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Guidelines For
Shielded Metal Arc
Welding (SMAW)
WARNING
This document contains general information about the topics discussed herein.
This document is not an application manual and does not contain a complete
statement of all factors pertaining to those topics.
This installation, operation, and maintenance of arc welding equipment and the
employment of procedures described in this document should be conducted
only by qualified persons in accordance with applicable codes, safe practices,
and manufacturer's instructions.
Always be certain that work areas are clean and safe and that proper ventilation
is used. Misuse of equipment, and failure to observe applicable codes and safe
practices, can result in serious personal injury and property damage.
155 095 A
July 2005
Processes
Stick (SMAW) Welding
ARC WELDING can be hazardous.
www.manaraa.com
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Summary of Contents for Miller Shielded Metal Arc Welding
- Page 1 155 095 A July 2005 Processes Stick (SMAW) Welding Guidelines For Shielded Metal Arc Welding (SMAW) WARNING ARC WELDING can be hazardous. This document contains general information about the topics discussed herein. This document is not an application manual and does not contain a complete statement of all factors pertaining to those topics.
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Page 2: Table Of Contents
..............SECTION 2 − PRINCIPLES OF SHIELDED METAL ARC WELDING (SMAW) . -
Page 3: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. - Page 4 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.
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Page 5: Additional Symbols For Installation, Operation, And Maintenance
D Read Owner’s Manual before using or servic- support unit. ing unit. D If using lift forks to move unit, be sure forks are D Use only genuine Miller/Hobart replacement long enough to extend beyond opposite side of parts. unit. -
Page 6: Principal Safety Standards
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11 ting of Containers and Piping, American Welding Society Standard... -
Page 7: Section 2 − Principles Of Shielded Metal Arc Welding (Smaw)
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 creat- ing the arc and provides the shielding gas and slag covering to protect the weld from contamination. -
Page 8: Section 3 − Shielded Metal Arc Welding (Smaw) Procedure
SECTION 3 − SHIELDED METAL ARC WELDING (SMAW) PROCEDURE 3-1. Typical Stick Welding Set-Up Y Welding current starts as soon as electrode touches the workpiece. Workpiece Make sure workpiece is clean before welding. Work Clamp Place as close to the weld as possible. -
Page 9: Electrode And Amperage Selection Chart
3-2. Electrode And Amperage Selection Chart 3/32 6010 5/32 & 3/16 6011 7/32 1/16 5/64 3/32 6013 5/32 3/16 7/32 3/32 5/32 7014 3/16 7/32 3/32 5/32 7018 3/16 7/32 3/32 5/32 7024 3/16 7/32 3/32 Ni-Cl 5/32 3/16 3/32 308L 5/32 6010... -
Page 10: Striking An Arc − Scratch Start Technique
3-3. Striking An Arc − Scratch Start Technique Y Welding current starts as soon as electrode touches the workpiece. The scratch-start technique is preferred for ac welding. Electrode Workpiece Drag electrode across workpiece like striking a match; immediately lift electrode slightly after touching work. -
Page 11: Positioning Electrode Holder
3-5. Positioning Electrode Holder After learning to start and hold an arc, practice running beads of weld Groove Welds metal on flat plates using a full elec- trode. Hold the electrode nearly perpen- dicular to the work, although tilting it ahead (in the direction of travel) °... -
Page 12: Electrode Movement During Welding
3-6. Electrode Movement During Welding A single stringer bead is satisfac- tory 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. Stringer Bead − Steady Move- ment Along Seam Weave Bead −... -
Page 13: Conditions That Affect Weld Bead Shape
3-7. Conditions That Affect Weld Bead Shape IMPORTANT: Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Electrode Angle Correct Angle ° - ° Drag Angle Too Small Angle Too Large Arc Length Spatter Normal Too Long... -
Page 14: Poor Weld Bead Characteristics
3-8. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration S-0053-A 3-9. Good Weld Bead Characteristics Fine Spatter Uniform Bead Moderate Crater During Welding Weld a new bead or layer for each 1/8 in (3.2 mm) thickness in metals being welded. -
Page 15: Typical Weld Joints
3-10. Typical Weld Joints Butt Joint Butt Joint Lap Joint Tee Joint Lap Joint Tee Joint Flat Position Welds Horizontal Position Welds Butt Joint Butt Joint Lap Joint Tee Joint Lap Joint Tee Joint Vertical Position Welds Overhead Position Welds 804 248 155 095 Page 13 www.manaraa.com... -
Page 16: Welding Butt Joints
3-11. Welding Butt Joints Types Of Butt Joint Welds Tack Welds Prevent butt joint distortion by tack weld- ing 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”... -
Page 17: Welding Tee Joints
3-12. Welding Tee Joints Electrode 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. ° For maximum strength weld both Or Less sides of upright section. -
Page 18: Welding Horizontal Beads And Butt Joints
3-14. Welding Horizontal Beads And Butt Joints Single Pass Bead Weld When welding horizontally, gravity may distort the mol- ten metal. Tilt Electrode 15° This technique is not Toward Direction suitable for all electrodes. Of Welding. Direction Of Welding 90° Electrode Backing Strip Bevel edges if warranted by ma-... -
Page 19: Welding Vertical Beads And Butt Joints
3-15. Welding Vertical Beads And Butt Joints Single Pass Bead Weld When welding vertically, gravity may distort the mol- ten metal. 1/2 in This technique is not (12 mm) 90° suitable for all electrodes. Electrode Whipping Up Motion Backing Strip Weld vertically by carrying the weld upward or starting at the top Weave Bead... -
Page 20: Welding Vertical Tee Joints And Lap Joints
3-16. Welding Vertical Tee Joints And Lap Joints When welding vertically, Tee Joint Weld gravity may distort the mol- 90° ten metal. This technique is not suitable for all electrodes. For maximum strength, weld both sides of joint. Arrows Show Lifting Up Of Electrode And Return To Crater. -
Page 21: Welding Overhead Butt Joints And Tee Joints
3-17. Welding Overhead Butt Joints And Tee Joints Butt Joint Weld When welding overhead, gravity may distort the mol- ten metal. This technique is not suitable for all electrodes. Electrode 90° Backing Strip 90° Welding overhead is the most dif- Direction Of ficult welding skill to master. -
Page 22: Weld Test
3-18. Weld Test Vise Weld Joint 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 de- termine the cause. If the weld is porous (many holes), the arc length was probably too long. -
Page 23: Excessive Spatter
4-2. Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. Possible Causes Corrective Actions Amperage too high for Decrease amperage or select larger electrode. electrode. Arc length too long or voltage Reduce arc length or voltage. -
Page 24: Excessive Penetration
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 −... - Page 25 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)
- Page 26 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. www.manaraa.com...
- Page 27 Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org www.manaraa.com...
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