SMAW Welding Techniques

1. SMAW Welding Techniques

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

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

4. Fill Pass Cover Pass Root Pass Hot Pass

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

6. Progression (vertical) • 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

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

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

9. Horizontal • Fillet/Groove - stringers (small weave may be used in tight place) • Bead Placement - bottom to top

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

11. Overhead • 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

12. Dimensions • Reinforcement -ASME flush 1/16 AWS flush 1/8 discuss keyholeing, 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

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

14. Open Root Technique • 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.

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

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

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

19. 700 300 450 Electrode Work Angles

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

21. Transverse Angle Effects

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

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. SMAWPipe WeldingTechniques

27. Positions • 1G • 2G • 5G • 6G • 1F • 2F • 2FR • 4F • 5F

28. 1G Position Pipe rotated, Electrode is always at the top Either a split bead or weave technique may be used

29. 2G Position Pipe Axis Vertical, Weld is Horizontal, Pipe is considered in a “fixed” position. Always use a split bead technique Always work from the bottom up.

30. 5G Position Axis of the Pipe is Horizontal, The weld in vertical. Progression may be up or down. A weave bead is best used.

31. 6G Position Pipe axis is fixed in position at a 45 degree incline. Thhe position includes flat, horizontal, vertical, and overhead welds. A split bead tecvhnique is best used.

32. 1F Position Pipe is rotated. The pipe axis is at a 45 degree incline. Welding is to occur at the top of the pipe. Split bead or weave technique may be used.

33. 2F Position Fixed Position Best to use a split bead technique

34. 2FR Position A split bead technique is best used. Rotated

35. 4F Position A split bead technique is best used

36. 5F Position Not Rotated. Progression may be up or down. Split beads or weaves can be used on 5F-up welds, split beads are best used on 5F-down welds.

37. Fill Pass Cover Pass Root Pass Hot Pass

38. Always work from the bottom up when using the split bead technique Always be careful not to create a tight area where slag may get trapped under the next weld. It is better to weave slightly than to leave a tight area. Plan your sequence of beads!

39. Always work toward the smaller side of the fillet. (It will be easier to get to) Always be careful not to create a tight area where slag may get trapped under the next weld. It is better to weave slightly than to leave a tight area. Plan your sequence of beads!

40. Techniques • Stringer (push, drag, or whip), or Weave

41. Progression (vertical) • 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 drag angle

42. Travel Speed • Stay on the leading edge of the puddle

43. Keyholeing

44. Root Openings • Small will allow more amperage which will in turn make welding smoother and easier, as well as easier arc starts. • Larger root openings will allow more penetration.

45. Root Faces • Larger root faces will allow more amperage which will in turn make welding smoother and easier, as well as easier arc starts. • Smaller root faces will allow more penetration.

46. Tacking, Tack Grinding • 3/4” long • feather both ends • clean and flatten tops • start on top, burn through before end • run completely onto tack before stopping • grind lumps off before next pass • stagger all starts and stops between passes • stagger all starts and stops between beads in a single pass • Don’t overgrind tacks.

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

48. 1/16-1/8 Butt Joint Preperation (Joints without backing) 600 included angle Root faces Tacking Feather Tacks

49. Open Root Technique • 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.

50. Restarts • Stagger all starts and stops or use runon, runoff tabs • Feather all restarts & start on top, or start in front and remelt • Also stagger all beads on a single pass. • Use a longer arc length when starting a weld.