Smag
Smag
Smag
2010−02
Processes
Stick (SMAW) Welding
Guidelines For
Shielded Metal Arc
Welding (SMAW)
Protect yourself and others from injury — read and follow these precautions.
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
process, be sure to treat them carefully.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
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 Install cylinders in an upright position by securing to a stationary
D Protect yourself and others from flying sparks and hot metal.
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.
155 095 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
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.
3 4
Tools Needed:
151 593
AMPERAGE
RANGE
ELECTRODE
DIAMETER
100
150
200
250
300
350
400
450
50
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
PENETRATION
ELECTRODE
POSITION
USAGE
DC*
AC
S-0049
S-0049
Direction Of Welding
Fillet Welds
10°- 30°
45°
45°
Direction Of Welding
S-0660
S-0054-A
Notes
Electrode Angle
Correct Angle
10° - 30°
Arc Length
Spatter
Travel Speed
S-0661
2 3 4
S-0053-A
1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During
Welding
4 No Overlap
5 Good Penetration Into Base
Metal
2 3 4 5
S-0052-B
804 248
S-0662
1 Electrode
2 Fillet Weld
Keep arc short and move at definite
1 rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.
45° For maximum strength weld both
Or Less sides of upright section.
2
3 Multi-Layer Deposits
Weld a second layer when a heavi-
er fillet is needed. Use any of the
weaving patterns shown in Section
3-6. Remove slag before making
another weld pass.
3
S-0060 / S-0058-A / S-0061
1 Electrode
2
Single-Layer Fillet Weld
30°
Or Less
3
Multi-Layer Fillet Weld
S-0063 / S-0064
15°
30°
Direction Of Direction Of
90°
Welding Welding
30°
Make First Weld Pass (Root Pass). Make Second Weld Pass.
45°
Direction Of
Welding
Direction Of
Welding
Whipping Up 1 Electrode
Motion
Direction Of
2 Backing Strip
Welding
Weld vertically by carrying the
weld upward or starting at the top
Weave Bead and welding down. Welding up-
1/2 in. (12 mm) ward is easier and is shown in
Wide these illustrations.
Bevel edges if warranted by ma-
terial thickness (see Section
3-11). Tack weld a backing strip
to the plates to make the first
weld pass (root pass) easier.
90°
Direction Of
90°
1st Pass
2nd Pass
Hesitate With
Slight Up And
Direction Of
Direction Of
Down Motion. OR
Welding
Welding
Shorten Arc At
Arrowheads
When At Center
Of Weld.
3rd Pass 4th Pass
Direction Of
Welding
Arrows Show Lifting Up
Of Electrode And Return To
Crater.
90°
Shows Shows
Weaving Weaving
Motion. Motion.
Direction Of
Direction Of
Welding
Welding
OR
90° 90°
Shows
Weaving
Motion.
Direction Of
Welding
90°
804 260
1
1/2 in (12 mm) 2 3
Direction Of
Welding
1/2 in
(12 mm)
30°
1 Vise
2 Weld Joint
3 Hammer
Strike the weld joint in the direction
shown. A good weld bends over but
does not break.
3 If the weld breaks, examine it to de-
termine the cause.
3 If the weld is porous (many holes),
the arc length was probably too
2 To 3 in. long.
(51-76 mm) If the weld contains bits of slag, the
2 To 3 in.
(51-76 mm) arc may have been too long or the
2 electrode was moved incorrectly
1/4 in. 2 which allowed molten slag to be
(6.4 mm) 1 trapped in the weld. This may hap-
1
pen on a V-groove joint made in
several layers and calls for addi-
tional cleaning between layers.
If the original beveled surface is vis-
ible the material was not fully melted
which is often caused by insufficient
heat or too fast a travel speed.
S-0057-B
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding.
Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding.
Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.
4-6. Burn-Through
4-8. Distortion
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ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2010 Miller Electric Mfg. Co. 2010−01