Objectives
-List and identify the components of a shielded metal arc welding station
-Define constant current welding machine and identify the welding process with which it would be used
-List three methods used in welding machines for creating AC or DC welding current
-Determine the correct size welding leads to use for any required current capacity
-Demonstrate the ability to identify and/or specify carbon steel, low-alloy steel, corrosion-resistant steel, and nonferrous covered electrodes using the AWS electrode classification system
-Determine the correct shade of welding lens needed for welding a given thickness of metal using a particular welding process
-Define constant current welding machine and identify the welding process with which it would be used
-List three methods used in welding machines for creating AC or DC welding current
-Determine the correct size welding leads to use for any required current capacity
-Demonstrate the ability to identify and/or specify carbon steel, low-alloy steel, corrosion-resistant steel, and nonferrous covered electrodes using the AWS electrode classification system
-Determine the correct shade of welding lens needed for welding a given thickness of metal using a particular welding process
Vocabulary
Electrode
(DC)Direct Current
(AC) Alternating Current
SMAW Shielded Metal Arc Welding
Stinger/electrode holder
Ground
Lead/whip
Ferrous and Nonferrous
(CC) Constant Current
Shields, Helmets and Shades
(DC)Direct Current
(AC) Alternating Current
SMAW Shielded Metal Arc Welding
Stinger/electrode holder
Ground
Lead/whip
Ferrous and Nonferrous
(CC) Constant Current
Shields, Helmets and Shades
Laboratory focus
Practice SMAW in the flat (1) and horizontal (2) positions using 6013 electrode on 1/4" mild steel
Making a Weld with the SMAW Process
Shielded Metal Arc Welding
OBJECTIVE:
To make welds in the horizontal and vertical positions with the Shielded Metal Arc Welding process.
EQUIPMENT: A constant current power supply, work cable / clamp, and electrode cable / clamp.
MATERIAL:
Weld # 1 = Weld beads on a 4x6" piece of 1/4" mild steel plate and a 1/8" E6013 electrode. This is called padding. Try to keep the weld uniform, they should overlap the previous weld by 1/2 the width.
Weld #2 = Two 3" pieces of 1/4" mild steel plate and a 1/8" E6013 electrode. 2F TEE joint
Weld #3 = Two 3" pieces of 1/4" mild steel plate and a 1/8" E6013 electrode. 1F Lap joint
GENERAL INFORMATION:
Joining members of plates coming in at 90 degree angles to each other with a fillet weld is the most commonly used joint in the welding industry.
Most fillet welds are made in the horizontal position. When placed in this position, the welding speed is increased, the molten metal has less tendency to run, and better penetration is achieved. The strength of this joint depends on the joint fitting close together.
Many welds are made out of the flat and horizontal welding position. Vertical down welding is generally done on thin materials and/or for fast travel speeds. Vertical up welding is done for penetration purposes at reduced travel speeds, and/or deposit rates.
INSTRUCTIONS:
Make horizontal fillet welds first in the horizontal position, and then with the out of position electrodes, vertical up position.
Making a Weld with the SMAW Process
Shielded Metal Arc Welding
OBJECTIVE:
To make welds in the horizontal and vertical positions with the Shielded Metal Arc Welding process.
EQUIPMENT: A constant current power supply, work cable / clamp, and electrode cable / clamp.
MATERIAL:
Weld # 1 = Weld beads on a 4x6" piece of 1/4" mild steel plate and a 1/8" E6013 electrode. This is called padding. Try to keep the weld uniform, they should overlap the previous weld by 1/2 the width.
Weld #2 = Two 3" pieces of 1/4" mild steel plate and a 1/8" E6013 electrode. 2F TEE joint
Weld #3 = Two 3" pieces of 1/4" mild steel plate and a 1/8" E6013 electrode. 1F Lap joint
GENERAL INFORMATION:
Joining members of plates coming in at 90 degree angles to each other with a fillet weld is the most commonly used joint in the welding industry.
Most fillet welds are made in the horizontal position. When placed in this position, the welding speed is increased, the molten metal has less tendency to run, and better penetration is achieved. The strength of this joint depends on the joint fitting close together.
Many welds are made out of the flat and horizontal welding position. Vertical down welding is generally done on thin materials and/or for fast travel speeds. Vertical up welding is done for penetration purposes at reduced travel speeds, and/or deposit rates.
INSTRUCTIONS:
Make horizontal fillet welds first in the horizontal position, and then with the out of position electrodes, vertical up position.
- Clean base material if necessary and tack the plates together at a 90° angle to each other.
- Adjust amperage with the controls on the power source. Document the procedures on the following pages.
- For horizontal fillet welds, hold the electrode at a 45° angle from the horizontal plane, start the weld at the edge of the plate, and hold / maintain proper work and electrode angle and ESD electrode to surface distance
- For E6013 electrode use a slight electrode angle.
- Maintain the proper bead shape at the beginning, middle, and end of the plate. The bead size should be approximately a 3/16” to 1/4” fillet. Run the weld bead the entire length of the plate and chip the slag off and wire brush off the weld.
Assignment for video (download file)
| welding_worksheet_for_electrode_video.docx |