Tack Welding. Ship Terms Introduction Course Overview 2

Tack Welding

Ship Terms

• Introduction

• Course Overview

2

Course Objectives• Practice safety

• Distinguish between welding and tack welding

• Follow tack welding standards

• Identify tack welding parts, types and materials

• Setup and operate SMAW equipment

3

Benefits

4

Tack Welding Safety• Practice safety regulations

• Wear correct PPE

• Recognize safety signs and signals

5

What’s the Difference?

6

The size of the weld!

Site Accidents• Mental/physical

stress

• Medications, illness or injury

• Alcohol and drug abuses

• Foot & vehicle traffic congestion

• Hurried shift changes

• Faulty or damaged equipment

7

PPE Illustration

8

Lab 1: Wear PPE• Observe how Personal Protective

Equipment should be worn when welding.

9

Observe Tack Welding

• Activity 1: Pay attention to what you see, hear, feel and smell in the environment while observing tack welding in action.

10

Safety Precautions

11

Welding Accidents Video

• Activity 2: Watch video and discuss questions.

Insert (welding) Photo Here

12

Lab 2: SMAW Tack Welding• Observe and listen as SMAW tack

welding is being performed.

13

Tack Welding Safety Quiz

Test Your Knowledge!

14

PPE Application Assessment

Test Your Knowledge!

15

Tack Welding Basics• Follow tack welding

quality standards

• Identify tack weld types and structural components

• Prepare weld surfaces

16

Welding Defined

• A fabrication process that joins materials into one piece by melting and adding a filler to form a pool of molten material that cools to become a strong joint.

17

Tack Welding

• Tack welding is a “Short” weld.

18

Whatever you do, right or wrong, in a tack weld will

directly impact the quality of welding operation by

the person following you!

Good and Bad Tack Welds

19

Tack welding helps prevent joint distortion.

Travel to Fast Travel Too Slow Amperage Too Low

Amperage Too High Arc Too Short Arc Too Slow

A Good Weld!

Lab 3: Tack Welding Demo• Observe a good and bad tack weld being

demonstrated.

20

Tack Welding Preparation

• Insert Photo Here (Preparation of weld surface)

“In Process” describes the preparation of materials

and surfaces for tack welding.

21

Lab 4: Tack Weld Surface Prep• Observe a tack weld surface being

prepared.

• Insert Photo Here (Preparation of weld surface)

22

Tack Welding Standards

Welding codes can vary by project. Check with

your supervisor if you are unsure of the regulating

codes for your project.

• This course will provide you with knowledge to perform tack welding procedures generally required of entry-level shipfitters at most any shipyard.

23

AWS Welding Standards

• Activity 3: Study tack welding standards and American Welding Society (AWS) Codes

24

Tack Welding Positions

A number is designated as the code that

corresponds with each welding position.

1—Flat

2—Vertical

3—Horizontal

4—Overhead

• Insert Photo Here (A tack welding position)

25

Welding Position Designations

• Activity 4: Identify welding position designations.– 2G– 1F– 3F– 4G

26

Lab 5: Welding Position Demo• Observe welding positions being

demonstrated and explained.

• Insert Photo Here (Welding Positions)

27

Structural Components/Shapes

These are the most common components

used in entry-level shipfitting.

1. I-Beam

2. H-Beam

3. Tee Bar

4. Angle

5. Channel

7. Square Tubing

9. Flat Bar

28

Component Identifiers

Certain identifiers are unique to several of

the structural members common to fitting.

29

Lab 6: Structural Components• Study structural components.

30

Tack Welding Terms

There are many “buzz” words in ship fitting.

Electro

de • Use the glossary of terms in your PG to learn new words!

Stick

Rod

Cable

Flux

31

Tack Welding Basics Quiz

Test Your Knowledge!

32

SMAW Equipment• Setup and operate

SMAW equipment safely

• Adjust basic power supplies

• Attach welding leads, cables, electrodes and ground clamps

33

SMAW• Shielded Metal Arc

Welding is the main welding process used in tack welding.

SMAW is a process which melts and joins

metals by heating them with an arc that is

struck between a coated metal electrode

and the work piece.

34

SMAW Features1. Stick Welding Power Source—Constant Current

(CC), AC or DC

2. Insulated Electrode Holder (whip)

3. Workpiece

4. Work Clamp

35

Lab 7: SMAW Demo• Observe basic hook up and features of

SMAW process.

-+

On

Off

Ground Lead

Electrode Holder

Workpiece

Electrode Lead

Welding Machine

Arc

Electrode

36

Voltage and Current

• Voltage is actually the measure of current flow:– Voltage and Current

– Voltage (Volts)

– Current

LEARN THIS SYMBOL!This is the international safety symbol for high voltage. It means “CAUTION, RISK OF ELECTRIC SHOCK.”

37

Amperage

• Amperage = Intensity

Intensity or amperage of the current directly

impacts tack weld quality because this is

the heat source.

38

Welding Leads and Polarity

Two Concepts: DCEP or DCEN

Welding lead that holds ground clamp

Welding lead that holds electrode holder

Polarity = Direction of current flow

39

Lab 8: Hooking Up Weld Leads• Observe the hook up of DCEP and DCEN

weld leads.

40

SMAW Equipment• AC—alternating only • DC—direct only• AC/DC—both alternating

and direct

Machine classifications indicate to the

welder which type of welding procedure that

machine is designed to support.41

SMAW Equipment Selection• Identify:

– Welding process– Welding current – Maximum amperage – Primary power connections

42

Exercise: Equipment Selection• Welding process?• Welding current?• Maximum amperage?• Primary power connections?

43

Electrode/Amperage Selection

Ask yourself: Are the correct

outlets and power connections

available for safe hookup?

44

Lab 9: Weld Machine Demo• Observe how a welding machine

functions and how the power sources vary.

45

String Welding Lead• After machine

selection, first string the welding lead.

The larger the lead,

the more current it can conduct!

Welding lead.

46

Weld Lead End Connections• Proper end connections need to be made

to effectively setup welding leads.

Ground Clamp

Lugs Electrode Holder

47

Line ControlLine Control Quick Reference Guide

1.Inspect lines for damage before doing any work.

2.Adhere to OSHA standards by making any repairs needed

to insulation cuts or breaks. (Breaks can cause arcs which

damage surfaces and cables.)

3.Adjust line length to reach the work area but not so long that

it must always be coiled.

4.String lines to prevent tripping or damage from traffic in

area.5.Remove lines from walkways or aisles and place overhead

when necessary.

6.Protect lines with boards or ramps when overhead stringing

cannot be done. (This offers safety from foot and vehicular

traffic in work area.)

7.Avoid damaging equipment when stringing lines.

8.Never string lines over machine instrumentation wires or

tubing. (Line weight or movement can cause damage.)

9.Secure welding lines away from nip points.

10.Check for any detached materials or equipment that could

be shifted or collapse under the weight or movement of lines.

11.Use rope to tie off welding lines when stringing overhead

or between floors. (Rope can safely support the weight of the

line without causing damage.)

 Use the line control quick reference guide!48

Lab 10: Cable Connections• Observe how to make cable connections

and string cable safely.

• Practice working with a partner.

49

Electrode Holders

Electrode holders are used to grip the electrode while the tack

weld is being completed.

50

Ground Clamp Location

Ground clamps form a connection between the material

being worked and the lead serving as a return path for

electrical current.

51

Workpiece Clamp Location Quick Reference Guide

1.Consult with your supervisor before proceeding if you have

any questions.

2.Position clamp to avoid current passing through any

contacting surface.

3.Disconnect workpiece lead at the battery to protect electrical

systems when using mobile equipment.  

4.Remove batteries when welding is performed near them.

(Hydrogen gas produced by batteries is very explosive.)

5.Have an electrician to isolate an electrical system as

needed for protection.

6.Don’t ever connect workpiece clamps to pipes loaded with

flammable or corrosive material.

7.Ensure the workpiece clamp makes a good connection to

the workpiece.

8.Clean work surfaces by removing dirt, paint or other foreign

substances that could overheat the workpiece clamp.

9.Change workpiece clamps when they do not close fully or

are otherwise damaged.

Ground Clamp Location

Use the Workpiece Clamp Location Quick Reference Guide!

52

Lab 11: Attach a Ground Clamp• Observe how to attach a ground clamp

for SMAW.

• Practice working with a partner.

53

Tack Weld Cleaning

Common Cleaning Tools:•Chipping hammers•Wire brushes•Needle guns•Grinders•Scaling guns

54

Lab 12: Use Hand Tools• Observe how to use hand tools to clean

and prepare surfaces.

55

Welding Equipment Safety Cheat Sheet

1.Never remove your face shield if a rod gets stuck. When it

releases, it will flash.

2.Properly ground welding machines to avoid coming in contact with

primary current since this can lead to electrical shock or worse!

3.Take precautions to avoid direct contact with the primary circuit of

a welding machine because this can cause electrocution.

4.Never run engine-driven generators or alternators indoors

because they can cause carbon monoxide poisoning.

5.Do not attempt to stop a falling welding machine. They are very

heavy and can severely injure you.

6.Identify the electrical disconnect for a welding machine before

hookup and use so that in an emergency you can quickly disable

the power source.

7.Do not conduct welding or cutting of any kind around batteries

due to the explosive nature of battery acid.

8.Do not attempt to blow off or clean engine-driven machines while

they are running. Moving parts can sling debris and cause injury.

9.Close all covers and cowlings before starting machines to avoid

exposure to moving parts.

10.Continue to wear eye and hand protection when cleaning

equipment due to work surfaces and materials remaining hot for

extended periods.

11.Never wear jewelry or body studs of any kind and keep all

exposed body hair shaven and/or protected from heat or flames.

12.Remain aware at all times that environmental conditions can

create heat stress.

Welding Equipment Safety

Use the Welding Equipment Safety Cheat Sheet!56

SMAW Equipment Quiz

Test Your Knowledge!

57

SMAW Electrodes• Recognize and select

electrodes

• Identify electrodes based on code classifications

• Determine applications of low hydrogen electrode groups

• Handle and store electrodes according to procedures

58

SMAW Electrodes

In SMAW, the electrode is consumable vs.

nonconsumable electrodes used in other welding

processes.

• Consumable electrodes melt into the weld joint and become part of the initial weld.

59

Electrode Flux• SMAW electrodes have a metal core with

a flux coating. – Flux—shields the weld – Wire core—transfers the current to the

material.

60

Lab 13: Tack Welding Demo• Observe how to use electrodes to tack

weld.

Insert Photo Here

61

Electrode Classification

Know how the lettering and numbering works when

selecting electrodes for tack welding.

62

Electrode Classification

• Activity 5: Locate the classification of each electrode and describe what each number and letter represents.

63

Electrode Groups

Electrode groups are created based on general

characteristics, and the “Low-Hydrogen” electrode

is the most common to tack welding.

Insert Photo Here

64

Electrode Selection

Current range of welding equipment, base metal

properties, weld positions and design requirements

all play a significant part in electrode selection.

65

Compatibility Demonstration

• Activity 6: Watch how to test for base metal and electrode compatibility.

66

Electrode Storage & Handling

Proper handling of electrodes is serious business!

• Store filler metal in warm, dry area away from floor.

• Place them to avoid possible damage.

• Put electrodes in oven if containers have been opened.

67

Lab 14: Low Hydrogen Demo• Observe how a low hydrogen E7018

electrode works when tack welding.

Insert Photo Here

68

SMAW Electrodes Quiz

Test Your Knowledge!

69

SMAW Techniques• Setup SMAW

equipment

• Strike an arc

• Tack weld using 6010 and 7018 electrodes

70

Weld Coupons

Weld coupons are used for welding practice.

Always prep your welding coupon just as you would a

regular workpiece.

71

Preparing Test Coupons

1. Use hand tool to realign workpieces on the sides and ends

2. Tack the far ends of workpieces

3. Make intermediate tack welds as needed to maintain workpiece alignment

72

Compatibility Demonstration

• Activity 7: Observe and listen to information about different weld coupons.

Insert Photo

73

Lab 15: Tack Welding Demo• Observe how the first steps of tack

welding are performed.

Insert Photo Here

74

SMAW Components• Find the following:

– Stick welding power source

– Insulated electrode holder

– Workpiece– Ground clamp

7575

Stick Welding Setup

• Follow steps 1-7 in PG for simple setup.

76

Lab 16: Setup Equipment• Observe how to setup SMAW equipment:

– Workpiece– Work clamp– Electrode holder

Answer the questions in your PG.

77

Striking an Arc

• Two Techniques:– Scratch start– Tapping

78

Scratch Start Technique

• Remember:– Welding current

starts as soon as you touch the workpiece Part 1—Electrode

Part 2—Workpiece

Part 3—Arc

79

Tapping Technique

• Bring electrode straight down to workpiece

• Lift slightly

Part 1—Electrode

Part 2—Workpiece

Part 3—Arc

80

Lab 17: Striking an Arc• Observe how to strike an arc:

– Scratch start technique– Tapping technique

Exercise caution and apply all safety rules when

striking an arc!

81

Positioning Electrode Holder• Best Results:

– Hold a short arc– Travel at uniform speed– Feed electrode downward at constant rate

Fillet Welds

82

Lab 18:Fillet Welding Demo• Observe the techniques of fillet tack

welding.

83

Electrode Movement1. Stringer Bead

2. Weave Bead

3. Weave Patterns

84

Conditions Affecting Beads1. Electrode Angle

2. Arc Length

3. Travel Speed

85

Poor Weld Beads1. Large spatter deposits

2. Rough, uneven bead

3. Slight crater during welding

4. Bad overlap

5. Poor penetration

86

Good Weld Beads1. Fine spatter

2. Uniform bead

3. Moderate crater during welding

4. No overlap

5. Good penetration into base metal

87

Lab 19: Good and Bad Demo• Observe the differences between good

and bad tack welds.

88

Welding Coupon Test• Strike weld joint in the direction shown • When test coupon breaks, weld will be

examined for proper penetration and tie-ins

89

Lab 20: Creating Tack Welds• Integrate your skills!

• REMEMBER! Always wear required PPE and

adhere to the guidelines for safe welding.

90

SMAW Techniques Quiz

Test Your Knowledge!

91

Summary

SMAW Techniques

Tack Welding Basics SMAW Equipment

SMAW Electrodes

Tack Welding Safety

92

Tack Welding Application Assessment

Test Your Skills & Knowledge!

93

What’s Next?

• Let’s take a look at what’s next in the course curriculum.

94