SMAW(Stick Welding)

*SMAW Unit TopicsDuring this overview, we will discuss the following topics:SafetySMAW Basics Equipment Set-UpWelding VariablesProcess Advantages and Limitations AWS ConnectionNational Academic Standards Connection

The SMAW process is great for maintenance and repair work!

* Unit ObjectivesUpon successful completion of the SMAW Unit of Study, you will have learned to:Properly protect yourself and others while weldingSet up and operate SMAW equipmentStrike and maintain an arcMake welds in four positions using different electrodesUnderstand a weld inspection processApply the AWS electrode classification systemTake the next step to becoming a certified welder

Most structural steel welders are required to be certified

*SMAW Safety

*SMAW SafetySMAW Safety is supplemental and does not replace the information found in Arc Welding BasicsUnderstand and follow all safety precautions listed in Safety in Welding, Cutting, and Allied Processes (ANSI Z49.1) and Arc Welding Safety (E205)Understand and follow all warning labels found:On welding equipmentWith all consumable packagingWithin instruction manualsRead Material Safety Data Sheets (MSDS)If you ever have a question about your safety or those around you, PLEASE ASK YOUR INSTRUCTOR!

*SMAW SafetyFumes and Gases can be dangerousKeep your head out of the fumesUse enough ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general areaThe SMAW process can withstand wind and exhaust near the arc from ventilation equipmentElectric Shock can kill to receive a shock your body must touch the electrode and work or ground at the same timeDo not touch the electrode or metal parts of the electrode holder with skin or wet clothingKeep dry insulation between your body and the metal being welded or groundArc Rays can injure eyes and skin - Choose correct filter shade (See chart below)

** Information taken from ANSI Z49.1:2005**

*SMAW Principles

*SMAW PrinciplesThe American Welding Society defines SMAW as Shielded Metal Arc WeldingSMAW:Is commonly known as Stick welding or manual arc welding Is the most widely used arc welding process in the worldCan be used to weld most common metals and alloys

*SMAW Welding CircuitCurrent flows through the electrode cable, to the electrode holder, through the electrode, and across the arcOn the work side of the arc, the current flows through the base material to the work clamp and back to the welding machine

*SMAW ProcessLets take a little closer look at the SMAW process1Travel directionElectrodeArc2Weld Puddle3Shielding Gas4Solidified Weld Metal5Slag6

*1- The Electrode Is a consumable - it gets melted during the welding processIs composed of two partsCore Rod (Metal Filler)Carries welding current Becomes part of the weldFlux Coating Produces a shielding gasCan provide additional filler Forms a slag

*2- The ArcAn arc occurs when the electrode comes in contact with the work-piece and completes the circuit like turning on a light!The electric arc is established in the space between the end of the electrode and the workThe arc reaches temperatures of 10,000F which melts the electrode and base materialCan you identify the weld joint and position being used?

*3- Weld PuddleAs the core rod, flux coating, and work pieces heat up and melt, they form a pool of molten material called a weld puddle The weld puddle is what a welder watches and manipulates while welding1/8 E6013 at 125 Amps AC

*4- Shielding GasA shielding gas is formed when the flux coating melts.This protects the weld puddle from the atmosphere preventing contamination during the molten state

The shielding gas protects the molten puddle from the atmosphere while stabilizing the arc

*5- Solidified Weld MetalAs the molten weld puddle solidifies, it forms a joint or connection between two pieces of base materialWhen done properly on steel, it results in a weld stronger than the surrounding base metal

*6- SlagSlag is a combination of the flux coating and impurities from the base metal that float to the surface of the weld. Slag quickly solidifies to form a solid coatingThe slag also slows the cooling rate of the weld The slag can be chipped away and cleaned with a wire brush when hardThis welder chips the slag off of a weld during the repair of railroad tracks

*Application Activity

*Application ActivityLets review the SMW process 1 = __________

2 = __________

3 = __________

4 = __________

5 = __________

6 = __________

*Equipment Set Up

*SMAW Equipment Set UpTurn power supply onConnect work clampSelect electrode a. Type b. Diameter4. Adjust output a. Polarityb. Amperage 6. Insert electrode into electrode holder

* SMAW Process VariablesSettings on the machine Polarity : AC, DC+, DC-Amperage OutputOperator Controlled VariablesWork AngleTravel AngleArc LengthTravel Speed

A straight AC machine will not have a polarity switch like this AC/DC machine

*Striking an Arc and Making a Weld

*Striking an Arc To begin the SMAW Process, you must first strike an arc. This can be done using one of the following techniques:Scratch start scratch the electrode on the base metal like a matchTap Start tap the rod against the base metal

*Work AngleThe work angle is the angle between the electrode and the work as depicted on the leftWork angles can vary depending on the position the weld is being made in

90

*

Travel AngleAlso commonly called Lead AngleThe travel (lead) angle is the angle between the electrode and the plane perpendicular to the weld axis20-30

*Arc LengthAfter striking the arc, maintain a 1/8 distance between the electrode and the workpieceIf the arc length becomes too short, the electrode will get stuck to the workpiece or short outIf the arc length becomes too long; spatter, undercut, and porosity can occurArc Length = 1/8

*Travel Speed The travel speed is the speed at which the electrode moves along the base material while weldingToo fast of a travel speed results in a ropey or convex weld Too slow of a travel speed results in a wide weld with an excessive metal depositThe travel speed impacts the shape of the bead.End of Weld

*Filling the CraterAt the end of the weld, the operator breaks the arc which creates a craterUse a short pause or slight back step at the end of the weld to fill the craterLarge craters can cause weld crackingBack stepping is a short move in the opposite direction of weld travel

*Restarting a BeadHere is the proper technique for restarting a weld:1. Strike Arc Here

2. Move Electrode to Crown of Crater

3. Resume Forward Travel

*Troubleshooting Welds

*Troubleshooting Welds

ABCDEFGThese welds were cut and etched with nitric acid to show penetration

*SMAW Advantages and Limitations

*Advantages of SMAWLow initial costPortableEasy to use outdoors All position capabilitiesEasy to change between many base materialsWhat safety precautions should be taken by these welders?

*Limitations of SMAWLower consumable efficiency Difficult to weld very thin materialsFrequent restartsLower operating factorHigher operator skill required for SMAW than some other processesBuilding a barge in a large shipyard

*AWS Classification of SMAW Electrodes

*E70XXElectrodeTensile in KsiWelding Position: 1 = All Position, 2 = Flat & HorizontalType of Current and Coating

AWS Classification of SMAW Electrodes

*Lesson Plans

*SMAW Lesson #1Objective: Strike and establish an arcEquipment: Single Process Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MPMaterial: Mild Steel Plate 1/8 or thicker1/8 Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC

*SMAW Lesson #2Objective: To run a straight bead on flat plate and to fill the craterEquipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MPMaterial: Mild Steel Plate 3/16 or thicker1/8 Fleetweld 37 (E6013)

GoodPoor

*SMAW Lesson #3Objective: To run a bead with the whip techniqueEquipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MP

Material: Mild Steel Plate 3/16 or thicker1/8 Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC

*SMAW Lesson #4Objective: To build a padEquipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MP

Material: Mild Steel Plate 3/16 or thicker1/8 Fleetweld 37 (E6013)

*SMAW Lesson #5Objective: To make a fillet weld on a lap joint in the horizontal position (AWS Position 2F)Equipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MP

Material: Mild Steel Plate - 10 gauge 1/8 Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC

2FTop ViewSide View

*SMAW Lesson #6Objective: To make a fillet weld on a tee joint in the horizontal position (AWS Position 2F)Equipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MPMaterial: Mild Steel Plate - 10 gauge 1/8 Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC2F

*SMAW Lesson #7Objective: To make a fillet weld on a tee joint in the horizontal position (AWS Position 2F)Equipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MPMaterial: Mild Steel Plate - 10 gauge 1/8 Excalibur 7018 (E7018) for DC or Lincoln 7018AC (E7018) for AC2F

*SMAW Lesson #8Objective: To make a three pass fillet weld on a tee joint in the horizontal position (AWS Position 2F)Equipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MP

Material: Mild Steel Plate 1/8 Excalibur 7018 (E7018) for DC or Lincoln 7018AC (E7018) for AC2F

*SMAW Lesson #9Objective: To make a fillet weld on a lap joint in the vertical position welding down (AWS Position 3FD)Equipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MP

Material: Mild Steel Plate - 10 gauge 1/8 Fleetweld 37 (E6013)

3FD

*SMAW Lesson #10Objective: To make a fillet weld on a tee joint in the vertical position welding down (AWS Position 3FD)Equipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MPMaterial: Mild Steel Plate - 10 gauge 1/8 Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC

3FD

*SMAW Lesson #11Objective: To make a fillet weld on a lap joint in the overhead position (AWS Position 4F)Equipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MP

Material: Mild Steel Plate - 10 gauge 1/8 Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC

4F

*SMAW Lesson #12Objective: To make a fillet weld on a tee joint in the overhead position (AWS Position 4F)Equipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MP

Material: Mild Steel Plate - 10 gauge 1/8 Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC4F

*SMAW Lesson #13Objective: To make a single pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F)Equipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MPMaterial: Mild Steel Plate 1/41/8 Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC3F

*SMAW Lesson #143FObjective: To make a three pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F)Equipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MP

Material: Mild Steel Plate 1/4 1/8 Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC

*SMAW Lesson #15Objective: To make a single pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F)Equipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MP

Material: Mild Steel Plate 1/41/8 Excalibur 7018 (E7018) for DC or Lincoln 7018AC (E7018) for AC

3F

*SMAW Lesson #16Objective: To make a three pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F)Equipment: Single Process - Constant Current Power Source Idealarc 250 and accessoriesPrecision TIG 225 and accessoriesMulti-ProcessPower MIG 350 MPMaterial: Mild Steel Plate 1/4 1/8 Excalibur 7018 (E7018) for DC or Lincoln 7018AC (E7018) for AC

3F

*AWS Connection

*AWS ConnectionThe SMAW Welding Unit of study incorporates the following information taken from the AWS EG 2.0 requirements:Set up for SMAW operations on carbon steelOperate SMAW equipment on carbon steelMake SMAW fillet welds on carbon steel

*English, Math, and Science Connection

*National Academic Standards CrosswalkThe unit, just completed, has covered parts of academic content listed in the National Academic Standards as follows:

NM-PROB.CONN.PK-12.3: Recognizes and applies mathematics in contexts outside of mathematics.NLA-STANDARD 1: Uses the general skills and strategies of the writing process.NLA-STANDARD 7: Uses reading skills and strategies to understand and interpret a variety of informational texts.NS-PHYSICAL SCIENCE: (Experiences) interactions of energy and matter.

*SECTION OVERVIEW:Section Overviews are provided on the introductory slides at the front of each topical area to explain the intended use for the slides included in the section. Slide numbers are included on the Section Overview slides for easy reference when preparing for delivery of the slide content.

TEACHER NOTES: Teacher Notes are included on the Section Overview slides as a reference tool when making class preparations. Suggested Activities are included as ideas for teachers to use to help students gain practical experience with the welding content. However, these are designed to be supplemented by each teacher based on local program needs.Slides have been developed to incorporate content information regarding performance standards from the American Welding Society (AWS) and the National Academic Standards for English, Science, and Math.

INDIVIDUAL WELDING LESSON NOTES ARE AVAILABLE IN LESSON PLAN FACILITATORS GUIDE*SECTION OVERVIEW:This slide is meant to start generating conversation and thoughts about content to be covered in this lesson.

TEACHER NOTES: Bulleted information on topical areas is provided to lead class discussion on areas which are to be covered in the training.

*SECTION OVERVIEW:This slide is included to explain the objectives of this unit of study.

TEACHER NOTES: Teachers could use this opportunity to give a high-level overview of the importance and application of SMAW welding in todays society.

*SECTION OVERVIEW:The next few slides are meant to point out safety requirements when doing SMAW welding.

TEACHER NOTES: Slides 4-6: Bulleted information on topical areas is provided to lead class discussion on important areas of safety to be practiced in the SMAW welding environment.To download your own copy of Safety in Welding, Cutting and Allied Processes (ANSI Z49.1) go to: www.aws.org/technical/facts/Z49.1-2005-all.pdfTo download your own copy of Lincoln Electrics Arc Welding Safety (E205) document go to: http://content.lincolnelectric.com/pdfs/products/literature/e205.pdfTo order copies of Lincoln Electrics Arc Welding Safety (E205) document and poster (E201) go to: www.lincolnelectric.com (Quick Link: Literature Request)MSDS can be obtained from Lincoln Consumable packaging, online at www.lincolnelectric.com (Quick Link: MSDS) or by calling 1-216-481-8100For a free DVD on Welding Safely, submit order form in the back of the Lesson Plan Facilitators Guide (shipping and handling charges apply).See Facilitators Guide for more information on welding hazards such as Fumes and Gases and Electrical Shock.***SECTION OVERVIEW:These slides are meant to lead into the discussion of the SMAW process

TEACHER NOTES:Slides 7-16: For more information on the American Welding Society, see Arc Welding Basics and www.aws.orgDiscussion could be given on stick electrodes commonly being between 9-18 long, and come in diameters ranging from 1/16 to 1/4. An activity could be to show 3 electrodes all the same diameter: E6010 or E6011, E7018, and E7024. Ask students to compare flux coatings (color, thickness, feel) The size of the electrode is determined by the diameter of its metal core. PLEASE NOTE: The overall diameter of the electrode changes due to flux coating even though metal diameter remains the same.An arc digs into the base metal much like water from a nozzle on a garden hose digs into the earth. (The flow of the water is like welding current and water pressure is similar to voltage)

**********SECTION OVERVIEW:These slides provide an overview of the SMAW process.

TEACHER NOTES: (Explanation of Activity)Slides 17-18: After discussing the parts included on this slide, students will take a quiz as an application activity. For the activity, have participants work individually and mark 1-6 on a piece of paper. Explain that this activity is meant to check whether each student understands SMAW before beginning to apply the process in the lab. Project slide on the screen and have each student fill in the blanks on a piece of paper to be turned in. Collect papers and discuss.Answers to the Application Activity are:1. Electrode2. Arc3. Weld Puddle4. Shielding Gas5. Solidified Weld Metal6. Slag

**SECTION OVERVIEW:These slides explain how to set up the equipment for SMAW and the process variables used.

TEACHER NOTES:Slides 19-21: These slides explain SMAW equipment set up and operator controlled variablesThe exposed metal end of the electrode should fit securely within the jaws of the electrode holderDiscuss how the correct amperage setting for any given electrode is important to ensure proper shape of bead, proper penetration, and minimal spatter. Explain when the amperage is set too high the bead may be flat, have excessive spatter, have some porosity and the electrode will overheat. If the amperage setting is too low, difficulty is experienced in striking the arc and maintaining the correct arc length. The weld bead becomes convex with excessive overlap and poor penetration. Discuss polarity All stick electrodes run on DC. Not all will weld on AC. All electrodes have a preferred polarity and most are designated by the AWS.

***SECTION OVERVIEW:These slides discuss striking an arc and making a weldTEACHER NOTES:Slides 22-29: When using these slides, teachers may prefer to discuss the importance of the following topics:Striking an arcWork angleTravel angleArc lengthTravel speedFilling a craterRestarting the bead********SECTION OVERVIEW:The next slide discusses several troubleshooting topics.TEACHER NOTES:Slide 30-31: Weld troubleshooting. The beads on the pad depict changes in welding variables and their results. Discuss the following:A Good Weld: Proper Current, Travel Speed and Arc LengthB Current too low: Ropey, convex bead appearanceC Current too High: Excess spatter and possible burn-through of base materialsD Arc Length too short: Poor wet-in at toes, electrode can short to base materialE Arc Length too Long: Excess spatter, undercut and porosityF Travel Speed too slow: Wide weld with excess metal depositG Travel Speed too high: Ropey and convex bead

**SECTION OVERVIEW:This section is meant to lead into a discussion regarding the advantages and limitations of using the SMAW process. TEACHER NOTES:Slides 32-34: The advantages and limitations of SMAW Advantages: Low start up costs SMAW equipment is less expensive than GMAW equipmentPortable electrode leads are easy to move from job to job Easy to use outdoors - The process does not require a shielding gas so it is resistant to windsAll position capabilitiesSMAW can be used on variety of materials just change the electrode and youre ready for the next projectLimitations:Electrodes are 60-65% efficient - 1.5 to 2 of the electrode (stub) is thrown away. The slag and spatter also contribute to SMAW consumable losses.Difficult to weld very thin material Frequent restarts Most electrodes are 9-18 in length. As the electrodes are consumed they continually need to be replacedOperating factor of 5-25% - Operators using the SMAW process spend only 5-25% of their time welding. Time is spent chipping slag, cleaning spatter, changing electrodes, repositioning the part, etc.It takes practice to become a good welder using the SMAW process. The GMAW process is generally easier to learn.***SECTION OVERVIEW:This section is meant to lead into a discussion regarding the AWS Classification of SMAW ElectrodesTEACHER NOTES:Slides 35-36:

For more information on the AWS classification of SMAW electrodes see Lincoln Electrics free Stick Electrode Product Catalog - http://content.lincolnelectric.com/pdfs/products/literature/c210.pdf *9*SECTION OVERVIEW:These slides are used for practicing lesson content in the lab setting.

TEACHER NOTES:Slides 37-53: When using these slides, teachers might want to reference information included in the Facilitators Guide.Recommended equipment Only one of the single process or multi-process machines is required to complete the lesson.

*****************SECTION OVERVIEW:The next few slides discuss the connection of this unit with AWS and the certification process. TEACHER NOTES: Slide 54-55: Content included in this unit of study is designed to be used by interested students as a building block in the learning process if interested in pursuing a certification program**SECTION OVERVIEW:The next slide discusses how the content covered in the welding unit is applicable to English, Math, and Science classes.TEACHER NOTES: Slides 56-57: These slides contain information regarding how this welding unit of study relates to the National Academic Standards.

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