Manufacturing Practice 2

J 4121

SECTION 1 − SAFETY PRECAUTIONS

1-1. Symbol Usage

1-2. Arc Welding Hazards

ELECTRIC SHOCK can kill.

FUMES AND GASES can be hazardous.

ARC RAYS can burn eyes and skin.

WELDING can cause fire or explosion.

FLYING METAL can injure eyes.

CYLINDERS can explode if damaged.

1-3. Additional Symbols For Installation, Operation, And Maintenance

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 creating 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.

SECTION 3 − SHIELDED METAL ARC WELDING (SMAW) PROCEDURE

3-2. Electrode And Amperage Selection Chart

• ElectrodeE6010

E 60 1 "10"

Electrode Tensile strength Position Type of Coating and Current

Digit Type of Coating Welding Current 10 High cellulose sodium DC+11 High cellulose potassium AC or DC- or DC+12 High titania sodium AC or DC-13 High titania potassium AC or DC+14 iron powder titania AC or DC- or DC+15 low hydrogen sodium DC+16 low hydrogen potassium AC or DC+27 iron powder iron oxide AC or DC- or DC+ 18 iron powder low hydrogen AC or DC+20 High iron oxide AC or DC- or DC+22 High iron oxide AC or DC-24 iron powder titania AC or DC- or DC+28 Low hydrogen potassium iron powder AC or DC+

3-3. Striking An Arc − Scratch Start Technique

3-4. Striking An Arc − Tapping Technique

3-5. Positioning Electrode Holder

3-6. Electrode Movement During Welding

3-7. Conditions That Affect Weld Bead Shape

3-8. Poor Weld Bead Characteristics

3-9. Good Weld Bead Characteristics

3-10. Typical Weld Joints

3-11. Welding Butt Joints

3-14. Welding Butt Joints

30⁰30⁰

Single Pass Flat Butt Joint Weld Or First Pass Of Multi-Layer Deposit

3-18. Weld Test

SECTION 4 − WELDING TROUBLESHOOTING

• The structure of the welding symbol

SECTION 5 - SYMBOLS

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