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.

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

4. SMAW Process :

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.

12. WELDING CALCULATION

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