Welding Section

3.1 INTRODUCTION
Some products are made of only one component: bolts, nails, steel balls for bearings, staples,
screws and paper clips. Almost all products, however, are assembled from components that were
manufactured as individual parts. Observe, for example, motorcycles, computers, washing machines,
power tools, and airplanes and how their numerous components are assembled and joined so that they
can function reliably. A typical automobile has 15,000 components, all of them must be assembled,
using several joining methods. Joining is an all inclusive term, covering processes such as welding,
brazing, soldering, adhesive bonding, and mechanical fastening.

Welding is a process for joining two similar or dissimilar metals by fusion. It joins different
metals/alloys, with or without the application of pressure and with or without the use of filler metal.
The fusion of metal takes place by means of heat. The heat may be generated either from combustion of
gases, electric arc, electric resistance, friction between two metals or by chemical reaction. During some
type of welding processes, pressure may also be employed, but this is not an essential requirement for
all welding processes. Welding provides a permanent joint but it normally affects the metallurgy of the
components. It is therefore usually accompanied by post weld heat treatment for most of the critical
components.

There are two groups of welding processes according to the state(phase) of the base material
during the welding process:
1. Liquid-state welding (fusion welding), and
2. Solid-state welding.

Fusion welding is by far the more important category. In fusion welding, the base material is
heat to melt. The most important processes in this group fall in the following categories:

1. Oxy-fuel gas welding: an oxy-fuel gas produces a flame to melt the base material;
2. Arc welding: heating and melting of the material is accomplished by an electric arc;

In solid-state welding, two parts are jointed together under pressure or a combination of
pressure and heat. If heat is applied, the contact temperature is below the melting point of the base
metal. Three welding processes are the most popular from this group,

1. Diffusion welding: parts coalesce by solid-state diffusion;

2. Friction welding: coalescence is achieved by the heat of friction between two parts;
3. Resistance welding: the source of heat is the electrical resistance on the interface between
two parts held together under pressure.

The welding is widely used as a fabrication and repairing process in industries. Some of the
typical applications of welding include the fabrication of ships, pressure vessels, automobile bodies, off-
shore platform, bridges, welded pipes, sealing of nuclear fuel and explosives, etc.
3.2 ELECTRIC ARC WELDING
Arc welding is the welding process, in which heat is generated by an electric arc struck between
an electrode and the work piece. Electric arc is luminous electrical discharge between two electrodes
through ionized gas.

Electric arc between the electrode and work piece closes the electric circuit. The arc
temperature may reach 5500°C, which is sufficient for fusion the work piece edges and joining them.
When a long joint is required the arc is moved along the joint line. The front edge of the weld pool melts
the welded surfaces when the rear edge of the weld pool solidifies forming the joint. Most of these
processes use some shielding gas while others employ coatings or fluxes to prevent the weld pool from
the surrounding atmosphere. Following are the more popular arc welding processes.

1. Shielded Metal Arc Welding (SMAW)/Manual Metal Arc Welding (MMAW)/Stick welding.
2. Gas Metal Arc Welding (GMAW) ( generally called as MIG/MAG welding)
3. Gas Tungsten Arc Welding (GTAW) ( generally called as TIG welding)
4. Plasma Arc Welding ( popular in Plasma Arc Cutting)

3.3 SHIELDED METAL ARC WELDING (SMAW)

Shielded metal arc welding or stick welding is a process which melts and joins metals by heating
them with an arc between a coated metal electrode and the workpiece. The electrode outer coating,
called flux, decomposes due to arc heat and assists in creating arc stability and provides the shielding
gas and slag to protect the weld from contamination. Inner core of the electrode supply the filler
material for making a weld.

Figure 3.1: Principle of SMAW

3.3.1 Shielded Metal Arc Welding Equipment:

It consisting of the following parts:
a. Power source (AC or DC);
b. Welding electrode;
c. Work piece;
 d. Welding leads (electric cables) connecting the electrode and work piece to the power
supply.

The stick welding power source provides constant current (CC) and may be either alternating
current (AC) or direct current (DC), depending on the electrode being used. The best welding
characteristics are usually obtained using DC power source.

The power in a welding circuit is measured in voltage and current. The voltage (Volts) is
governed by the arc length between the electrode and the workpiece and is influenced by electrode
diameter. Current is a more practical measure of the power in a weld circuit and is measure in amperes
(Amps).
The amperage needed to weld depends on electrode diameter, the size and thickness of the
pieces to be welded, and the position of the welding. Thin metals require less current than thick metals,
and a small electrode requires less amperage than a large one.

Figure 3.2: Arc welding set up.

Transformers, motor generators and rectifier sets are used as arc welding machines. These
machines supply high electric currents at low voltage and an electrode is used to produce the necessary
arc.
Sizes of welding machines are rated according to their approximate amperage capacity at 60%
duty cycle, such as 150,200,250,300,400,500 and 600 amperes. This amperage is the rated current
output at the working terminal.

Transformer based welding machine

The transformers type of welding machine produces A.C current and is considered to be the
least expensive. It takes power directly from power supply line and transforms it to the voltage required
for welding. Transformers are available in single phase and three phases in the market.

Motor generators welding machine

These are D.C generators sets, in which electric motor and alternator are mounted on the same
shaft to produce D.C power as part of the requirement for welding. These are designed to produce D.C
current in either straight or reversed polarity. The polarity selected for welding depends upon the kind
of electrode used and the material to be welded.
Rectifiers based welding machine
These are essentially transformers, containing an electrical device which changes A.C into D.C by
virtue of which the operator can use both types of power (A.C or D.C, but only one at a time). In addition
to the welding machine, certain accessories are needed for carrying out the welding work.

Welding cables
Two welding cables are required, one from machine to the electrode holder and the other,
from the machine to the ground clamp. Flexible cables are usually preferred because of the case of using
and coiling the cables. Cables are specified by their current carrying capacity, say 300 A, 400 A, etc.

3.3.2 Electrodes
Filler rods used in arc welding are called electrodes. These are made of metallic wire called core
wire, having approximately the same composition as the metal to be welded. These are coated
uniformly with a protective coating called flux. While fluxing an electrode; about 20mm of length is left
at one end for holding it with the electrode holder. It helps in transmitting full current from electrode
holder to the front end of the electrode coating. Flux acts as an insulator of electricity.

In general, electrodes are classified into five main groups; mild steel, carbon steel, special alloy
steel, cast iron and non-ferrous. The greatest range of arc welding is done with electrodes in the mild
steel group.
Various constituents like titanium oxide, potassium oxide, cellulose, iron or manganese, Ferro-
silicates, carbonates, gums, clays, asbestos, etc., are used as coatings on electrodes. While welding, the
coating or flux vaporizes and provides a gaseous shield to prevent atmospheric attack.
The size of electrode is measured and designated by the diameter of the core wire and length,
apart from the brand and code names; indicating the purpose for which they are most suitable.

Classification of the stick electrodes:

The American Welding Society (AWS) numbering system can tell a welder quite a bit about a specific
stick electrode including what application it works best in and how it should be used to maximize
performance. The prefix "E" designates an arc welding electrode (for example: E6010). The first two
digits of a 4 digit number indicate minimum tensile strength. For example, E6010 is a 60,000 psi tensile
strength electrode while.
E 60 1 0
Electrode Tensile Strength Welding Position Type of Coating & Current

The next to last digit indicates position. The "1" designates an all position electrode, "2" is for
flat and horizontal positions only; while "4" indicates an electrode that can be used for flat, horizontal,
vertical down and overhead. The last digit indicates the type of coating and the correct polarity or
current to use. See chart below:

Digit Type of Coating Welding Current

0 High cellulose sodium DC+
1 High cellulose potassium AC, DC+ or DC-
2 High titania sodium AC, DC-
 3 High titania potassium AC, DC+
4 Iron powder, titania AC, DC+ or DC-
5 Low hydrogen sodium DC+
6 Low hydrogen potassium AC, DC+
7 High iron oxide, iron powder AC, DC+ or DC-
8 Low hydrogen potassium, iron powder AC, DC+ or DC-
Table 3.1: Electrodes Specifications

3.4 WELDING TOOLS AND ACCESSORIES

3.4.1 Electrode holder

The electrode holder is connected to the end of the welding cable and holds the electrode. It
should be light, strong and easy to handle and should not become hot while in operation. Figure shows
one type of electrode holder. The jaws of the holder are insulated, offering protection from electric
shock.

3.4.2 Ground clamp/Work Clamp

It is connected to the end of the ground cable and is clamped to the work or welding table to
complete the electric circuit. It should be strong and durable and give a low resistance connection.

Figure 3.3: Electrode holder Figure 3.4: Ground clamp

3.4.3 Wire brush and chipping hammer
A wire brush is used for cleaning and preparing the work for welding. A chipping hammer is used
for removing slag formation on welds. One end of the head is sharpened like a cold chisel and the other,
to a blunt, round point. It is generally made of tool steel. Molten metal dispersed around the welding
heads, in the form of small drops, is known as spatter. When a flux coated electrode is used in welding
process, then a layer of flux material is formed over the welding bead which contains the impurities of
weld material. This layer is known as slag. Removing the spatter and slag formed on and around the
welding beads on the metal surface is known as chipping.

Figure 3.5: Wire brush Figure 3.6: Chipping hammer

3.4.4 Welding table and cabin

It is made of steel plate and pipes. It is used for positioning the parts to be welded properly.
Welding cabin is made-up by any suitable thermal resistance material, which can isolate the surrounding
by the heat and light emitted during the welding process. A suitable draught should also be provided for
exhausting the gas produced during welding.

3.4.5 Face shield

A face shield is used to protect the eyes and face from the rays of the arc and from spatters or
flying particles of hot metal. It is available either in hand or helmet type. The hand type is convenient to
use wherever the work can be done with one hand. The helmet type welding screen leaves both hands
free for the work.

Shields are made of light weight non-reflecting fiber and fitted with dark glasses to filter out the
harmful rays of the arc. In some designs, a cover glass is fitted in front of the dark lens to protect it from
spatter. Shading of the Arc welding screens is from DIN 9 to 13, Hand held type screen is fixed with
shading DIN 10 or DIN 11 and auto darkening helmet has variable shade setting from DIN 9 to DIN 13.
(* DIN stands for "Deutsches Institut für Normung", meaning "German institute for standardisation").
3.4.6 Hand gloves & Apron
Welding gloves can protect you from electric shock, flames, hot parts, sharp or flying metal, and
arc rays. Proper gloves are the first line of defense against the hand hazards of welding and cutting. All
welders and cutters wear protective apron and gloves while working. Different processes may use
different gloves.
Nature of the Hazard

sparks.
that are wet, torn, damaged, or have insulation failure.

Hand-held type Helmet type

Figure 3.7: Face shields Figure 3.8: Hand gloves & Apron
3.5 TYPES OF JOINTS
The following are the various joints used in the fabrication of work based on the application.
 Figure 3.9: Types of welding joints.

A butt joint is used to join two members aligned in the same plane (fig. 3.18, view A). This joint is
frequently used in plate, sheet metal, and pipe work. A joint of this type may be either square or
grooved.

Corner and tee joints are used to join two members located at right angles to each other (fig.
3.18, views B and C). In cross section, the corner joint forms an L-shape, and the tee joint has the shape
of the letter T. Various joint designs of both types have uses in many types of metal structures.

A lap joint, as the name implies, is made by lapping one piece of metal over another (fig. 3.18,
view D). This is one of the strongest types of joints available; however, for maximum joint efficiency, you
should overlap the metals a minimum of three times the thickness of the thinnest member you are
joining. Lap joints are commonly used with torch brazing and spot welding applications.

An edge joint is used to join the edges of two or more members lying in the same plane. In most
cases, one of the members is flanged, as shown in figure 3.18, view E. While this type of joint has some
applications in plate work, it is more frequently used in sheet metal work. An edge joint should only be
used for joining metals 1/4 inch or less in thickness that are not subjected to heavy loads.

3.6 WELDING POSITIONS

Depending upon the location of the welding joints, appropriate position of the electrode and
hand movement is selected. The figure shows different welding positions.
 Figure 3.10: Welding positions
Flat position welding, in this position, the welding is performed from the upper side of the joint,
and the face of the weld is approximately horizontal. Flat welding is the preferred term; however, the
same position is sometimes called down hand.

Horizontal position welding, in this position, welding is performed on the upper side of an
approximately horizontal surface and against an approximately vertical surface.

Vertical position welding, in this position, the axis of the weld is approximately vertical as shown
in figure.
Overhead position welding, in this welding position, the welding is performed from the
underside of a joint.

3.7 TECHNIQUES OF WELDING

3.7.1 Preparation of work

Before welding, the work pieces must be thoroughly cleaned of rust, scale and other foreign
material. The piece of metal generally welded without beveling the edges, however, thick work piece
should be beveled to ensure adequate penetration and fusion of all parts of the weld. But, in either
case, the parts to be welded must be separated slightly to allow better penetration of the weld.

The following information is useful for the beginners:

Plate thickness, mm Electrode size, mm Suitable current range, amp

1.6 1.6 40-60
2.5 2.5 50-80
4.0 3.2 90-130
6.0 4.0 120-170
8.0 5.0 180-270
25.0 6.0 (Multi layers) 300-400

Table 3.2: Plate thickness Vs Electrode size Vs Suitable current

3.7.2 Striking an arc
The following are the stages and methods of striking an arc and running a bead
Select an electrode of suitable kind and size for the work and set the welding current at a
proper value.
Fasten the ground clamp to either the work or welding table.
strike the arc by either of the following methods

Scratch Start Technique

Drag electrode across workpiece like striking a match; immediately lift electrode slightly after
touching work. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use
a quick twist to free it.

Touch and with draw

In this method, the arc is started by keeping the electrode perpendicular to the work and
touching or bouncing it lightly on the work. This method is preferred as it facilitates restarting
the momentarily broken arc quickly. If the electrode sticks to the work, quickly bend it back and
forth, pulling at the same time. Make sure to keep the shield in front of the face, when the
electrode is freed from sticking.

1. Electrode, 2. Workpiece, 3. Arc

a. Strike and withdraw b. Touch and withdraw (Tapping Technique)

Figure 3.11: striking an arc

 Figure 3.12: Groove Weld

Figure 3.13: Fillet Welds

To produce the best results, hold a short arc, travel at a uniform speed, and feed the electrode downward
at a constant rate as it melts.
3.7.3 Weaving
A steady, uniform motion of the electrode produces a satisfactory bead. However, a slight
weaving or oscillating motion is preferred, as this keeps the metal molten a little longer and allows the
gas to escape, bringing the slag to the surface. Weaving also produces a wider bead with better
penetration.
 3. Weave Patterns,

Figure 3.14: Electrode Movement During Welding

Use weave patterns to cover a wide area in one pass of the electrode. Limit weave width to a
maximum of 2-1/2 times diameter of electrode.

3.7.4 Conditions That Affect Weld Bead Shape

Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal.

Figure 3.15: Electrode Angle

Figure 3.16: Effect of Arc Length

Figure 3.17: Effect of Travel Speed

 Figure 3.18: Poor Weld Bead Characteristics

Figure 3.19: Good Weld Bead Characteristics

3.8 ADVANTAGES & DISADVANTAGES OF SMAW

Advantages
1. Shielded Metal Arc Welding can be carried out in any position with good weld quality.
2. SMAW is the simplest of all the arc welding processes.
3. This welding process finds innumerable applications, because of the availability of a wide variety of
electrodes.
4. Big range of metals and their alloys can be welded easily.
5. The process can be very well employed for hard facing and metal resistance etc.
6. Joints (e.g., between nozzles and shell in a pressure vessel) which because of their position are
difficult to be welded by automatic welding machines can be easily accomplished by flux shielded metal
arc welding.
7. The SMAW/MMAW welding equipment is portable and the cost is fairly low.

Limitations
1. Due to flux coated electrodes, the chances of slag entrapment and other related defects are more as
compared to MIG and TIG welding.
2. Duo to fumes and particles of slag, the arc and metal transfer is not very clear and thus welding
control in this process is a bit difficult as compared to MIG welding.
3. Due to limited length of each electrode and brittle flux coating on it, mechanization is difficult.
4. In welding long joints (e.g., in pressure vessels), as one electrode finishes, the weld is to be progressed
with the next electrode. Unless properly cared, a defect (like slag inclusion or insufficient penetration)
may occur at the place where welding is restarted with the new electrode
5. The process uses stick electrodes and thus it is slower as compared to MIG welding.
3.9 SAFE PRACTICE

1. Always weld in a well ventilated place. Fumes given off from welding are unpleasant and in some
cases may be injurious, particularly from galvanized or zinc coated parts.
2. Do not weld around combustible or inflammable materials, where sparks may cause a fire.
3. Never weld containers, which have been used for storing gasoline, oil or similar materials, without
first having them thoroughly cleaned.
4. Check the welding machine to make sure that it is properly grounded and that all leads properly
insulated.
5. Never look at the arc with the naked eye. The arc can burn your eyes severely. Always use a face
shield while welding.
6. Prevent welding cables from coming in contact with hot metal, water, oil, or grease. Avoid dragging
the cables around sharp corners.
7. Ensure proper insulation of the cables and check for openings.
8. Wear the safety hand gloves, apron and leather shoes while working.
9. Turn off the machine when leaving the work.
10. Apply eye drops after welding is over for the day, to relieve the strain on the eyes.
11. While welding, stand on dry footing and keep the body insulated from the electrode, any other parts
of the electrode holder and the work.

ELECTRIC SHOCK can kill.

1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats or covers big enough to
prevent any physical contact with the work or ground.
4.
can kill.
5. Turn off all equipment when not in use.
6. Do not touch electrode holders connected to two welding machines at the same time since
double open-circuit voltage will be present.
7. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld
as practical.

HOT PARTS can burn

1. Do not touch hot parts bare handed.
2. Allow cooling period before working on equipment.
3. To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing
to prevent burns.
FUMES AND GASES can be hazardous.
1. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your
health.
2. Keep your head out of the fumes. Do not breathe the fumes.
3. If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding
fumes and gases.
4. If ventilation is poor, wear an approved air-supplied respirator.
5. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of
the arc can react with vapors to form highly toxic and irritating gases.
6. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the
coating is removed from the weld area. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
1. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared)
rays that can burn eyes and skin. Sparks fly off from the weld.
2. Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face
and eyes from arc rays and sparks when welding or watching .
3. Wear approved safety glasses with side shields under your helmet.
4. Use protective screens or barriers to protect others from flash, glare and sparks; warn others
not to watch the arc.
5. Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or
wool) and foot protection.

WELDING can cause fire or explosion.

1. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause
fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion,
overheating, or fire. Check and be sure the area is safe before doing any welding.
2. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly
cover them with approved covers.
3. Do not weld where flying sparks can strike flammable material.
4. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
5. Remove any combustibles, such as butane lighter or matches, from your presence before doing
any welding.
6. After completion of work, inspect area to ensure it is free of sparks, glowing embers, and
flames.

FLYING METAL or DIRT can injure eyes.

1. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they
can throw off slag.
2. Wear approved safety glasses with side shields even under your welding helmet.

ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices.

1. Wearers of Pacemakers and other Implanted Medical Devices should keep away.
2. Implanted Medical Device wearers should consult their doctor and the device manufacturer before
going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.

3.10 WELDING GROOVE (BUTT) JOINTS

Types of Groove (Butt) Joint Welds

1. Tack Welds
Prevent butt joint distortion by tack welding the
materials in position before final weld.

Workpiece distortion occurs when heat is applied locally

the weld. Distortion will also cause the edges of a butt

joint to pull together ahead of the electrode as the weld
cools.

2. Square Groove Weld

3. Single V-Groove Weld
4. Double V-Groove Weld

Materials up to 3/16 in. (5 mm) thick can often be

welded without special preparation using the square
groove weld. However, when welding thicker materials it
may be necessary to prepare the edges (V-groove) of
butt joints to ensure good welds.

The single or double V-groove weld is good for materials

-19 mm) thick. Generally, the single V-
groove is used on materials up to 3/4 in. (19 mm) thick
and when, regardless of thickness, you can weld from
one side only. Create a 30 degree
bevel with oxyacetylene or plasma cutting equipment.
Remove scale from material after cutting. A grinder can
also be used to prepare bevels.

Groove (Butt) Joint Training Procedure

Practice welding butt joints on 1/8 in. (4 mm) or thicker
material. (Avoid thinner materials since they require
greater skill.)
Separate the squared edges of the material about 1/16
in. (1.6 mm) and make a butt weld all the way through
with a 1/8 in. electrode. (You may need to adjust the
weld current and travel speed to obtain the desired
weld.) Perform a similar exercise on
1/4 in. (6 mm) material, depositing a bead on each side
of the joint and fusing one to the another (no bevel
needed).
 Practice making a single V-groove weld on 1/4 in. (6 mm)
plate beveled 30°. Start with a 1/8 in. electrode for the
first bead and finish with a 5/32 in. (4 mm) electrode. Be
sure to penetrate about 1/32 in. (1 mm) beyond the

thicker materials. Generally, deposit a bead for each 1/8

in. (3mm) of material thickness, cleaning the joint
between layers. On heavier plates, it may be necessary
to weave the top layers to fill the groove.

3.11 WELDING LAP JOINT

1 Electrode
2 Single-Layer Fillet Weld

Move electrode in circular motion.

Weld a second layer when a heavier fillet is needed.

Remove slag before making another weld pass.

Weld both sides of joint for maximum strength.

3.12 WELDING TEE JOINTS

 1. Electrode
2. Fillet Weld

Keep arc short and move at definite rate of speed. Hold

electrode as shown to provide fusion into the corner.
Square edge of the weld surface.

For maximum strength weld both sides of upright section.

3. Multi-Layer Deposits

Weld a second layer when a heavier fillet is needed. Use

any of the weaving patterns shown. Remove slag before
making another weld pass.

3.13 WELDING TROUBLESHOOTING

3.13.1 Porosity

pockets in weld metal.

Possible Causes Corrective Actions

Arc length too long. Reduce arc length.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag,
and dirt from work surface before welding.
Damp electrode. Use dry electrode.

3.13.2 Excessive Spatter

that cool to solid form near weld bead.

Possible Causes Corrective Actions
Amperage too high for electrode. Decrease amperage or select larger electrode.
Arc length too long or voltage too high. Reduce arc length or voltage.
3.13.3 Incomplete Fusion

completely with base metal or a preceeding weld bead.

Possible Causes Corrective Actions

Insufficient heat input. Increase amperage. Select larger electrode and increase
amperage.
Improper welding technique Place stringer bead in proper location(s) at joint during
welding.
Adjust work angle or widen groove to access bottom
during welding.
Momentarily hold arc on groove side walls when using
weaving technique.
Keep arc on leading edge of weld puddle.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag,
and dirt from work surface before welding.

3.13.4 Lack of Penetration

Lack Of Penetration shallow fusion between weld metal

and base metal.
Lack of Penetration, Good Penetration

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must
provide access to bottom of groove.
Improper weld technique. Keep arc on leading edge of weld puddle.
Reduce travel speed.
Insufficient heat input. Increase amperage. Select larger electrode and increase
amperage.
3.13.5 Excessive Penetration

weld metal melting through base

metal and hanging underneath weld.
Excessive Penetration, Good Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.
Improper weld technique. Adjust travel speed.

3.13.6 Burn Through

Burn-
base metal resulting in holes where no metal remains.

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.

3.13.7 Waviness of Bead

does not cover joint formed by base metal.

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

3.13.8 Distortion

during welding that forces base

metal to move.
Possible Causes Corrective Actions
Use restraint (clamp) to hold base metal in position.
Excessive heat input. Make tack welds along joint before starting welding
operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
 Welding Exercises

Exercise 1

Objective: To run a straight bead on flat plate and to fill the crater.

Equipment:
Multi Process Constant Current Power Source
EWM Pico Mig 180 (MIG & SMAW)
ESAB Buddy Arc 200 (TIG & SMAW)
Tools:
Chipping Hammer, Wire Brush, Flat Nose Tong and Face Shield.

Material:
Mild steel Plate, 6 mm thick.
ESAB-FERROARC Medium Coated Mild steel Electrode, Ø3.15 mm X 450 mm, E6013

Operations to be carried out

1. Cleaning the work pieces
2. tack welding
3. full welding
4. cooling
5. finishing

Procedure:
1. Clean base metal and position flat on the table.
2. Check the connections to table and Electrode holder.
3. Set polarity and amperage: DC+ at 90 -130 A for a Ø3.15 mm E6013 electrode.
4. Hold the electrode upright to the base metal, inclined at a 65 to 70 degree angle in the
direction of travel.
5. Strike and establish the arc. Maintain a normal arc length, 2 to 3 mm, and move the
electrode across the plate at a uniform rate. Observe the back of the molten puddle, or crater,
as the arc builds up the bead. Allow the arc force to penetrate the base metal and deposit filler
metal. Correct speed will be indicated by the proper shape and size of the bead.
6. Make beads one to two inches long and extinguish the arc by withdrawing the electrode.
7. Re-strike the arc and run another bead. Move over the plate, increasing the length of the
beads until you are able to stop and start as desired.
8. Practice until you can make uniform beads 3 or 4 inches long.
9. Clean the slag off each bead by chipping with the chipping hammer and brush clean with the
wire brush. Always chip slag away from you.
10. Visually inspect the bead for shape, penetration, and uniformity.
Figure W- E1: MS Plate with Straight Bead
 Welding Exercises

Exercise 2

Objective: Welding Groove (Butt) Joints

Equipment: Multi Process Constant Current Power Source

EWM Pico Mig 180 (MIG & SMAW)
ESAB Buddy Arc 200 (TIG & SMAW)

Tools: Chipping Hammer, Wire Brush, Flat Nose Tong and Face Shield.

Material: Mild steel Plates, 6 mm Thick.

ESAB-FERROARC Medium Coated Mild steel Electrode, Ø3.15 mm X 450 mm, E6013

Operations to be carried out

1. Cleaning the work pieces
2. tack welding
3. full welding
4. cooling
5. finishing

Procedure:
1. Clean base metal and prepare the V-groove on the edges to be joined.
2. Check the connections to table and Electrode holder.
3. Set polarity and amperage: DC+ at 90 -130 A for a Ø3.15 mm E6013 electrode..
4. Position flats on the table and Tack weld the edges as shown in the 3.9 Welding Groove
(Butt) Joints
5. Hold the electrode upright to the base metal, inclined at a 65 to 70 degree angle in the
direction of travel.
6. Strike and establish the arc. Maintain a normal arc length, 2 to 3 mm, and move the
electrode across the plate at a uniform rate. Observe the back of the molten puddle, or crater,
as the arc builds up the bead. Allow the arc force to penetrate the base metal and deposit filler
metal.
7. Clean the slag off each bead by chipping with the chipping hammer and brush clean with the
wire brush. Always chip slag away from you.
8. Visually inspect the joint for shape, penetration, uniformity and defects.
 Figure W- E1: Single Vee Butt Joint

References:

Safety and Health Fact Sheet No. 37, May 2008

http://www.aws.org/technical/facts/FACT-37.pdf

2. Guidelines For Shielded Metal Arc Welding (SMAW)

www.millerwelds.com
http://www.millerwelds.com/pdf/guidelines_smaw.pdf

http://www.lincolnelectric.com/en-us/education-center/documents/smawfacilitatorguide.pdf
www.lincolnelectric.com

4. Basic Welding Filler Metal Technology by ESAB Welding

http://www.esabna.com/EUWeb/AWTC/Lesson2_4.htm
www.esab.com

5. Manufacturing Engineering and Technology by Serope Kalpakjian & Steven R. Schmid.