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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