Guidelines For Shielded Metal Arc Welding (SMAW)

155 095 B
2010−02
Processes
Stick (SMAW) Welding
Guidelines For
Shielded Metal Arc
Welding (SMAW)
Visit our website at
www.MillerWelds.com

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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
SECTION 2 − PRINCIPLES OF SHIELDED METAL ARC WELDING (SMAW) . . . . . . . . . . . . . . . . . . . . . . . . .
5
SECTION 3 − SHIELDED METAL ARC WELDING (SMAW) PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
3-1. Typical Stick Welding Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
3-2. Electrode And Amperage Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
3-3. Striking An Arc − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3-4. Striking An Arc − Tapping Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3-5. Positioning Electrode Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
3-6. Electrode Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-7. Conditions That Affect Weld Bead Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-8. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-9. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-10. Typical Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-11. Welding Butt Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-12. Welding Tee Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-13. Welding Lap Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-14. Welding Horizontal Beads And Butt Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-15. Welding Vertical Beads And Butt Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-16. Welding Vertical Tee Joints And Lap Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-17. Welding Overhead Butt Joints And Tee Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-18. Weld Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 4 − WELDING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-1. Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-2. Excessive Spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-3. Incomplete Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-4. Lack Of Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-5. Excessive Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-6. Burn-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-7. Waviness Of Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-8. Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2009−08
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
. Indicates special instructions.
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury.
hazards.
1-2. Arc Welding Hazards
D Properly install and ground this equipment according to its
The symbols shown below are used throughout this manual
Owner’s Manual and national, state, and local codes.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
D Always verify the supply ground − check and be sure that input
to avoid the hazard. The safety information given below is
power cord ground wire is properly connected to ground terminal in
only a summary of the more complete safety information
disconnect box or that cord plug is connected to a properly
found in the Safety Standards listed in Section 1-5. Read and
grounded receptacle outlet.
follow all Safety Standards.
D When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Only qualified persons should install, operate, maintain, and
D Keep cords dry, free of oil and grease, and protected from hot metal
repair this unit.
and sparks.
D Frequently inspect input power cord for damage or bare wiring −
During operation, keep everybody, especially children, away.
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
ELECTRIC SHOCK can kill.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
Touching live electrical parts can cause fatal shocks
with a separate cable.
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
D Do not touch electrode if you are in contact with the work, ground,
power circuit and machine internal circuits are also
or another electrode from a different machine.
live when power is on. In semiautomatic or automatic
D Do not touch electrode holders connected to two welding ma-
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
chines at the same time since double open-circuit voltage will be
electrically live. Incorrectly installed or improperly
present.
grounded equipment is a hazard.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Do not touch live electrical parts.
D Wear a safety harness if working above floor level.
D Wear dry, hole-free insulating gloves and body protection.
D Keep all panels and covers securely in place.
D Insulate yourself from work and ground using dry insulating mats
D Clamp work cable with good metal-to-metal contact to workpiece
or covers big enough to prevent any physical contact with the work
or worktable as near the weld as practical.
or ground.
D Insulate work clamp when not connected to workpiece to prevent
D Do not use AC output in damp areas, if movement is confined, or if
contact with any metal object.
there is a danger of falling.
D Do not connect more than one electrode or work cable to any
D Use AC output ONLY if required for the welding process.
single weld output terminal.
D If AC output is required, use remote output control if present on
unit.
SIGNIFICANT DC VOLTAGE exists in inverter weld-
D Additional safety precautions are required when any of the follow-
ing power sources AFTER removal of inputpower.
ing electrically hazardous conditions are present: in damp
D Turn Off inverter, disconnect input power, and discharge input
locations or while wearing wet clothing; on metal structures such
capacitors according to instructions in Maintenance Section
as floors, gratings, or scaffolds; when in cramped positions such
before touching any parts.
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
HOT PARTS can burn.
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
D Do not touch hot parts bare handed.
age. In most situations, use of a DC, constant voltage wire welder
D Allow cooling period before working on equip-
is recommended. And, do not work alone!
ment.
D Disconnect input power or stop engine before installing or
D To handle hot parts, use proper tools and/or
servicing this equipment. Lockout/tagout input power according to
wear heavy, insulated welding gloves and
OSHA 29 CFR 1910.147 (see Safety Standards).
clothing to prevent burns.
155 095 Page 1

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FUMES AND GASES can be hazardous.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
shirt, cuffless trousers, high shoes, and a cap.
health.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D Keep your head out of the fumes. Do not breathe the fumes.
D After completion of work, inspect area to ensure it is free of sparks,
D If inside, ventilate the area and/or use local forced ventilation at the
glowing embers, and flames.
arc to remove welding fumes and gases.
D Use only correct fuses or circuit breakers. Do not oversize or by-
D If ventilation is poor, wear an approved air-supplied respirator.
pass them.
D Read and understand the Material Safety Data Sheets (MSDSs)
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
and the manufacturer’s instructions for metals, consumables,
for hot work and have a fire watcher and extinguisher nearby.
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
FLYING METAL or DIRT can injure eyes.
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
ing air is safe.
they can throw off slag.
D Do not weld in locations near degreasing, cleaning, or spraying op-
D Wear approved safety glasses with side
erations. The heat and rays of the arc can react with vapors to form
shields even under your welding helmet.
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
BUILDUP OF GAS can injure or kill.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
D Shut off shielding gas supply when not in use.
can give off toxic fumes if welded.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
ELECTRIC AND MAGNETIC FIELDS (EMF)
visible and invisible (ultraviolet and infrared) rays
can affect ImplantedMedical Devices.
that can burn eyes and skin. Sparks fly off from the
weld.
D Wearers of Pacemakers and other Implanted
D Wear an approved welding helmet fitted with a proper shade of
Medical Devices should keep away.
filter lenses to protect your face and eyes from arc rays and
D Implanted Medical Device wearers should consult their doctor
sparks when welding or watching (see ANSI Z49.1 and Z87.1
and the device manufacturer before going near arc welding, spot
listed in Safety Standards).
welding, gouging, plasma arc cutting, or induction heating
D Wear approved safety glasses with side shields under your
operations.
helmet.
D Use protective screens or barriers to protect others from flash,
NOISE can damage hearing.
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant
Noise from some processes or equipment can
material (leather, heavy cotton, or wool) and foot protection.
damage hearing.
WELDING can cause fire or explosion.
D Wear approved ear protection if noise level is
high.
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
CYLINDERS can explode if damaged.
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
Shielding gas cylinders contain gas under high
sparks, explosion, overheating, or fire. Check and be sure the area is
pressure. If damaged, a cylinder can explode. Since
safe before doing any welding.
gas cylinders are normally part of the welding
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
process, be sure to treat them carefully.
this is not possible, tightly cover them with approved covers.
D Protect compressed gas cylinders from excessive heat, mechani-
D Do not weld where flying sparks can strike flammable material.
cal shocks, physical damage, slag, open flames, sparks, and arcs.
D Protect yourself and others from flying sparks and hot metal.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Be alert that welding sparks and hot materials from welding can
D Keep cylinders away from any welding or other electrical circuits.
easily go through small cracks and openings to adjacent areas.
D Never drape a welding torch over a gas cylinder.
D Watch for fire, and keep a fire extinguisher nearby.
D Never allow a welding electrode to touch any cylinder.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
D Never weld on a pressurized cylinder − explosion will result.
cause fire on the hidden side.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
D Do not weld on closed containers such as tanks, drums, or pipes,
tings designed for the specific application; maintain them and
unless they are properly prepared according to AWS F4.1 (see
associated parts in good condition.
Safety Standards).
D Turn face away from valve outlet when opening cylinder valve.
D Do not weld where the atmosphere may contain flammable dust,
D Keep protective cap in place over valve except when cylinder is in
gas, or liquid vapors (such as gasoline).
use or connected for use.
D Connect work cable to the work as close to the welding area as
D Use the right equipment, correct procedures, and sufficient num-
practical to prevent welding current from traveling long, possibly
ber of persons to lift and move cylinders.
unknown paths and causing electric shock, sparks, and fire
D Read and follow instructions on compressed gas cylinders,
hazards.
associated equipment, and Compressed Gas Association (CGA)
D Do not use welder to thaw frozen pipes.
publication P-1 listed in Safety Standards.
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1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can injure.
D Do not install or place unit on, over, or near
D Keep away from moving parts such as fans.
combustible surfaces.
D Keep all doors, panels, covers, and guards
D Do not install unit near flammables.
closed and securely in place.
D Do not overload building wiring − be sure power supply system is
D Have only qualified persons remove doors, panels, covers, or
properly sized, rated, and protected to handle this unit.
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
FALLING EQUIPMENT can injure.
finished and before reconnecting input power.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
READ INSTRUCTIONS.
D Use equipment of adequate capacity to lift and
support unit.
D Read and follow all labels and the Owner’s
D If using lift forks to move unit, be sure forks are long enough to
Manual carefully before installing, operating, or
extend beyond opposite side of unit.
servicing unit. Read the safety information at
the beginning of the manual and in each
D Keep equipment (cables and cords) away from moving vehicles
section.
when working from an aerial location.
D Use only genuine replacement parts from the manufacturer.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu-
D Perform maintenance and service according to the Owner’s
ally lifting heavy parts or equipment.
Manuals, industry standards, and national, state, and local
codes.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
D High-frequency (H.F.) can interfere with radio
starting to weld again.
navigation, safety services, computers, and
D Do not block or filter airflow to unit.
communications equipment.
D Have only qualified persons familiar with
FLYING SPARKS can injure.
electronic equipment perform this installation.
D The user is responsible for having a qualified electrician prompt-
D Wear a face shield to protect eyes and face.
ly correct any interference problem resulting from the installa-
tion.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
D If notified by the FCC about interference, stop using the
face, hand, and body protection.
equipment at once.
D Sparks can cause fires — keep flammables away.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
STATIC (ESD) can damage PC boards.
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D Put on grounded wrist strap BEFORE handling
boards or parts.
ARC WELDING can cause interference.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
MOVING PARTS can injure.
computers and computer-driven equipment
such as robots.
D Keep away from moving parts.
D Be sure all equipment in the welding area is
D Keep away from pinch points such as drive
electromagnetically compatible.
rolls.
D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
WELDING WIRE can injure.
D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D Do not press gun trigger until instructed to do
D Be sure this welding machine is installed and grounded
so.
according to this manual.
D Do not point gun toward any part of the body,
D If interference still occurs, the user must take extra measures
other people, or any metal when threading
such as moving the welding machine, using shielded cables,
welding wire.
using line filters, or shielding the work area.
155 095 Page 3

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1-4. California Proposition 65 Warnings
For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California
California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.)
tive harm.
For Diesel Engines:
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
Diesel engine exhaust and some of its constituents are
California to cause cancer and birth defects or other
known to the State of California to cause cancer, birth
reproductive harm. Wash hands after handling.
defects, and other reproductive harm.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
from Global Engineering Documents (phone: 1-877-413-5184, website:
site: www.ansi.org).
www.global.ihs.com).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for the Preparation of Containers and Piping for Welding
Work, NFPA Standard 51B, from National Fire Protection Association,
and Cutting, American Welding Society Standard AWS F4.1, from Glob-
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
al Engineering Documents (phone: 1-877-413-5184, website:
OSHA, Occupational Safety and Health Standards for General Indus-
www.global.ihs.com).
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
National Electrical Code, NFPA Standard 70, from National Fire Protec-
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
www.nfpa.org and www. sparky.org).
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
phone for Region 5, Chicago, is 312-353-2220, website:
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
www.osha.gov).
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Safety in Welding, Cutting, and Allied Processes, CSA Standard
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
W117.2, from Canadian Standards Association, Standards Sales, 5060
www.cpsc.gov).
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
Applications Manual for the Revised NIOSH Lifting Equation, The Na-
800-463-6727, website: www.csa-international.org).
tional Institute for Occupational Safety and Health (NIOSH), 1600
Safe Practice For Occupational And Educational Eye And Face Protec-
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
tion, ANSI Standard Z87.1, from American National Standards Institute,
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). Welding current creates an EMF field
welding circuit as possible.
around the welding circuit and welding equipment. EMF fields may inter-
fere with some medical implants, e.g. pacemakers. Protective
5. Connect work clamp to workpiece as close to the weld as
measures for persons wearing medical implants have to be taken. For
possible.
example, access restrictions for passers−by or individual risk assess-
ment for welders. All welders should use the following procedures in
6. Do not work next to, sit or lean on the welding power source.
order to minimize exposure to EMF fields from the welding circuit:
7. Do not weld whilst carrying the welding power source or wire
feeder.
1. Keep cables close together by twisting or taping them, or using a
cable cover.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables
device manufacturer before performing or going near arc welding, spot
to one side and away from the operator.
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body.
mended.
155 095 Page 4

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SECTION 2 − PRINCIPLES OF SHIELDED METAL ARC
WELDING (SMAW)
Shielded Metal Arc Welding (SMAW) 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, assists in creat-
ing the arc and provides the shielding gas and slag covering to protect the weld from contamination. The electrode
core provides most of the weld filler metal.
When the electrode is moved along the workpiece at the correct speed the metal deposits in a uniform layer called
a bead.
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 sources.
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 measured 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.
It is preferable to weld on work in the flat or horizontal position. However, when forced to weld in vertical or overhead
positions it is helpful to reduce the amperage from that used when welding horizontally. Best welding results are
achieved by maintaining a short arc, moving the electrode at a uniform speed, and feeding the electrode downward
at a constant speed as it melts.
More specific information on the Stick welding procedure is provided in the following sections.
1
Stick Welding Power Source
− Constant Current (CC), AC
Or DC
2
Insulated Electrode Holder
3
Workpiece
1
4
Work Clamp
2
3
4
Ref. 157 858
155 095 Page 5

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SECTION 3 − SHIELDED METAL ARC WELDING (SMAW)
PROCEDURE
3-1. Typical Stick Welding Set-Up
!
Welding current starts as soon as
electrode touches the workpiece.
1
Workpiece
Make sure workpiece is clean before
welding.
2
Work Clamp
5
Place as close to the weld as possible.
4
3
Electrode
Before striking an arc, insert an electrode
2
in the electrode holder. A small diameter
electrode requires less current than a
large one. Follow recommendations of
the electrode manufacturer when setting
weld amperage (see Section 3-2).
4
Insulated Electrode Holder
5
Electrode Holder Position
6
Arc Length
3
Arc length is the distance from the elec-
trode to the workpiece. A short arc with
6
correct amperage will give a sharp,
crackling sound. Correct arc length is re-
lated to electrode diameter. Examine the
1
7
weld bead to determine if the arc length
is correct.
Arc length for 1/16 and 3/32 in. diameter
electrodes should be about 1/16 in. (1.6
mm); arc length for 1/8 and 5/32 in. elec-
trodes should be about 1/8 in. (3 mm).
7
Slag
Use a chipping hammer and wire brush to
remove slag. Remove slag and check
weld bead before making another weld
pass.
Tools Needed:
151 593
155 095 Page 6

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3-2. Electrode And Amperage Selection Chart
RANGE
AMPERAGE
ELECTRODE
DIAMETER
50
100
150
200
250
300
350
400
450
3/32
1/8
6010
5/32
&
3/16
6011
7/32
1/4
1/16
5/64
3/32
1/8
6013
5/32
3/16
7/32
1/4
3/32
1/8
5/32
7014
3/16
7/32
1/4
3/32
1/8
5/32
7018
3/16
7/32
1/4
3/32
1/8
5/32
7024
3/16
7/32
1/4
3/32
1/8
Ni-Cl
5/32
3/16
3/32
308L
1/8
5/32
TION
DC*
AC
POSITION
USAGE
ELECTRODE
PENETRA
6010
EP
ALL
DEEP
MIN. PREP, ROUGH
HIGH SPATTER
6011
EP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
SMOOTH, EASY,
7014
EP,EN
ALL
MED
FAST
LOW HYDROGEN,
7018
EP
ALL
MED
STRONG
FLAT
SMOOTH, EASY,
7024
EP,EN
HORIZ
LOW
FASTER
FILLET
NI-CL
EP
ALL
LOW
CAST IRON
308L
EP
ALL
LOW
STAINLESS
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Ref. S-087 985-A
155 095 Page 7

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3-3. Striking An Arc − Scratch Start Technique
!
Welding current starts as
soon as electrode touches the
workpiece.
. The scratch-start technique is
preferred for ac welding.
1
1
Electrode
2
Workpiece
3
Arc
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.
2
3
S-0049
3-4. Striking An Arc − Tapping Technique
!
Welding current starts as
soon as electrode touches the
workpiece.
1
Electrode
2
Workpiece
1
3
Arc
Bring electrode straight down to
workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.
2
3
S-0049
155 095 Page 8

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