WELCOMEIN

TRAINING PRESENTATION

Date:16/06/2015

Prepared by :

ILiyas Mahmed Siroya

QA/QC Dept.(Alfanar Steel)

SMAW

SHIELDED METAL ARC WELDING /

STICK WELDING

TRAINING PRESENTATION

SMAW is commonly known as ‘Stick’

welding or manual arc welding also

SMAW Process :

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)

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

Electrode storage and reconditioning

Low hydrogen electrodes are manufacturedwith 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

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

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

Measurement of welding throat thickness

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.

WELDING CALCULATION

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

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

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

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

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

THE END

Thanking you all on behalf of QA/QC Department

Alfanar steel

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