Miler Guide for Smaw New

8/10/2019 Miler Guide for Smaw New

1/34

155 095 B

201002

Processes

Stick (SMAW) Welding

Guidelines ForShielded Metal ArcWelding (SMAW)

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3-1. T!ical Stick Welding Set-"! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

#

3-2. $lectrode And A%!erage Selection &'art . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Striking An Arc Scratc' Start Tec'niue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*

3-+. Striking An Arc Ta!!ing Tec'niue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*

3-,. ositioning $lectrode older . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . /3-#. $lectrode Moe%ent uring Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

3-. &onditions T'at Aect Weld ead S'a!e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

3-*. oor Weld ead &'aracteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

3-/. 4ood Weld ead &'aracteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

3-10. T!ical Weld 5oints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

3-11. Welding utt 5oints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1+

3-12. Welding Tee 5oints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1,

3-13. Welding 6a! 5oints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1,

3-1+. Welding ori7ontal eads And utt 5oints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1#

3-1,. Welding Vertical eads And utt 5oints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

3-1#. Welding Vertical Tee 5oints And 6a! 5oints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1*

3-1. Welding 8er'ead utt 5oints And Tee 5oints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1/

3-1*. Weld Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

S!"#$%& ' W!$&G #*%+B!S,%%#$&G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-0

+-1. orosit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

+-2. $9cessie S!atter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

+-3. :nco%!lete ;usion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

+-+. 6ack 8 enetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

+-,. $9cessie enetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

+-#. urn-T'roug' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

+-. Wainess 8 ead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

+-*. istortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

#AB! %F "%!S

S!"#$%& 1 SAF!# P*!"A+#$%&S / *!A B!F%*! +S$&G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. S%bol "sage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1-2. Arc Welding a7ards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-3. Additional S%bols ;or :nstallation< 8!eration< AndMaintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-+. &aliornia ro!osition #, Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-,. rinci!al SaetStandards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .+

1-#. $M; :nor%ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .+

S!"#$%& - P*$&"$P!S %F S,$!! M!#A A*" W!$&G (SMAW) . . . . . . . . . . . . . . . . . . . . . . . . . 5

S!"#$%& S,$!! M!#A A*" W!$&G (SMAW) P*%"!+*! . . . . . . . . . . . . . . . . . . . . . . . . . . . .


3/34

S!"#$%& 1 SAF!# P*!"A+#$%&S / *!A B!F%*! +S$&Gso% =200/0*

2

Protect 3oursel4 and others 4ro inur3 6 read and 4ollow these 7recautions.

1/1. S38ol +sage

A&G!* $ndicates a ha:ardous situation which; i4not a$6$&T?:& S8&@< M8V:4 A?TS< and 8T A?TS 'a7ards.&onsult s%- bols and related instructions below or necessaractions to aoid t'e 'a7ards.

1/-. Arc Welding ,a:ards

#he s38ols shown 8elow are used throughout thisanual to call attention to and identi43 7ossi8le ha:ards.

When 3ou see the s38ol; watch out; and 4ollow the relatedinstructions to a

isconnect in!ut !ower or sto! engine beore installing orsericing t'is eui!%ent. 6ockoutEtagout in!ut !ower according

to 8SA 2/ &;? 1/10.1+ (see Saet Standards).

ro!erl install and ground t'is eui!%ent according to its8wnerFs Manual and national< state< and local codes.

Alwas eri t'e su!!l ground c'eck and be sure t'atin!ut !ower cord ground wire is !ro!erl connected to groundter%inal in disconnect bo9 or t'at cord !lug is connected toa !ro!erl grounded rece!tacle outlet.

W'en %aking in!ut connections< attac' !ro!er groundingconduc- tor irst double-c'eck connections.

@ee! cords dr< ree o oil and grease< and !rotected ro% 'ot%etal and s!arks.

;reuentl ins!ect in!ut !ower cord or da%age or bare wiring re!lace cord i%%ediatel i da%aged bare wiring can kill.

Turn o all eui!%ent w'en not in use.

o not use worn< da%aged< undersi7ed< or !oorl s!liced cables.

o not dra!e cables oer our bod.

: eart' grounding o t'e work!iece is reuired< ground it

directl wit' a se!arate cable. o not touc' electrode i ou are in contact wit' t'e work.)

Batter3 7osts; terinals and related accessories containlead and lead co7ounds; cheicals ?nown to the

State o4 "ali4ornia to cause cancer and 8irth de4ectsor other re7roducti


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10/34

S!"#$%& - P*$&"$P!S %F S,$!! M!#A A*"W!$&G (SMAW)

S'ielded Metal Arc Welding (SMAW) or Stick welding is a !rocess w'ic' %elts and Goins %etals b 'eating t'e%wit' an arc between a coated %etal electrode and t'e work!iece. T'e electrode outer coating< called lu9< assists increat- ing t'e arc and !roides t'e s'ielding gas and slag coering to !rotect t'e weld ro% conta%ination. T'eelectrode core !roides %ost o t'e weld iller %etal.

W'en t'e electrode is %oed along t'e work!iece at t'e correct s!eed t'e %etal de!osits in a unior% laer calleda bead.

T'e Stick welding !ower source !roides constant current (&&) and %a be eit'er alternating current (A&) or directcurrent (&)< de!ending on t'e electrode being used. T'e best welding c'aracteristics are usuall obtained using& !ower sources.

T'e !ower in a welding circuit is %easured in oltage and current. T'e oltage (Volts) is goerned b t'e arc lengt'between t'e electrode and t'e work!iece and is inluenced b electrode dia%eter. &urrent is a %ore !ractical%easure o t'e !ower in a weld circuit and is %easured in a%!eres (A%!s).

T'e a%!erage needed to weld de!ends on electrode dia%eter< t'e si7e and t'ickness o t'e !ieces to be weldedue

Welding current starts assoon as electrode touchesthe wor?7iece.

+he scratch#start techni*ueis preferred for ac elding.

11 $lectrode

2 Work!iece

3 Arc

rag electrode across work!iecelike striking a %atc'D i%%ediatel litelectrode slig'tl ater touc'ingwork. : arc goes out< electrode waslited too 'ig'. : electrode sticks towork!iece< use a uick twist to reeit.

2

3

S-00+/

/'. Stri?ing An Arc #a77ing #echni>ue

Welding current starts assoon as electrode touchesthe wor?7iece.

1 $lectrode

2 Work!iece1

3 Arc

ring electrode straig't down towork!ieceD t'en lit slig'tl tostart arc. : arc goes out< electrodewas lited too 'ig'. : electrodesticks to work!iece< use a uicktwist to ree it.

2

3

S-00+/


14/34

/5. Positioning !lectrode ,older

Groo


15/34

/. !lectrode Mo


16/34


17/34

/2. "onditions #hat A44ect Weld Bead Sha7e

Weld -ead shape is affected -y electrode angle, arc length, tra$el speed, and thic&ness of -ase metal.

!lectrode Angle

&orrect Angle

10 - 30

Angle Too S%all rag Angle Too 6arge

Arc ength

S!atter

Too S'ort or%al Too 6ong

#ra


18/34

/. Poor Weld Bead "haracteristics

1 6arge S!atter e!osits

2 ?oug'< "neen ead

3 Slig't &rater uringWelding

+ ad 8erla!

, oor enetration

1

2 3 +

,

S-00,3-A

/9. Good Weld Bead "haracteristics

1 ;ine S!atter

2 "nior% ead3 Moderate &rater uring

Welding

+ o 8erla!

, 4ood enetration :nto aseMetal

1

2 3 + ,

S-00,2-


19/34

/10. #37ical Weld oints

4rooe (utt) 5oint 4rooe (utt) 5oint

6a! 5oint Tee 5oint 6a! 5oint Tee 5oint

Flat Position Welds ,ori:ontal Position Welds

4rooe (utt) 5oint 4rooe (utt) 5oint

6a! 5oint Tee 5oint 6a! 5oint Tee 5oint

ertical Position Welds %


20/34

/11. Welding Groo


21/34


22/34

/1-. Welding #ee oints

1

+,

2 8r 6ess

1 $lectrode

2 ;illet Weld

@ee! arc s'ort and %oe atdeinite rate o s!eed. oldelectrode as s'own to !roideusion into t'e corner. Suareedge o t'e weld surace.

;or %a9i%u% strengt' weld bot'

sides o u!rig't section.3 Multi-6aer e!osits

Weld a second laer w'en a'eai- er illet is needed. "se ano t'e weaing !atterns s'own inSection3-#. ?e%oe slag beore %akinganot'er weld !ass.

2

1

3S-00#0 E S-00,*-A E S-00#1

/1. Welding a7 oints

308r 6ess

1

1 $lectrode

2 Single-6aer ;illetWeld

Moe electrode in circular %otion.

3 Multi-6aer ;illetWeld

Weld a second laer w'en a'eai- er illet is needed. ?e%oeslag beore %aking anot'erweld !ass. Weld bot' sides o

Goint or %a9i- %u% strengt'.

2

Single-6aer ;illet Weld

308r 6ess

1

3

Multi-6aer ;illet Weld


23/34

/1'. Welding ,ori:ontal Beads And Groo


24/34

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tion

8

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tion8

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lding

irec

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8

We

lding

/15. Welding ertical Beads And Groo


25/34


26/34

irec

tion

8

We

lding

irec

tion

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We

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We

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lding

/1. Welding ertical #ee oints And a7 oints

#ee oint Weld/0

When elding$ertically, gra$ity maydistort the mol# ten metal.

+his techni*ue is notsuita-le for all electrodes.

;or %a9i%u% strengt'

Documents

Miler Guide for Smaw New