 in.) 16 Gauge (.063 in.) 14 Gauge (.078 in.) 1/8 in. (.125 in.) 3/16 in. (.188 in.) 1/4 in. (.25 in.) 5/16 in. (.313 in.) 3/8 in. (.375 in.) 1/2 in. (.5 in.
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
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