SMAWSMAW

Shielded Metal Arc WeldingShielded Metal Arc Welding

OFW/OFCOFW/OFC

OXY FUEL WELDINGOXY FUEL WELDING

OXY FUEL CUTTINGOXY FUEL CUTTING

PurgePurge

To blow or clean out the lines on the To blow or clean out the lines on the Oxy/Acetylene setupOxy/Acetylene setup

FluxFlux

Powdered coating around the Powdered coating around the electrode used in SMAW process.electrode used in SMAW process.

1) Cleans metal/weld while welding1) Cleans metal/weld while welding 2) Cools Metal/weld/electrode while 2) Cools Metal/weld/electrode while

weldingwelding 3) Stabilizes the arc while welding3) Stabilizes the arc while welding 4) Keeps out atmospheric gases from 4) Keeps out atmospheric gases from

the the molten puddlemolten puddle

ElectrodeElectrode

Flux covered conductive rod used as Flux covered conductive rod used as filler in the SMAW processfiller in the SMAW process

SlagSlag

Protective coating over completed Protective coating over completed weld made up of burnt flux, weld made up of burnt flux, impurities that have rose to the top impurities that have rose to the top of weld which aid in the cooling of weld which aid in the cooling process.process.

CraterCrater

Indentation in the weld (below base Indentation in the weld (below base metal) usually happens at the end of metal) usually happens at the end of the weldthe weld

Arc LengthArc Length

Distance between the tip of the Distance between the tip of the electrode and the base metal. Also electrode and the base metal. Also known as Arc Gap.known as Arc Gap.

Long Arc = large GapLong Arc = large Gap Short Arc = Small GapShort Arc = Small Gap

Shorter the Gap = Cooler the ArcShorter the Gap = Cooler the Arc Longer the Gap = Hotter the ArcLonger the Gap = Hotter the Arc

Rod AngleRod Angle

Angle the electrode is held from the Angle the electrode is held from the base metalbase metal

1)Base Angle (BA)1)Base Angle (BA)

2)Direction of Travel Angle (DOTA)2)Direction of Travel Angle (DOTA)

PorosityPorosity

Gas Pocket in/on the weld that is a Gas Pocket in/on the weld that is a defect in the weld. defect in the weld.

Long arc will cause Long arc will cause Dirty base metalDirty base metal Broken flux from the rod.Broken flux from the rod.

FusionFusion

Combining or joining of two materialsCombining or joining of two materials

PenetrationPenetration

Depth of FusionDepth of Fusion

DuctilityDuctility

Ability of metal to be bent or Ability of metal to be bent or stretched without breakingstretched without breaking

1) Rolled1) Rolled 2) Bent2) Bent 3) Stretched3) Stretched

AlloyAlloy

What metal is made up of (Elements)What metal is made up of (Elements)

1) Periodic Table1) Periodic Table ZincZinc MagnesiumMagnesium IronIron

Flashback/BackfireFlashback/Backfire

Hissing or Popping sound from tip of Hissing or Popping sound from tip of torch caused by gas and flame torch caused by gas and flame going back into the tip.going back into the tip.

1)1) Tip to closeTip to close

2)2) Dirty TipDirty Tip

3)3) Malfunction of equipmentMalfunction of equipment

AmpsAmps

The measure of Electrical FlowThe measure of Electrical Flow

1) electrons traveling 1) electrons traveling 2) Water running out of a garden 2) Water running out of a garden

hose hose would be compared to Amps would be compared to Amps 3) Water Flow/Electrical Flow3) Water Flow/Electrical Flow

VoltsVolts

Measure of Electrical PressureMeasure of Electrical Pressure

1) Force of electrons1) Force of electrons 2) Compared to your finger over a 2) Compared to your finger over a

running running garden hose to generate garden hose to generate more more pressure.pressure.

3) water pressure/Electrical pressure3) water pressure/Electrical pressure

PuddlePuddle

Molten metal that follows the Molten metal that follows the electrode, this solidifies to create the electrode, this solidifies to create the weld.weld.

Arc Flash/Flash BurnArc Flash/Flash Burn

Dangerous lights produced during Arc Dangerous lights produced during Arc Welding that damage your eyes/skin Welding that damage your eyes/skin if not protected with shaded/filtered if not protected with shaded/filtered lens or protective clothing.lens or protective clothing.

Dangerous lights: Ultraviolet/InfraredDangerous lights: Ultraviolet/Infrared Arc Flash: Burns unprotected eyesArc Flash: Burns unprotected eyes Flash Burn: Burns unprotected skinFlash Burn: Burns unprotected skin SMAW <125 amps shade 10SMAW <125 amps shade 10

Flash/Arc BurnFlash/Arc BurnUltraviolent/Infrared LightUltraviolent/Infrared Light

Butt JointButt Joint

Corner JointCorner Joint

Outside Inside

Edge JointEdge Joint

T JointT Joint

Lap JointLap Joint

Electrode #’sElectrode #’s

Tensile Strength

60 = 60,000 psi

70 = 70,000 psi

80 = 80,000 psi

90 = 90,000 psi

Welding Position

1 = All Positions

2 = Flat/Horizontal

3 = Flat Only

Special Characteristics

0 = Deep/DC + / Fast Freeze

1 = Deep/AC/DC + / Fast Freeze

3 = Shallow /AC/DC+/DC-

8 = Medium / AC/DC+/Low Hydro

E 60 1 1

Electrode

X 1000 lbs sq inch Tensile Strength

Position

Special Characteristics•Current Type

•Flux Characteristics

•Metal Type

•Penetration

E 60 11E 60 11

E 60 1 1

Electrode

60,000 psi

All Position

Special Characteristics•Deep Penetration

•Cellulose Potassium flux

•Fast Freeze

•AC/DC+ (current)

E 60 1 0E 60 1 0

E 60 1 0

60,000 psi

All Position

Electrode

Special Characteristics•Deep Penetration

•Cellulose sodium flux

•Fast Freeze

•DC+ (current)

E 70 1 8 E 70 1 8

E 70 1 8

70,000 psi

All Position

Electrode

Special Characteristics•Medium Penetration

•Iron Powder Low Hydrogen flux

•AC/ DC+ (current)

E 60 1 3E 60 1 3

E 60 1 3

60,000 psi

All Position

Electrode

Special Characteristics•Shallow Penetration

•Titania Potassium flux

•AC / DC+ / DC - (current)

Electrode #’s Quiz SlideElectrode #’s Quiz Slide

Tensile Strength

60 = 60,000 psi

70 = 70,000 psi

80 = 80,000 psi

90 = 90,000 psi

Welding Position

1 = All Positions

2 = Flat/Horizontal

3 = Flat Only

Special Characteristics

0 = Deep/DC + / Fast Freeze

1 = Deep/AC/DC + / Fast Freeze

3 = Shallow /AC/DC+/DC-

8 = Medium / AC/DC+/Low Hydro

E Electrode

8080,000 psi tensile strength 2 Flat/Horizontal

Position 1 Fast Freeze

Deep Penetration

AC/DC +

E Electrode

60

60,000 psi tensile strength 3 Flat Position

Only8

Low Hydrogen Flux

Medium Penetration

AC/DC +

B. Welding Procedures (Cont.)B. Welding Procedures (Cont.)

b. A tapping movement is where the b. A tapping movement is where the electrode is quickly tapped on the surface electrode is quickly tapped on the surface of the metal to prevent it from sticking to of the metal to prevent it from sticking to the base metal.the base metal.

4 Things Required for a Good 4 Things Required for a Good WeldWeld

Amp Setting :Amp Setting : Heat and (proper current Heat and (proper current type)type)

Travel SpeedTravel Speed

Rod Angle: Rod Angle: (Base Angle/Direction of Travel (Base Angle/Direction of Travel Angle)Angle)

Arc Length: Gap Should Equal Diameter of Arc Length: Gap Should Equal Diameter of ElectrodeElectrode

B. Welding Procedures (Cont.)B. Welding Procedures (Cont.)

8. There are two methods used in starting 8. There are two methods used in starting the arc.the arc. A striking movement is similar to striking a A striking movement is similar to striking a

match.match.

Welding PositionsWelding Positions

FlatFlat

HorizontalHorizontal

VerticalVertical: V Up/V Down : V Up/V Down (v up Gives deeper (v up Gives deeper penetration)penetration)

OverheadOverhead

Flame Types Flame Types

OxygenOxygen

Odorless GasOdorless Gas

Colorless GasColorless Gas

Line Colors GreenLine Colors Green

Right Handed Threads on FittingsRight Handed Threads on Fittings

Types of Combustible GasesTypes of Combustible Gases

3 types commonly Used for Fuel in 3 types commonly Used for Fuel in Oxy/Fuel Welding and CuttingOxy/Fuel Welding and Cutting

AcetyleneAcetylene PropanePropane Mapp Gas Mapp Gas ((mmethylethylaacetylene-cetylene-ppropadiene ropadiene ppropane)ropane)

acetyleneacetylene

Colorless GasColorless Gas Garlic OdorGarlic Odor Unstable after 15psi Line PressureUnstable after 15psi Line Pressure Absorbed into Acetone (cork) to Absorbed into Acetone (cork) to

allow higher pressures in Tankallow higher pressures in Tank Red Colored Hoses w/ Left Handed Red Colored Hoses w/ Left Handed

ThreadsThreads

Duty CycleDuty Cycle

The amount of time a welding The amount of time a welding machine can be operated machine can be operated continuouslycontinuously

70% Duty Cycle= 70% of an hour70% Duty Cycle= 70% of an hour 70% Duty Cycle = 7 minutes every 70% Duty Cycle = 7 minutes every

10 min10 min

PolarityPolarity

DC+DC+ DC-DC- DCEPDCEP DCENDCEN Reverse PolarityReverse Polarity Straight Straight

PolarityPolarity