Training SMAW Module
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This document provides a training presentation on shielded metal arc welding (SMAW), also known as stick welding. It discusses electrode types E6013 and E7018, including their composition, properties and applications. It also covers topics like welding positions, defects, calculations, storage and techniques. The presentation aims to equip welders with knowledge on performing SMAW and passing certification tests for different welding positions.
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Pipe welding involves joining pipes together without fittings through various welding positions and techniques. It is more complicated than structural welding due to the cylindrical shape of pipes. There are four principal pipe welding positions defined by the orientation of the pipe: horizontal rolled (1G), vertical (2G), horizontal fixed (5G), and 45-degree inclined (6G). Additionally, there are restricted positions (R), fillet welds (F), and groove welds (G) used in pipe welding. Improperly executed pipe welds can lead to ultimate failure of the pipe at the welding point.
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2. The process uses the flux coating on the electrode to produce shielding gas and form slag.
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The document provides an overview and guide for teaching Shielded Metal Arc Welding (SMAW) including learning objectives, safety procedures, welding principles, equipment setup, the welding process, troubleshooting techniques, electrode classification, and sample lesson plans. Key topics covered include striking an arc, travel speed, arc length, filler metals, and the advantages and limitations of the SMAW process.
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Geometric imperfections and inclusions are two main categories of welding defects. Geometric imperfections include misalignment, overlap, undercutting, concave and convex welds, and cracking. Inclusions refer to slag, tungsten, sulfide and oxide materials becoming part of the weld. Other defects discussed include porosity, incomplete fusion, spatter, unacceptable weld profiles, lamellar tearing, and crater. The document emphasizes that welding defects can significantly impact weld performance and longevity, so detection techniques are important and defects detrimental to structural integrity should be repaired.
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- Files are made of hardened steel and have rows of teeth for shaping metal. They vary in shape, cut, and coarseness. Common types include flat, mill, square and round files.
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3. This module provides learning activities and information sheets to help students achieve the competency of striking an arc and depositing a straight bead when performing shielded metal arc welding on carbon steel plates.
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This document provides guidance on shielded metal arc welding (SMAW). It discusses several key considerations for SMAW including:
1. Proper preparation of the welding area by removing dirt and rust to avoid defects.
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3. Maintaining the proper arc length, which is less than the electrode diameter, and angle of the electrode for quality welds.
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Here are the key points about cutting tools:
- Hacksaw is used for cutting metals like plates, pipes, rods, and bars. It has an adjustable frame that holds replaceable blades with teeth.
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1. Welding is a method of joining two metals by applying heat to melt and fuse them.
2. Flux is a fusible material or gas used to dissolve and/or prevent the formation of oxides, nitrides or other undesirable inclusions formed in welding.
3. This module provides learning activities and information sheets to help students achieve the competency of striking an arc and depositing a straight bead when performing shielded metal arc welding on carbon steel plates.
Welding electrodes Classification & baking
An electrode is a coated metal wire used in welding. There are consumable electrodes that are consumed during welding like in stick welding, and non-consumable electrodes like in TIG welding. The numbers and letters on electrodes indicate properties like tensile strength and position used. Electrodes are classified as basic, cellulosic, rutile, or high iron powder based on coating composition and intended use. Basic electrodes require baking and provide high strength welds. Cellulosic electrodes do not require baking but produce higher hydrogen welds. Rutile electrodes are for general fabrication and baking is optional. Electrodes must be baked if exposed to air beyond specifications to remove moisture.
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II. FCAW uses a continuously fed consumable tubular electrode containing a flux along with a shielding gas or flux to protect the weld area. It can be performed manually or automatically in all positions and allows for higher deposition rates than SMAW.
III. The document outlines electrode types used, important process variables and discusses issues like
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This document provides information on occupational health and safety (OHS) procedures, practices, and regulations. It discusses defining roles and responsibilities, identifying workplace hazards and controls, educating and training workers, and documenting OHS activities. Key aspects of an OHS program include hazard identification and risk assessment, education and training requirements, and maintaining records of inspections, incidents, and other OHS-related documentation. The document also outlines emergency preparedness procedures such as developing emergency response plans, conducting drills, and ensuring all workers understand emergency protocols.
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The document discusses various welding processes. It defines welding as a process of joining metal pieces through significant diffusion when heated to melting point and fused together. The key welding processes discussed include arc welding, gas welding, resistance welding and their various methods. Arc welding generates heat from an electric arc between an electrode and workpiece. Gas welding uses a flame from fuel gas combustion. Resistance welding applies heat and pressure simultaneously to join metal pieces. Each process is described along with its applications and advantages.
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The document discusses various welding defects that can be visually detected, including cracks, lack of solid metal, lack of fusion, lack of smoothly blended surfaces, and miscellaneous defects. It provides details on different types of each defect, their causes, and methods for prevention. It also discusses welding repairs, noting that repairs require authorization and testing to ensure defects have been fully removed before performing the repair weld.
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Selecting electric and hydraulic tools
This document provides guidance on selecting electric and hydraulic tools for tasks. It discusses identifying the appropriate tools for jobs and their standard applications. It outlines learning objectives around identifying common electric and power tools, analyzing power tool safety rules, and understanding the importance of tool selection. Activities are described to help learners practice matching tools to tasks, learn about tool safety from a video, understand tool classifications, and identify tools in images. Guidelines are provided on tool maintenance and common power tool defects. The overall purpose is to teach learners how to properly select electric and hydraulic tools for industrial arts electrical installation and maintenance tasks.
Welding Presentation
1. Welding is a metal joining process that involves applying heat, pressure, or both to joining materials. There are several types of welding processes including solid state welding, fusion welding, and pressure welding.
2. Solid state welding joins metals below their melting point using mechanical pressure and heat. Examples are cold welding, ultrasonic welding, friction welding, and friction stir welding.
3. Resistance welding generates heat for welding through electrical resistance across components. Common resistance welding methods are spot welding, seam welding, and projection welding.
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Signed off_ SMAW11 _q1_m3_Laying Out Beads and Carbon Steel Plates_v3.pdf
Signed off_ SMAW11 _q1_m3_Laying Out Beads and Carbon Steel Plates_v3.pdf
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1. Proper preparation of the welding area by removing dirt and rust to avoid defects.
2. Using the correct current setting based on electrode diameter to achieve a stable arc without excess spatter or lack of penetration.
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Here are the key points about cutting tools:
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- Files are made of hardened steel and have rows of teeth for shaping metal. They vary in shape, cut, and coarseness. Common types include flat, mill, square and round files.
- Cold chisels are wedge-shaped for cutting, shearing and chipping metal. Types include flat, cape, diamond, and round-nose chisels for different tasks.
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Training SMAW Module
- 1. WELCOME IN TRAINING PRESENTATION Date:16/06/2015 Prepared by : ILiyas Mahmed Siroya QA/QC Dept.(Alfanar Steel)
- 2. SMAW SHIELDED METAL ARC WELDING / STICK WELDING TRAINING PRESENTATION
- 3. SMAW is commonly known as ‘Stick’ welding or manual arc welding also
- 5. ELECTRODE: Mainly uses electrode according to Standard -American Welding Society (AWS) D1.1 (1)E6013 (High Titania potassium ) –Strength and Toughness Describing :E6013 Electrode Minimum Tensile Strength (6) X 10,000psi =413 Mpa E6013 Indicates the flux coating (High titania Potassium) Welding Position: 1 - All-Position (F,H,V,OH) 2 - Flat and Horizontal 3 - Flat Only Advantage/Disadvantage: E6013 –Partial penetration/fusion (AC & DCEP/DCEN) DCEN – It will puts more heat into the electrode therefore higher deposition/melting rate with less penetration (We should use DCEN up to 5 mm Thickness) DCEP – It will puts more heat into the work piece with best penetration (We should use DECP more than 5mm Thickness)
- 6. ELECTRODE: (1) E7018 (LOW HYDROGEN ELECTRODE) Describing :E7018 Electrode Minimum Tensile Strength (7) X 10,000psi =482 Mpa E7018 Indicates the coating (K, Iron powder) – High Strength and Toughness Welding Position: 1 - All-Position (F,H,V,OH) 2 - Flat and Horizontal 3 - Flat Only Advantage/Disadvantage: E7018 –Deep penetration/Fusion and current used (AC/DCEP Only) E7018 has a very good deposition rate, providing a quiet steady arc with low spatter and medium penetration Weld deposits are of X-ray quality with easy slag removal, exceptional mechanical properties and a smooth uniform bead appearance E7018 mainly used in shop/field welding of bridges and structural
- 7. Electrode storage and reconditioning Low hydrogen electrodes are manufactured with moisture levels below 0.07% then packaged in hermetically sealed containers. An open electrode should be stored at 100 – 1500C in portable oven. If needed they can be reconditioned by baking for one hour at 3500C in mother oven. Should be a common practice of baking when using low hydrogen electrodes. E7018
- 8. FILLET WELDS IN PLATE — TEST POSITION Welder Test : If welder Pass 1F position –Can do weld, Flat (F) position If welder Pass 2F Position –Can do weld, Flat (F) & Horizontal (H) position If welder Pass 3F Position –Can do weld, Flat (F),Horizontal (H) &Vertical (V) position If welder Pass 4F Position- Can do weld, Flat (F), Horizontal (H) & Overhead (O) When welder passed in 3F & 4F position test then qualified for all position
- 9. WELDING TECHNICAL DETAIL S2 is Minimum thickness S1 is Maximum thickness H is Welding LEG LENGTH B is Welding THROAT/THICKNESS When fillet weld comes single side then B (THROAT/THICKNESS) is 70% OF MINIMUM THICKNESS & H ( LEG LENGTH ) is EQUAL OF MINIMUM THICKNESS When fillet weld comes double side then B (THROAT/THICKNESS) is 50% OF MINIMUM THICKNESS & H ( LEG LENGTH ) 70% OF MINIMUM THICKNESS
- 10. Measurement of welding throat thickness
- 11. WELDING CALCULATION DETAIL If we use E7018 electrode on baseplate area following advantages are obtained: (1) Can withstand higher load (static/dynamic) without failure. (2) Good fusion obtained between beam & base plate. (3) Good mechanical/chemical properties are achieved.
- 13. Defects in SMAW (1) Porosity Causes : Grease/ hydrocarbon/ water contamination on surface Too high arc voltage / arc length Incorrect/insufficient de-oxidant in electrode, filler or parent metal Damp fluxes/ corroded electrode Prevention : Must clean welding area prior start the welding Reduce arc voltage or arc length Use electrode with sufficient de-oxidation activity Use dry electrodes in good condition
- 14. Defects in SMAW (2) Slag Inclusions Causes : Heavy mill scale / rust on work surface Incomplete slag removal (1st run) from underlying surface of multi pass weld Unfused flux due to damage coating Prevention : Grind surface prior welding Improve intern slag removal Use electrode in good condition
- 15. Defects in SMAW (3) Undercut Causes : Melting of top edge due too high welding current ( especially at free edge) or high travel speed Attempting an Horizontal/Vertical fillet weld leg length >9.0 MM Excessive/Incorrect weaving / Incorrect electrode angle Prevention : Reduce power input , especially approaching a free edge where overheating can occur Weld in a flat position or use multirun technique Direct arc towards thicker member Measured in both Length & Depth
- 16. Defects in SMAW (4) Spatter Causes : High arc power Damp electrodes Wrong selection size of electrode Prevention : Reduce arc power Use dry electrodes Must be choose electrode size as per job
- 17. Check-Point/List for welder 1 Turn power supply on 2 Connect work clamp 3 Select electrode a. Type (E6013/E7018) b. Diameter (Ф2.5, Ф3.2 & Ф4.0mm) 4 Adjust output a. Current/Polarity (DCEP/DCEN) b. Amperage Setting 5 Insert electrode into electrode holder 6 Work Angle 7 Travel Angle 8 Arc Length 9 Travel Speed 10 Tools like….(1) Chipping Hammer (2) Wire brush (3) Cleaning brush (4) Chisel for metal ELE.DIA E6013 E7018 2.5 mm 45 -90 Amp 70 – 100 Amp 3.2 mm 80 – 130 Amp 115 – 165 Amp 4.0 mm 105 – 180 Amp 150 – 220 Amp
- 18. THE END Thanking you all on behalf of QA/QC Department Alfanar steel
- 19. Photo Gallery
- 20. Photo Gallery
- 21. Photo Gallery