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SMAW - WELDING INTRODUCTION FOR GRADE 11.ppt

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(Stick Welding) SMAW
TABLE OF CONTENTS • Guide Card…………...3 • L.O……………….4-6 • Objectives………7-6 • Overview………..8 • Activity Card…………16 • Assessment Card.....19 • Enrichment Card……21 • Reference Card...….23 • Answer key…..……..25 2 The SMAW process is great for maintenance and repair work!
Guide Card 3
Learning Competencies Subject Matter Content: •1. Essentials of welding •2. International welding codes and standards •3. Acceptable weld profiles •4. Weld defects, causes and remedies •5. Welding Procedure Specifications (WPS) •6. Welding techniques and procedures •7. Safe welding practices 4
Learning Competencies Subject Matter Content standard: The leaner demonstrates an understanding of the concepts and underlying principle in Shielded Metal Arc Welding (SMAW) Performance standard: The learner independently performs Shielded Metal Arc Welding (SMAW) processes based on market standards. 5
Learning Competencies Subject Matter Learning competency: L.O. 1 WELD CARBON STEEL PLATES IN FLAT POSITION (1G) • 1.4 Conducts visual inspection on the finished weldment in accordance with welding standards for TOPIC: 1.4.4 Uniformity of beads DOMAIN/COMPONENT PERFORM GROOVE WELDING ON CARBON STEEL PLATE (GW) CODE CODE: TLE_IAAW9-12GW-Ia-j-1 6
Objectives • At the end of the lesson the students are able to:  Familiarize the finish weldment visually acceptable in accordance with welding standards for uniformity of bead.  Perform and weld carbon steel plate in groove weld in accordance with welding standards for uniformity of bead.  Value the accuracy of their output(Smoothness and Uniformity of bead ripples must be in accordance with welding standard and finish at the exact given time). 7 Most structural steel welders are required to be certified
8 Overview • During this overview, we will discuss the following topics: • Arc • Bead • Weldbead • Weldment • Stringer bead • Wave bead • Standard length of bead by stroke The SMAW process is great for maintenance and repair work!
9 SMAW Process 1 Travel direction Electrode Arc 2 Weld Puddle 3 Shielding Gas 4 Solidified Weld Metal 5 Slag 6 Let’s take a little closer look at the SMAW process… 1 Travel direction Electrode Arc 2 Weld Puddle 3 Shielding Gas 4 Solidified Weld Metal 5 Slag 6
10 # 2- The Arc • An arc occurs when the electrode comes in contact with the work- piece and completes the circuit … like turning on a light! • The electric arc is established in the space between the end of the electrode and the work • The arc reaches temperatures of 10,000°F which melts the electrode and base material Can you identify the weld joint and position being used?
11 # 5- Solidified Weld Metal • As the molten weld puddle solidifies, it forms a joint or connection between two pieces of base material • When done properly on steel, it results in a weld stronger than the surrounding base metal
Bead Bead • - the deposited filler metal on and in the work surface when the wire or electrode is melted and fused into the steel. 12
Stringer bead Stringer bead •- is a narrow straight weld bead with only a dragging motion or light oscillation •- It also created by moving the electrode straight along the weld joint 13
Wave bead Wave bead •- is usually used on the last bead, or cap of the weld. It is made when you OSCILLATE the rod in a wide pattern back and forth or side to side moving of electrode 14
•STANDARD LENGTH OF WELD BEAD •Standard length of electrode 14” inches •Standard core diameter of electrode – 5/32” inches in diameter – 1/16” inches in diameter – 1/8” inches in diameter 15 Welding electrode standards define the characteristics and classification of welding rods used in various welding processes. The most common standard is the AWS (American Welding Society) classification system, which uses a numbering system to indicate tensile strength, welding position, and electrode coating type. AWS Classification System: "E": Indicates an electrode, specifically for arc welding. First two digits: Represent the tensile strength of the electrode's filler metal in thousands of pounds per square inch (ksi). For example, "70" indicates 70,000 psi. Third digit: Indicates the welding positions for which the electrode is suitable: "1": All positions (flat, horizontal, vertical, and overhead). "2": Flat and horizontal positions. "4": Flat, horizontal, vertical down, and overhead positions. Fourth digit: Indicates the electrode's flux covering type, welding current (DC or AC), and penetration level. Common Electrode Types: E6010/E6011: Deep penetration, often used for thick metals and pipe welding. E6013: Medium penetration, versatile, and suitable for general welding applications. E7018: Low-hydrogen, versatile, and suitable for heavy-duty applications. E7024: High deposition rate, excellent for beginners.
Activity Card 16
17 SMAW Lesson #1 • Objective: To run a straight bead on flat plate and to fill the crater • Equipment: – Single Process - Constant Current Power Source  Ideal arc 250 and accessories  Precision TIG 225 and accessories • Material: – Mild Steel Plate 3/16” or thicker – 1/8” Fleetweld 37 (E6013) Good Poor
18 SMAW Lesson #2 • Objective: To run a bead with the whip technique • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision SMAW 225 and accessories • Material: – Mild Steel Plate 3/16” or thicker – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC
19
Assessment Card 20
Assessment Card General Direction: Read each item carefully and encircle the letter of the correct answer from the choices. 1.In performing stringer bead, a 1/8” inches in diameter of electrode and 14” inches in length of electrode must produce a long straight bead which measuare_______? a) 12 inches weld bead b. 15 inches weld bead c. 6 inches weld bead d. 10 inches weld bead 2.The following are essentials for proper welding, EXCEPT? a) Correct brand electrode c. Correct arc length b) Correct travel speed d. Correct selection of electrode 3.It is one of the general strokes in welding? a) Weldment b. Bead c. Stringer bead d. Uphill technique 4.Weld defect may occur after the finish weldment, what is the acceptable weld profile of the bead. a) Smooth and uniform weld bead c. Smooth and rusty b) Smooth with defect d. Equal thickness of weld bead 5.Which of the following is NOT a safety precaution in the practical area? a) Avoid wearing jewelries c. Avoid hazardous chemical from expose b) Avoid horse playing d. Inspect the equipment before energizing 21
Enrichment Card 22
23 Enrichment Activity 1 2 3 4 5 6 Let’s review the SMAW process … • 1 = __________ • 2 = __________ • 3 = __________ • 4 = __________ • 5 = __________ • 6 = __________ Application Activity
Reference Card 24
• Curriculum Guide (CG), • WELDING FUNDAMENTALS (BOOK) • Lincoln electric 25 This welder chips the slag off of a weld during the repair of railroad tracks
Answer Key 26
Answer Key • 1. a • 2. a • 3. a • 4. b • 5. b 27
28 SMAW Safety
29 SMAW Safety • ‘SMAW Safety’ is supplemental and does not replace the information found in ‘Arc Welding Basics’ • Understand and follow all safety precautions listed in ‘Safety in Welding, Cutting, and Allied Processes’ (ANSI Z49.1) and Arc Welding Safety (E205) • Understand and follow all warning labels found: – On welding equipment – With all consumable packaging – Within instruction manuals • Read Material Safety Data Sheets (MSDS) If you ever have a question about your safety or those around you, PLEASE ASK YOUR INSTRUCTOR!
30 SMAW Safety • Fumes and Gases can be dangerous – Keep your head out of the fumes – Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area – The SMAW process can withstand wind and exhaust near the arc from ventilation equipment • Electric Shock can kill – to receive a shock your body must touch the electrode and work or ground at the same time – Do not touch the electrode or metal parts of the electrode holder with skin or wet clothing – Keep dry insulation between your body and the metal being welded or ground • Arc Rays can injure eyes and skin - Choose correct filter shade (See chart below) ** Information taken from ANSI Z49.1:2005**
31 SMAW Principles
32 SMAW Principles • The American Welding Society defines SMAW as Shielded Metal Arc Welding • SMAW: – Is commonly known as ‘Stick’ welding or manual arc welding – Is the most widely used arc welding process in the world – Can be used to weld most common metals and alloys
33 SMAW Welding Circuit • Current flows through the electrode cable, to the electrode holder, through the electrode, and across the arc • On the work side of the arc, the current flows through the base material to the work clamp and back to the welding machine
34 1- The Electrode • Is a consumable - it gets melted during the welding process • Is composed of two parts – Core Rod (Metal Filler)  Carries welding current  Becomes part of the weld – Flux Coating  Produces a shielding gas  Can provide additional filler  Forms a slag
35 3- Weld Puddle • As the core rod, flux coating, and work pieces heat up and melt, they form a pool of molten material called a weld puddle • The weld puddle is what a welder watches and manipulates while welding 1/8” E6013 at 125 Amps AC
36 4- Shielding Gas • A shielding gas is formed when the flux coating melts. • This protects the weld puddle from the atmosphere preventing contamination during the molten state The shielding gas protects the molten puddle from the atmosphere while stabilizing the arc 2 3 Shielding Gas 4
37 6- Slag • Slag is a combination of the flux coating and impurities from the base metal that float to the surface of the weld. • Slag quickly solidifies to form a solid coating • The slag also slows the cooling rate of the weld • The slag can be chipped away and cleaned with a wire brush when hard This welder chips the slag off of a weld during the repair of railroad tracks
38 Application Activity
39 Application Activity 1 2 3 4 5 6 Let’s review the SMW process … • 1 = __________ • 2 = __________ • 3 = __________ • 4 = __________ • 5 = __________ • 6 = __________
40 Equipment Set Up
41 SMAW Equipment Set Up 1. Turn power supply on 2. Connect work clamp 3. Select electrode a. Type b. Diameter 4. Adjust output a. Polarity b. Amperage 6. Insert electrode into electrode holder
42 SMAW Process Variables • Settings on the machine – Polarity : AC, DC+, DC- – Amperage Output • Operator Controlled Variables – Work Angle – Travel Angle – Arc Length – Travel Speed A straight AC machine will not have a polarity switch like this AC/DC machine
43 Striking an Arc and Making a Weld
44 Striking an Arc • To begin the SMAW Process, you must first strike an arc. This can be done using one of the following techniques: – Scratch start – scratch the electrode on the base metal like a match – Tap Start – tap the rod against the base metal
45 Work Angle • The work angle is the angle between the electrode and the work as depicted on the left • Work angles can vary depending on the position the weld is being made in 90°
46 Travel Angle • Also commonly called Lead Angle • The travel (lead) angle is the angle between the electrode and the plane perpendicular to the weld axis 20-30°
47 Arc Length • After striking the arc, maintain a 1/8” distance between the electrode and the workpiece – If the arc length becomes too short, the electrode will get stuck to the workpiece or ‘short out’ – If the arc length becomes too long; spatter, undercut, and porosity can occur Arc Length = 1/8”
48 Travel Speed • The travel speed is the speed at which the electrode moves along the base material while welding – Too fast of a travel speed results in a ropey or convex weld – Too slow of a travel speed results in a wide weld with an excessive metal deposit The travel speed impacts the shape of the bead. End of Weld
49 Filling the Crater • At the end of the weld, the operator breaks the arc which creates a ‘crater’ • Use a short pause or slight back step at the end of the weld to fill the crater • Large craters can cause weld cracking Back stepping is a short move in the opposite direction of weld travel
50 Restarting a Bead • Here is the proper technique for restarting a weld: 1. Strike Arc Here 2. Move Electrode to Crown of Crater 3. Resume Forward Travel
51 Troubleshooting Welds
52 Troubleshooting Welds A B C D E F G These welds were cut and etched with nitric acid to show penetration
53 SMAW Advantages and Limitations
54 Advantages of SMAW • Low initial cost • Portable • Easy to use outdoors • All position capabilities • Easy to change between many base materials What safety precautions should be taken by these welders?
55 Limitations of SMAW • Lower consumable efficiency • Difficult to weld very thin materials • Frequent restarts • Lower operating factor • Higher operator skill required for SMAW than some other processes Building a barge in a large shipyard
56 AWS Classification of SMAW Electrodes
57 E70XX Electrode Tensile in Ksi Welding Position: 1 = All Position, 2 = Flat & Horizontal Type of Current and Coating AWS Classification of SMAW Electrodes
58 Lesson Plans
59 SMAW Lesson #1 • Objective: Strike and establish an arc • Equipment: – Single Process – Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate 1/8” or thicker – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC
60 SMAW Lesson #2 • Objective: To run a straight bead on flat plate and to fill the crater • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate 3/16” or thicker – 1/8” Fleetweld 37 (E6013) Good Poor
61 SMAW Lesson #3 • Objective: To run a bead with the whip technique • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate 3/16” or thicker – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC
62 SMAW Lesson #4 • Objective: To build a pad • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate 3/16” or thicker – 1/8” Fleetweld 37 (E6013)
63 SMAW Lesson #5 • Objective: To make a fillet weld on a lap joint in the horizontal position (AWS Position 2F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate - 10 gauge – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 2F Top View Side View
64 SMAW Lesson #6 • Objective: To make a fillet weld on a tee joint in the horizontal position (AWS Position 2F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate - 10 gauge – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 2F
65 SMAW Lesson #7 • Objective: To make a fillet weld on a tee joint in the horizontal position (AWS Position 2F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate - 10 gauge – 1/8” Excalibur 7018 (E7018) for DC or Lincoln 7018AC (E7018) for AC 2F
66 SMAW Lesson #8 • Objective: To make a three pass fillet weld on a tee joint in the horizontal position (AWS Position 2F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate – ¼” – 1/8” Excalibur 7018 (E7018) for DC or Lincoln 7018AC (E7018) for AC 2F
67 SMAW Lesson #9 • Objective: To make a fillet weld on a lap joint in the vertical position welding down (AWS Position 3FD) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate - 10 gauge – 1/8” Fleetweld 37 (E6013) 3FD
68 SMAW Lesson #10 • Objective: To make a fillet weld on a tee joint in the vertical position welding down (AWS Position 3FD) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate - 10 gauge – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 3FD
69 SMAW Lesson #11 • Objective: To make a fillet weld on a lap joint in the overhead position (AWS Position 4F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate - 10 gauge – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 4F
70 SMAW Lesson #12 • Objective: To make a fillet weld on a tee joint in the overhead position (AWS Position 4F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate - 10 gauge – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 4F
71 SMAW Lesson #13 • Objective: To make a single pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate – 1/4” – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 3F
72 SMAW Lesson #14 3F • Objective: To make a three pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate – 1/4” – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC
73 SMAW Lesson #15 • Objective: To make a single pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate – 1/4” – 1/8” Excalibur 7018 (E7018) for DC or Lincoln 7018AC (E7018) for AC 3F
74 SMAW Lesson #16 • Objective: To make a three pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate – 1/4” – 1/8” Excalibur 7018 (E7018) for DC or Lincoln 7018AC (E7018) for AC 3F
75 AWS Connection
76 AWS Connection • The SMAW Welding Unit of study incorporates the following information taken from the AWS EG 2.0 requirements: – Set up for SMAW operations on carbon steel – Operate SMAW equipment on carbon steel – Make SMAW fillet welds on carbon steel
77 English, Math, and Science Connection
78 National Academic Standards Crosswalk • The unit, just completed, has covered parts of academic content listed in the National Academic Standards as follows: – NM-PROB.CONN.PK-12.3: Recognizes and applies mathematics in contexts outside of mathematics. – NLA-STANDARD 1: Uses the general skills and strategies of the writing process. – NLA-STANDARD 7: Uses reading skills and strategies to understand and interpret a variety of informational texts. – NS-PHYSICAL SCIENCE: (Experiences) interactions of energy and matter.

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SMAW - WELDING INTRODUCTION FOR GRADE 11.ppt

  • 1.
  • 2.
    TABLE OF CONTENTS •Guide Card…………...3 • L.O……………….4-6 • Objectives………7-6 • Overview………..8 • Activity Card…………16 • Assessment Card.....19 • Enrichment Card……21 • Reference Card...….23 • Answer key…..……..25 2 The SMAW process is great for maintenance and repair work!
  • 3.
  • 4.
    Learning Competencies Subject Matter Content: •1.Essentials of welding •2. International welding codes and standards •3. Acceptable weld profiles •4. Weld defects, causes and remedies •5. Welding Procedure Specifications (WPS) •6. Welding techniques and procedures •7. Safe welding practices 4
  • 5.
    Learning Competencies Subject Matter Contentstandard: The leaner demonstrates an understanding of the concepts and underlying principle in Shielded Metal Arc Welding (SMAW) Performance standard: The learner independently performs Shielded Metal Arc Welding (SMAW) processes based on market standards. 5
  • 6.
    Learning Competencies Subject Matter Learningcompetency: L.O. 1 WELD CARBON STEEL PLATES IN FLAT POSITION (1G) • 1.4 Conducts visual inspection on the finished weldment in accordance with welding standards for TOPIC: 1.4.4 Uniformity of beads DOMAIN/COMPONENT PERFORM GROOVE WELDING ON CARBON STEEL PLATE (GW) CODE CODE: TLE_IAAW9-12GW-Ia-j-1 6
  • 7.
    Objectives • At theend of the lesson the students are able to:  Familiarize the finish weldment visually acceptable in accordance with welding standards for uniformity of bead.  Perform and weld carbon steel plate in groove weld in accordance with welding standards for uniformity of bead.  Value the accuracy of their output(Smoothness and Uniformity of bead ripples must be in accordance with welding standard and finish at the exact given time). 7 Most structural steel welders are required to be certified
  • 8.
    8 Overview • During thisoverview, we will discuss the following topics: • Arc • Bead • Weldbead • Weldment • Stringer bead • Wave bead • Standard length of bead by stroke The SMAW process is great for maintenance and repair work!
  • 9.
    9 SMAW Process 1 Travel direction Electrode Arc 2 WeldPuddle 3 Shielding Gas 4 Solidified Weld Metal 5 Slag 6 Let’s take a little closer look at the SMAW process… 1 Travel direction Electrode Arc 2 Weld Puddle 3 Shielding Gas 4 Solidified Weld Metal 5 Slag 6
  • 10.
    10 # 2- TheArc • An arc occurs when the electrode comes in contact with the work- piece and completes the circuit … like turning on a light! • The electric arc is established in the space between the end of the electrode and the work • The arc reaches temperatures of 10,000°F which melts the electrode and base material Can you identify the weld joint and position being used?
  • 11.
    11 # 5- SolidifiedWeld Metal • As the molten weld puddle solidifies, it forms a joint or connection between two pieces of base material • When done properly on steel, it results in a weld stronger than the surrounding base metal
  • 12.
    Bead Bead • - thedeposited filler metal on and in the work surface when the wire or electrode is melted and fused into the steel. 12
  • 13.
    Stringer bead Stringer bead •-is a narrow straight weld bead with only a dragging motion or light oscillation •- It also created by moving the electrode straight along the weld joint 13
  • 14.
    Wave bead Wave bead •-is usually used on the last bead, or cap of the weld. It is made when you OSCILLATE the rod in a wide pattern back and forth or side to side moving of electrode 14
  • 15.
    •STANDARD LENGTH OFWELD BEAD •Standard length of electrode 14” inches •Standard core diameter of electrode – 5/32” inches in diameter – 1/16” inches in diameter – 1/8” inches in diameter 15 Welding electrode standards define the characteristics and classification of welding rods used in various welding processes. The most common standard is the AWS (American Welding Society) classification system, which uses a numbering system to indicate tensile strength, welding position, and electrode coating type. AWS Classification System: "E": Indicates an electrode, specifically for arc welding. First two digits: Represent the tensile strength of the electrode's filler metal in thousands of pounds per square inch (ksi). For example, "70" indicates 70,000 psi. Third digit: Indicates the welding positions for which the electrode is suitable: "1": All positions (flat, horizontal, vertical, and overhead). "2": Flat and horizontal positions. "4": Flat, horizontal, vertical down, and overhead positions. Fourth digit: Indicates the electrode's flux covering type, welding current (DC or AC), and penetration level. Common Electrode Types: E6010/E6011: Deep penetration, often used for thick metals and pipe welding. E6013: Medium penetration, versatile, and suitable for general welding applications. E7018: Low-hydrogen, versatile, and suitable for heavy-duty applications. E7024: High deposition rate, excellent for beginners.
  • 16.
  • 17.
    17 SMAW Lesson #1 •Objective: To run a straight bead on flat plate and to fill the crater • Equipment: – Single Process - Constant Current Power Source  Ideal arc 250 and accessories  Precision TIG 225 and accessories • Material: – Mild Steel Plate 3/16” or thicker – 1/8” Fleetweld 37 (E6013) Good Poor
  • 18.
    18 SMAW Lesson #2 •Objective: To run a bead with the whip technique • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision SMAW 225 and accessories • Material: – Mild Steel Plate 3/16” or thicker – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC
  • 19.
  • 20.
  • 21.
    Assessment Card General Direction:Read each item carefully and encircle the letter of the correct answer from the choices. 1.In performing stringer bead, a 1/8” inches in diameter of electrode and 14” inches in length of electrode must produce a long straight bead which measuare_______? a) 12 inches weld bead b. 15 inches weld bead c. 6 inches weld bead d. 10 inches weld bead 2.The following are essentials for proper welding, EXCEPT? a) Correct brand electrode c. Correct arc length b) Correct travel speed d. Correct selection of electrode 3.It is one of the general strokes in welding? a) Weldment b. Bead c. Stringer bead d. Uphill technique 4.Weld defect may occur after the finish weldment, what is the acceptable weld profile of the bead. a) Smooth and uniform weld bead c. Smooth and rusty b) Smooth with defect d. Equal thickness of weld bead 5.Which of the following is NOT a safety precaution in the practical area? a) Avoid wearing jewelries c. Avoid hazardous chemical from expose b) Avoid horse playing d. Inspect the equipment before energizing 21
  • 22.
  • 23.
    23 Enrichment Activity 1 2 3 4 5 6 Let’s reviewthe SMAW process … • 1 = __________ • 2 = __________ • 3 = __________ • 4 = __________ • 5 = __________ • 6 = __________ Application Activity
  • 24.
  • 25.
    • Curriculum Guide(CG), • WELDING FUNDAMENTALS (BOOK) • Lincoln electric 25 This welder chips the slag off of a weld during the repair of railroad tracks
  • 26.
  • 27.
    Answer Key • 1.a • 2. a • 3. a • 4. b • 5. b 27
  • 28.
  • 29.
    29 SMAW Safety • ‘SMAWSafety’ is supplemental and does not replace the information found in ‘Arc Welding Basics’ • Understand and follow all safety precautions listed in ‘Safety in Welding, Cutting, and Allied Processes’ (ANSI Z49.1) and Arc Welding Safety (E205) • Understand and follow all warning labels found: – On welding equipment – With all consumable packaging – Within instruction manuals • Read Material Safety Data Sheets (MSDS) If you ever have a question about your safety or those around you, PLEASE ASK YOUR INSTRUCTOR!
  • 30.
    30 SMAW Safety • Fumesand Gases can be dangerous – Keep your head out of the fumes – Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area – The SMAW process can withstand wind and exhaust near the arc from ventilation equipment • Electric Shock can kill – to receive a shock your body must touch the electrode and work or ground at the same time – Do not touch the electrode or metal parts of the electrode holder with skin or wet clothing – Keep dry insulation between your body and the metal being welded or ground • Arc Rays can injure eyes and skin - Choose correct filter shade (See chart below) ** Information taken from ANSI Z49.1:2005**
  • 31.
  • 32.
    32 SMAW Principles • TheAmerican Welding Society defines SMAW as Shielded Metal Arc Welding • SMAW: – Is commonly known as ‘Stick’ welding or manual arc welding – Is the most widely used arc welding process in the world – Can be used to weld most common metals and alloys
  • 33.
    33 SMAW Welding Circuit •Current flows through the electrode cable, to the electrode holder, through the electrode, and across the arc • On the work side of the arc, the current flows through the base material to the work clamp and back to the welding machine
  • 34.
    34 1- The Electrode •Is a consumable - it gets melted during the welding process • Is composed of two parts – Core Rod (Metal Filler)  Carries welding current  Becomes part of the weld – Flux Coating  Produces a shielding gas  Can provide additional filler  Forms a slag
  • 35.
    35 3- Weld Puddle •As the core rod, flux coating, and work pieces heat up and melt, they form a pool of molten material called a weld puddle • The weld puddle is what a welder watches and manipulates while welding 1/8” E6013 at 125 Amps AC
  • 36.
    36 4- Shielding Gas •A shielding gas is formed when the flux coating melts. • This protects the weld puddle from the atmosphere preventing contamination during the molten state The shielding gas protects the molten puddle from the atmosphere while stabilizing the arc 2 3 Shielding Gas 4
  • 37.
    37 6- Slag • Slagis a combination of the flux coating and impurities from the base metal that float to the surface of the weld. • Slag quickly solidifies to form a solid coating • The slag also slows the cooling rate of the weld • The slag can be chipped away and cleaned with a wire brush when hard This welder chips the slag off of a weld during the repair of railroad tracks
  • 38.
  • 39.
    39 Application Activity 1 2 3 4 5 6 Let’s reviewthe SMW process … • 1 = __________ • 2 = __________ • 3 = __________ • 4 = __________ • 5 = __________ • 6 = __________
  • 40.
  • 41.
    41 SMAW Equipment SetUp 1. Turn power supply on 2. Connect work clamp 3. Select electrode a. Type b. Diameter 4. Adjust output a. Polarity b. Amperage 6. Insert electrode into electrode holder
  • 42.
    42 SMAW Process Variables •Settings on the machine – Polarity : AC, DC+, DC- – Amperage Output • Operator Controlled Variables – Work Angle – Travel Angle – Arc Length – Travel Speed A straight AC machine will not have a polarity switch like this AC/DC machine
  • 43.
  • 44.
    44 Striking an Arc •To begin the SMAW Process, you must first strike an arc. This can be done using one of the following techniques: – Scratch start – scratch the electrode on the base metal like a match – Tap Start – tap the rod against the base metal
  • 45.
    45 Work Angle • Thework angle is the angle between the electrode and the work as depicted on the left • Work angles can vary depending on the position the weld is being made in 90°
  • 46.
    46 Travel Angle • Alsocommonly called Lead Angle • The travel (lead) angle is the angle between the electrode and the plane perpendicular to the weld axis 20-30°
  • 47.
    47 Arc Length • Afterstriking the arc, maintain a 1/8” distance between the electrode and the workpiece – If the arc length becomes too short, the electrode will get stuck to the workpiece or ‘short out’ – If the arc length becomes too long; spatter, undercut, and porosity can occur Arc Length = 1/8”
  • 48.
    48 Travel Speed • Thetravel speed is the speed at which the electrode moves along the base material while welding – Too fast of a travel speed results in a ropey or convex weld – Too slow of a travel speed results in a wide weld with an excessive metal deposit The travel speed impacts the shape of the bead. End of Weld
  • 49.
    49 Filling the Crater •At the end of the weld, the operator breaks the arc which creates a ‘crater’ • Use a short pause or slight back step at the end of the weld to fill the crater • Large craters can cause weld cracking Back stepping is a short move in the opposite direction of weld travel
  • 50.
    50 Restarting a Bead •Here is the proper technique for restarting a weld: 1. Strike Arc Here 2. Move Electrode to Crown of Crater 3. Resume Forward Travel
  • 51.
  • 52.
    52 Troubleshooting Welds A BC D E F G These welds were cut and etched with nitric acid to show penetration
  • 53.
  • 54.
    54 Advantages of SMAW •Low initial cost • Portable • Easy to use outdoors • All position capabilities • Easy to change between many base materials What safety precautions should be taken by these welders?
  • 55.
    55 Limitations of SMAW •Lower consumable efficiency • Difficult to weld very thin materials • Frequent restarts • Lower operating factor • Higher operator skill required for SMAW than some other processes Building a barge in a large shipyard
  • 56.
  • 57.
    57 E70XX Electrode Tensile in Ksi WeldingPosition: 1 = All Position, 2 = Flat & Horizontal Type of Current and Coating AWS Classification of SMAW Electrodes
  • 58.
  • 59.
    59 SMAW Lesson #1 •Objective: Strike and establish an arc • Equipment: – Single Process – Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate 1/8” or thicker – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC
  • 60.
    60 SMAW Lesson #2 •Objective: To run a straight bead on flat plate and to fill the crater • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate 3/16” or thicker – 1/8” Fleetweld 37 (E6013) Good Poor
  • 61.
    61 SMAW Lesson #3 •Objective: To run a bead with the whip technique • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate 3/16” or thicker – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC
  • 62.
    62 SMAW Lesson #4 •Objective: To build a pad • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate 3/16” or thicker – 1/8” Fleetweld 37 (E6013)
  • 63.
    63 SMAW Lesson #5 •Objective: To make a fillet weld on a lap joint in the horizontal position (AWS Position 2F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate - 10 gauge – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 2F Top View Side View
  • 64.
    64 SMAW Lesson #6 •Objective: To make a fillet weld on a tee joint in the horizontal position (AWS Position 2F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate - 10 gauge – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 2F
  • 65.
    65 SMAW Lesson #7 •Objective: To make a fillet weld on a tee joint in the horizontal position (AWS Position 2F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate - 10 gauge – 1/8” Excalibur 7018 (E7018) for DC or Lincoln 7018AC (E7018) for AC 2F
  • 66.
    66 SMAW Lesson #8 •Objective: To make a three pass fillet weld on a tee joint in the horizontal position (AWS Position 2F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate – ¼” – 1/8” Excalibur 7018 (E7018) for DC or Lincoln 7018AC (E7018) for AC 2F
  • 67.
    67 SMAW Lesson #9 •Objective: To make a fillet weld on a lap joint in the vertical position welding down (AWS Position 3FD) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate - 10 gauge – 1/8” Fleetweld 37 (E6013) 3FD
  • 68.
    68 SMAW Lesson #10 •Objective: To make a fillet weld on a tee joint in the vertical position welding down (AWS Position 3FD) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate - 10 gauge – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 3FD
  • 69.
    69 SMAW Lesson #11 •Objective: To make a fillet weld on a lap joint in the overhead position (AWS Position 4F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate - 10 gauge – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 4F
  • 70.
    70 SMAW Lesson #12 •Objective: To make a fillet weld on a tee joint in the overhead position (AWS Position 4F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate - 10 gauge – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 4F
  • 71.
    71 SMAW Lesson #13 •Objective: To make a single pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate – 1/4” – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 3F
  • 72.
    72 SMAW Lesson #14 3F •Objective: To make a three pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate – 1/4” – 1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC
  • 73.
    73 SMAW Lesson #15 •Objective: To make a single pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate – 1/4” – 1/8” Excalibur 7018 (E7018) for DC or Lincoln 7018AC (E7018) for AC 3F
  • 74.
    74 SMAW Lesson #16 •Objective: To make a three pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F) • Equipment: – Single Process - Constant Current Power Source  Idealarc 250 and accessories  Precision TIG 225 and accessories – Multi-Process  Power MIG 350 MP • Material: – Mild Steel Plate – 1/4” – 1/8” Excalibur 7018 (E7018) for DC or Lincoln 7018AC (E7018) for AC 3F
  • 75.
  • 76.
    76 AWS Connection • TheSMAW Welding Unit of study incorporates the following information taken from the AWS EG 2.0 requirements: – Set up for SMAW operations on carbon steel – Operate SMAW equipment on carbon steel – Make SMAW fillet welds on carbon steel
  • 77.
    77 English, Math, andScience Connection
  • 78.
    78 National Academic StandardsCrosswalk • The unit, just completed, has covered parts of academic content listed in the National Academic Standards as follows: – NM-PROB.CONN.PK-12.3: Recognizes and applies mathematics in contexts outside of mathematics. – NLA-STANDARD 1: Uses the general skills and strategies of the writing process. – NLA-STANDARD 7: Uses reading skills and strategies to understand and interpret a variety of informational texts. – NS-PHYSICAL SCIENCE: (Experiences) interactions of energy and matter.

Editor's Notes

  • #1 SECTION OVERVIEW: Section Overviews are provided on the introductory slides at the front of each topical area to explain the intended use for the slides included in the section. Slide numbers are included on the Section Overview slides for easy reference when preparing for delivery of the slide content. TEACHER NOTES: Teacher Notes are included on the Section Overview slides as a reference tool when making class preparations. Suggested Activities are included as ideas for teachers to use to help students gain practical experience with the welding content. However, these are designed to be supplemented by each teacher based on local program needs. Slides have been developed to incorporate content information regarding performance standards from the American Welding Society (AWS) and the National Academic Standards for English, Science, and Math. INDIVIDUAL WELDING LESSON NOTES ARE AVAILABLE IN LESSON PLAN FACILITATOR’S GUIDE
  • #8 SECTION OVERVIEW: This slide is meant to start generating conversation and thoughts about content to be covered in this lesson. TEACHER NOTES: Bulleted information on topical areas is provided to lead class discussion on areas which are to be covered in the training.
  • #28 SECTION OVERVIEW: The next few slides are meant to point out safety requirements when doing SMAW welding. TEACHER NOTES: Slides 4-6: Bulleted information on topical areas is provided to lead class discussion on important areas of safety to be practiced in the SMAW welding environment. To download your own copy of ‘Safety in Welding, Cutting and Allied Processes’ (ANSI Z49.1) go to: www.aws.org/technical/facts/Z49.1-2005-all.pdf To download your own copy of Lincoln Electric’s Arc Welding Safety (E205) document go to: http://content.lincolnelectric.com/pdfs/products/literature/e205.pdf To order copies of Lincoln Electric’s Arc Welding Safety (E205) document and poster (E201) go to: www.lincolnelectric.com (Quick Link: Literature Request) MSDS can be obtained from Lincoln Consumable packaging, online at www.lincolnelectric.com (Quick Link: MSDS) or by calling 1-216-481-8100 For a free DVD on Welding Safely, submit order form in the back of the Lesson Plan Facilitator’s Guide (shipping and handling charges apply). See Facilitator’s Guide for more information on welding hazards such as Fumes and Gases and Electrical Shock.
  • #31 SECTION OVERVIEW: These slides are meant to lead into the discussion of the SMAW process TEACHER NOTES: Slides 7-16: For more information on the American Welding Society, see ‘Arc Welding Basics’ and www.aws.org Discussion could be given on stick electrodes commonly being between 9-18” long, and come in diameters ranging from 1/16” to 1/4”. An activity could be to show 3 electrodes all the same diameter: E6010 or E6011, E7018, and E7024. Ask students to compare flux coatings (color, thickness, feel) The size of the electrode is determined by the diameter of its metal core. PLEASE NOTE: The overall diameter of the electrode changes due to flux coating even though metal diameter remains the same. An arc digs into the base metal much like water from a nozzle on a garden hose digs into the earth. (The flow of the water is like welding current and water pressure is similar to voltage)
  • #38 SECTION OVERVIEW: These slides provide an overview of the SMAW process. TEACHER NOTES: (Explanation of Activity) Slides 17-18: After discussing the parts included on this slide, students will take a quiz as an application activity. For the activity, have participants work individually and mark 1-6 on a piece of paper. Explain that this activity is meant to check whether each student understands SMAW before beginning to apply the process in the lab. Project slide on the screen and have each student fill in the blanks on a piece of paper to be turned in. Collect papers and discuss. Answers to the Application Activity are: 1. Electrode 2. Arc 3. Weld Puddle 4. Shielding Gas 5. Solidified Weld Metal 6. Slag
  • #40 SECTION OVERVIEW: These slides explain how to set up the equipment for SMAW and the process variables used. TEACHER NOTES: Slides 19-21: These slides explain SMAW equipment set up and operator controlled variables The exposed metal end of the electrode should fit securely within the jaws of the electrode holder Discuss how the correct amperage setting for any given electrode is important to ensure proper shape of bead, proper penetration, and minimal spatter. Explain when the amperage is set too high the bead may be flat, have excessive spatter, have some porosity and the electrode will overheat. If the amperage setting is too low, difficulty is experienced in striking the arc and maintaining the correct arc length. The weld bead becomes convex with excessive overlap and poor penetration. Discuss polarity – All stick electrodes run on DC. Not all will weld on AC. All electrodes have a preferred polarity and most are designated by the AWS.
  • #43 SECTION OVERVIEW: These slides discuss striking an arc and making a weld TEACHER NOTES: Slides 22-29: When using these slides, teachers may prefer to discuss the importance of the following topics: Striking an arc Work angle Travel angle Arc length Travel speed Filling a crater Restarting the bead
  • #51 SECTION OVERVIEW: The next slide discusses several troubleshooting topics. TEACHER NOTES: Slide 30-31: Weld troubleshooting. The beads on the pad depict changes in welding variables and their results. Discuss the following: A – Good Weld: Proper Current, Travel Speed and Arc Length B – Current too low: Ropey, convex bead appearance C – Current too High: Excess spatter and possible burn-through of base materials D – Arc Length too short: Poor wet-in at toes, electrode can ‘short’ to base material E – Arc Length too Long: Excess spatter, undercut and porosity F – Travel Speed too slow: Wide weld with excess metal deposit G – Travel Speed too high: Ropey and convex bead
  • #53 SECTION OVERVIEW: This section is meant to lead into a discussion regarding the advantages and limitations of using the SMAW process. TEACHER NOTES: Slides 32-34: The advantages and limitations of SMAW Advantages: Low start up costs – SMAW equipment is less expensive than GMAW equipment Portable – electrode leads are easy to move from job to job Easy to use outdoors - The process does not require a shielding gas so it is resistant to winds All position capabilities SMAW can be used on variety of materials – just change the electrode and you’re ready for the next project Limitations: Electrodes are 60-65% efficient - 1.5 to 2” of the electrode (stub) is thrown away. The slag and spatter also contribute to SMAW consumable losses. Difficult to weld very thin material – Frequent restarts – Most electrodes are 9-18” in length. As the electrodes are consumed they continually need to be replaced Operating factor of 5-25% - Operators using the SMAW process spend only 5-25% of their time welding. Time is spent chipping slag, cleaning spatter, changing electrodes, repositioning the part, etc. It takes practice to become a good welder using the SMAW process. The GMAW process is generally easier to learn.
  • #56 SECTION OVERVIEW: This section is meant to lead into a discussion regarding the AWS Classification of SMAW Electrodes TEACHER NOTES: Slides 35-36: For more information on the AWS classification of SMAW electrodes see Lincoln Electric’s free ‘Stick Electrode Product Catalog’ - http://content.lincolnelectric.com/pdfs/products/literature/c210.pdf
  • #58 SECTION OVERVIEW: These slides are used for practicing lesson content in the lab setting. TEACHER NOTES: Slides 37-53: When using these slides, teachers might want to reference information included in the Facilitator’s Guide. Recommended equipment – Only one of the single process or multi-process machines is required to complete the lesson.
  • #75 SECTION OVERVIEW: The next few slides discuss the connection of this unit with AWS and the certification process. TEACHER NOTES: Slide 54-55: Content included in this unit of study is designed to be used by interested students as a building block in the learning process if interested in pursuing a certification program
  • #77 SECTION OVERVIEW: The next slide discusses how the content covered in the welding unit is applicable to English, Math, and Science classes. TEACHER NOTES: Slides 56-57: These slides contain information regarding how this welding unit of study relates to the National Academic Standards.