WELCOMEIN
TRAINING PRESENTATION
Date:16/06/2015
Prepared by :
ILiyas Mahmed Siroya
QA/QC Dept.(Alfanar Steel)
SMAW
SHIELDED METAL ARC WELDING /
STICK WELDING
TRAINING PRESENTATION
SMAW is commonly known as ‘Stick’
welding or manual arc welding also
SMAW Process :
ELECTRODE: Mainly uses electrode according to Standard -American Welding Society (AWS) D1.1
(1)E6013 (High Titania potassium ) –Strength and Toughness Describing :E6013
Electrode
Minimum Tensile Strength (6) X 10,000psi =413 Mpa
E6013
Indicates the flux coating (High titania Potassium)
Welding Position: 1 - All-Position (F,H,V,OH)
2 - Flat and Horizontal
3 - Flat Only
Advantage/Disadvantage: E6013 –Partial penetration/fusion (AC & DCEP/DCEN)
DCEN – It will puts more heat into the electrode therefore higher deposition/melting rate with less
penetration (We should use DCEN up to 5 mm Thickness)
DCEP – It will puts more heat into the work piece with best penetration
(We should use DECP more than 5mm Thickness)
ELECTRODE:
(1) E7018 (LOW HYDROGEN ELECTRODE)
Describing :E7018
Electrode
Minimum Tensile Strength (7) X 10,000psi =482 Mpa
E7018
Indicates the coating (K, Iron powder) – High Strength and Toughness
Welding Position: 1 - All-Position (F,H,V,OH)
2 - Flat and Horizontal
3 - Flat Only
Advantage/Disadvantage: E7018 –Deep penetration/Fusion and current used (AC/DCEP Only)
E7018 has a very good deposition rate, providing a quiet steady arc with low spatter and medium penetration
Weld deposits are of X-ray quality with easy slag removal, exceptional mechanical properties and a smooth uniform bead appearance
E7018 mainly used in shop/field welding of bridges and structural
Electrode storage and reconditioning
Low hydrogen electrodes are manufacturedwith moisture levels below 0.07% then packaged in hermetically sealed containers.
An open electrode should be stored at 100 –
1500C in portable oven.
If needed they can be reconditioned by baking for one hour at 3500C in mother oven.
Should be a common practice of baking when using low hydrogen electrodes.
E7018
FILLET WELDS IN PLATE — TEST POSITION
Welder Test :
If welder Pass 1F position –Can do weld, Flat (F) position
If welder Pass 2F Position –Can do weld, Flat (F) & Horizontal (H) position
If welder Pass 3F Position –Can do weld, Flat (F),Horizontal (H) &Vertical (V) position
If welder Pass 4F Position- Can do weld, Flat (F), Horizontal (H) & Overhead (O)
When welder passed in 3F & 4F position test then qualified for all position
WELDING TECHNICAL DETAIL
S2 is Minimum thickness
S1 is Maximum thickness
H is Welding LEG LENGTH
B is Welding THROAT/THICKNESS
When fillet weld comes single side then B (THROAT/THICKNESS) is 70% OF MINIMUM THICKNESS &
H ( LEG LENGTH ) is EQUAL OF MINIMUM THICKNESS
When fillet weld comes double side then B (THROAT/THICKNESS) is 50% OF MINIMUM THICKNESS &
H ( LEG LENGTH ) 70% OF MINIMUM THICKNESS
Measurement of welding throat thickness
WELDING CALCULATION DETAIL
If we use E7018 electrode on baseplate area following advantages are obtained:
(1) Can withstand higher load (static/dynamic) without failure.
(2) Good fusion obtained between beam & base plate.
(3) Good mechanical/chemical properties are achieved.
WELDING CALCULATION
Defects in SMAW
(1) Porosity
Causes :
Grease/ hydrocarbon/ water
contamination on surface
Too high arc voltage / arc length
Incorrect/insufficient de-oxidant in
electrode, filler or parent metal
Damp fluxes/ corroded electrode
Prevention :
Must clean welding area prior start the
welding
Reduce arc voltage or arc length
Use electrode with sufficient de-oxidation
activity
Use dry electrodes in good condition
Defects in SMAW
(2) Slag Inclusions
Causes :
Heavy mill scale / rust on work surface
Incomplete slag removal (1st run) from
underlying surface of multi pass weld
Unfused flux due to damage coating
Prevention :
Grind surface prior welding
Improve intern slag removal
Use electrode in good condition
Defects in SMAW
(3) Undercut
Causes :
Melting of top edge due too high welding current ( especially at free edge) or high travel speed
Attempting an Horizontal/Vertical fillet weld leg length >9.0 MM
Excessive/Incorrect weaving / Incorrect electrode angle
Prevention :
Reduce power input , especially
approaching a free edge where
overheating can occur
Weld in a flat position or use multirun
technique
Direct arc towards thicker member
Measured in both Length & Depth
Defects in SMAW
(4) Spatter
Causes :
High arc power
Damp electrodes
Wrong selection size of electrode
Prevention :
Reduce arc power
Use dry electrodes
Must be choose electrode size as per job
Check-Point/List for welder
1 Turn power supply on
2 Connect work clamp
3 Select electrode
a. Type (E6013/E7018)
b. Diameter (Ф2.5, Ф3.2 & Ф4.0mm)
4 Adjust output
a. Current/Polarity (DCEP/DCEN)
b. Amperage Setting
5 Insert electrode into electrode holder
6 Work Angle
7 Travel Angle
8 Arc Length
9 Travel Speed
10 Tools like….(1) Chipping Hammer (2) Wire brush (3) Cleaning brush (4) Chisel for metal
ELE.DIA E6013 E7018
2.5 mm 45 -90 Amp 70 – 100 Amp
3.2 mm 80 – 130 Amp 115 – 165 Amp
4.0 mm 105 – 180 Amp 150 – 220 Amp
THE END
Thanking you all on behalf of QA/QC Department
Alfanar steel
Photo Gallery
Photo Gallery
Photo Gallery