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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Welding equipment's is the tools used in the welding
The following equipment's used in the welding
1. Power Source (AC or DC)
2. Electrode Holder
3. Welding Cables
4. Ground Clamp
5. Welding Electrodes
6. Welding Helmets & Hand Shield
7. Protective Cloths
8. Finishing tools – Wire brush, Chipping Hammers.
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Welding consumables include electrodes, wire, fluxes, and gases. Each consumable must match its specification and supplier, be in good condition, and receive any required treatment. Common consumables include rutile and basic electrodes that require different drying and storage depending on their properties and intended use. Welding codes identify consumables based on factors like strength, toughness, coating type, efficiency, positional capability, and hydrogen content. Proper identification, checks, and handling of consumables is important for welding quality.
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Welding is a process that joins materials by causing coalescence and can be accomplished with or without the use of filler material. There are several common welded joint types including butt, fillet, lap, and corner joints. Various welding processes are described including oxy-fuel welding, shielded metal arc welding (SMAW), gas metal arc welding (GMAW), and gas tungsten arc welding (GTAW). Key factors that affect the quality of a weld include current, voltage, travel speed, and gas selection depending on the specific process.
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- Shielded metal arc welding (SMAW) is one of the most commonly used welding processes, accounting for approximately 50% of welding in industry.
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- Constant current welding machines, which maintain a constant current output regardless of changes in arc length, are best suited for SMAW and allow welders to control heat input.
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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