A Series
A Series
A Series
Pocket Handbook
for Arc Welding Steel
a series
Compiledas a usefultool
for on-the-jobwelding
personnelby an AWS
PresidentialTask GrouP
I
@ 1994by AmericanWelding Society.A[ rightr rcserved
PrintEdin the UnitEdSrstesof America
r|FIilEfrffi
NOTD: Although carE wa$ lrken in choosing and presenting the drta in this guide, AwS carmot gu&&nreethat it is
enor frEe.Further, tlfs guide is not int€nded to b€ an e raustivet€afrnent of the topic ald theFfore may not include ell
available information, incftding wift rcspect to safety and heaith issuea.By publishing lhi$ grdde, AWS doesnot in$ne
anyorc using the infc,nnation it contains against any liability or indury to ploperty or pe$ons arising ftom Om use.
Tableof Contents
BasicSafety hecautions CarbonArc GougingElectrodes.......................
t5
ElectsodestClassification,Size,Amps, DepositionRarefor Mild Steelfor CMAW...........16
DepositionRate Recommended CopperCableSizes........................
l7
ClassificationSystemfor CarbonSteel Guideto ElectrodeConditioningandStorage........
Elecfiodes 1g
for SMAW....................................6
WeldingPositions- Filler (plate).........................
SMAW E6010Etecfodes.... 7 t9
'7 WeldingPositions- Groove(plate).....................
SMAW E60tI EIecrrodes....................................7 20
SMAW E6012Electrodes Welding Positions- pipe
SMAW E60I3 Elecnodes Thicknessand Weight of Steelplates-
SMAW E7018Elecuodes U32to 2 inch................... 23
SMAWE7024Elecrrodes....................................9
How to UseWeldFillercage.....................
ClassificationSyslemfor Solid and ComDosrE ..........
. 25
PipeSizeandWall Thicknesses.............................
26
CarbonSteelElectrodes for GMAW.-.........l0
GMAW ER7oS-XShortArc Elecrodes._.........11 Tests to Identit,rh€Mater.ial.....................,............
27
CMAW ER70S-XSprayArc Elecnodes........... Schedulefor Oxyfuel Cutting {
II
GMAW E7oC-XXMeratCoredEtecEodes......l2 usingNanual Gas 29
ClassificationSysieil for CarbonSteel usmgAcetyleneGas 30
Elecuodes for FCAW...................................
13 usingPropyleneGas 31
FCAW ETXT-X Gas-shielded Electrodes........l4 BasicWeldingSymbolsandTheirLocarion..........32
FCAWSelf-Shielded Elecrrodes.......................
r4 I-ocationof Elementsof a WeldingSymbol........ ...34
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BasicSafetyPrecautions
Burn Protection. Molten metal, sparks, slag, Electrical Hazards. Electuic shock can kill.
and hot work surfaces are produced by welding, However, it can be avoided.Live electdcalpafts
cutting, and allied processes.These can cause should not be touched. The manufacturer,s
bums if precautionary measures are not used. instructions and recorwended sale practices
Workers should wear protective clothing made should be read and undersrood.Faulry inslalla_
of fire-res istant material. pant cuffs, open pock- tlonr rmproper grcunding, and inconect opera-
ets, or other places on clothing that can catch tion and maintenanceof eleclricalequipmenl
and retain molten metal or sparks should not be are all sourcesof danger.
wom. High-top shoesor lealherlegging( and
Irre-resistant gloves shouldbe wom. pant lees All electrical equipment and the workpiece
should be wom over rhe oulside of hieh+op should be gounded. The wo*piece lead is
\hoes.Helmersor handshieldsLharprovidepro- not a ground lead. It is used only to complete
tection for the face, neck, and ears, and a head the welding circuit. A sepamte conlection is
covedng to protect the head should be used. In requlred to ground the workpiece. The work-
addition, approp ate eye protection should be piece should lrot be mistaken for a ground
useo. connection.
r
GlassificationSystemfor GarbonSteel Electrodesfor SMAW
- .]:y"9. ftis desisnaror
may bederered
hom theproducrrmprinrrcqurredfor
T',c:i5f
loenurcarronot theelectrode_
Designatesrhetensile str€ngth(miniinum), in ksi, of the weld nerat whe, poduced
in accord_
ancewith the tesr assemblyprepantion plocedue of this specificarion_
Desjgnate,rheweldingposirionin $hich etecEodes areusabte.tle rypeof coterins.anddle
lind of weldinscu-nenr
for sbich rheetectrode(aresuirabte.
EXXYY-THZR
SMAWEleclrodes SMAWElectrodes
E6010 E6011
Dlameter(tn,) Amps Dep.Ratel Diameter(in.) Amps o6p. Ratel
3/32 50 0.8 3/32 50 0.8
70 t.2 70 1.2
i/8 100 2.1 1/8 110 2.O
130 130
5/32 144 5/32 140 3.5
1',70 2.9 175 4.0
3/16 160 3.3 3t16 170 4.0
190 3.5 190 4.2
782 190 4.5 7/32 i75
I
230 5.1 220 5.1
r..Depsiliomre in lbs/b ba\edon l0o% e time.May vary s irhin
1 Deposition nte in tbs/br baed on 100%e time. May vdy w,thn
:,vr. rDeen'crency.wi-h a 2 \rub tos,.a app_o(halet)60a
alo%. The efficiency, with a 2,, snlb lo$, h apprcximaiely 60%.
f
SMAWElectrocle6 SMAWElectrodeg
E6012 E6013
Dlameter(ln.) Amps Dep.naler Di6meter(in.) Amps Dep.Raiel
t/8 100 60 0.9
130 2.9 1.2
5/32 165 3.2 1/8 100
200 135 3.0
3t16 224 4.O 5t32 140 2_6
244 180
7t32 275 4.8 3/16 180 3.2
320 5.6 220 4.r
1/4 320 5.6 7t3) 250 5.3
180 7.1 290 6.1
1 Deposition 6te in lbsAr brsed on 100%dc 1ine. May vary within 1. D€posnionrale id lbs4r basedon l |]O4]N 1ime.May vart wirhin
i10%, The eiTiciency,witl a 2 6tub to$, h approxinarely 60%. a10%. Ihe efficiencr. with a 2' stub los, is approxina;ry 60%.
SMAWElectrodeg SMAWEleclrodes
E7018 E7024
Diameter(ln.) Amps oep. Falel Diameter(in.) Amps Dep.Ral€l
3t32 70 1.4 l/8 140 4.2
:
Systemfor Solidand Gomposite
Ctassification
CarbonSteel Electrodesfor GMAW
Indicatesuseas either an elertrode or rod (ER), or use only as an elecrode (E).
Indicates,in 1,000psi (6.9 MPa) increnents, the rninimum tensile strengthof the weld metal
Foduced by the ele.tode when tested according to this specification. ln this case' 70 indi-
cates70,000psi.
Indicateswhetherthe fiIer netal is solid (S) or conposite (C)
E 7 0 C X Y
E Indicates the type of shietding gas used for classification of composite electrodes.Carbon
dioxide shielding is indicatedby "c'' and 75-80% tu/balance CO2is indicatedbv "M'.
Indicales the chernical conposition of a solid electode or the chemical composition of the
rveld metal producedby a conposite electtode.The use of lhe "GS" sutrix d€signaEsnller
metals intendedfor single-pa5sapPlicationsonly.
10
GMAWElectrodes GMAWElectrod.s
ER70$X ShortArc EF7oS-XSpralt Arc
Dlameter Dep. Dlameter Dep.
Amps Volts (lnJ Amps Volts Relel
(inJ Ralel
12
Classificataon
Systemfor CarbonSteelElectrodesfor FCAW
Designabesan elecEode.
This designatoris either 6 or 7. It indicatesthe mininum tensile snengfi (in psi x 10,000) of the
weld metal when the weld is nade in the mannerprescribedby this specification.
This designatoris eitlpr 0 or 1. Ii indicates fte posirions of welding for which the electrode is
idended. (0 is for flat andhorizontal position only. I is for aI posilions.)
This desigDatorindicatesthal the electode is a flux coredelectrode.
This designatoris somenumberftom I throush 14 or the letter ..c" with or withour an ,.S',foltow
ing. The nurnberrcfels to the usabiliry of the electrode.The .,G'. indicaresthat rhe exremalshield-
ing. polarity, andimpact propeniesare not specified.The ,.S,'indicaresrhai the electrodeis suirable
for a weld consistingof a single pass.Such an elecFodeis not suitabiefor a nulrj-pass weld.
An "M" designatorin tnis position indicatesthar the electrodeis classified usins 1s-BO% arconl
balanceCO) (lueldinggas.when he M designato'doesnomppear.n (igoif;s har eifte;de
shielding gasusedfor classification is CO, or tha! tlle producr is a ser-shielded Foducr.
EXXT-XMJIIz Optional Supplem€ntsl Deelglr'ton
D€signatesthat the electrodemeetsthe requirementsof tne diffusible hydrogen lest (an oprional
supplenental test of the weld metal with an averagevalue nor exceeding..2' n[ of Hz pef l00g of
deposiledmetal where "2" is 4, 8, or 16). l
ment of 20 ftlbr at -40'F (27J at -40'C)- Absenceof the "J" indicaiesnormal impacrr€quiremenb.
t3
;
FCAWElectrodes FCAWElectrodes
Self-Shielded
ETXT-XGas-Shielded
Olam. wFs Volls Amp Dep Diam. wFs Volts Amp
D€p.
(DCEP) Raler (ln) (ipm) Ratel
(in.) (ipm)
E71Tn! (DCEN)
.045 200 28 150 0.9
320 12] .045 15
600 140 18 225 2.6
.052 150 25 155
.068 56 1',l r60 2.r
600 37 430 l'l.6
l9 275 5.2
\^6 150 2',1 190 6.1
E70T-4 (DCEP)
500 39 500 20.r 3t32 165 354 13.8
5t64 l12 26 250 6.4 263 30 400 16.1
258 450 14.8 .tzo 101 450 13.0
3t32 124 30 350 9.6 33 550
2',t8 550 21.3 E70l-7 (DCEN)
'7
/64 140 30 550 t'7.l 3t32 135 2',7 325 8.8
190 36 700 23.O 26 29 400 t2.6
'7t64 t2D 29 400 11.5
l/8 111 32 600 t6.2
194 38 850 24.2 1',75 31 490 15.8
dc timeMavvarvwilhin
on1OO%
in lbs/hbased 1. Deposilion Fte in lb$/h! basedon 100% dc tine. Mav vary vnhin
1.Depositionrale
lr"r#**"^'^*-*-
74
CarbonArc GougingElectrodes
suggesledcurenl Bangestor lhe Commonlyused CAc-A ElectrodeTypesand Diameters
ElectrodeDiameter DC Electrode',vllhDCEBA AC Electrodewith AC,A
e
E
a
@
J
FH
E;
F6
=<
E.E
8
ctt
H
Hal=
t5
3@ 400 5@ 600 7m
WIRE FEEO SPEEO IN INCHES,MINUTE
16
Recomm€ndedCoPPerCableSizea
CabloSlzeEfor ComblnedLengthsot Electrodeand WorkCables
Percent 0 to 50 ft. 50 to lmft. 100to 150ft. 150to 200ft,
Amperea Dutycfcle
100 20 8 4 3 2
150 40 6 5 3 2
225 20 3 2 I
250 40 2 2
400 60 2n ao u0 3to
f
_+t_
500.-600"F 700'F(+s0)
Low Hydrogen ONEHOUR ONE.HALFHOUR
EXXl8, EXX28
90'F(120') 300"F(+s01
Low Hy&ogen
50%Max.RH
ONE & ONE-HALF HOUR TOTAL
EXX15,EXXl6
Low Hydrogen- s00.-600"F 650"F(r50)
High Tensile 90'F(*20) ONEHOUR ONE-HALFHOUR
300'F(r50")
DOO(15, EXXXl6, 50%Max.Rt{
E)C(xl8 ONE & ONE-HALF HOUR TOTAL
18
WeldingPositions- Flllet(plate)
WELOAXIS WELDAXIS
HOFIZONTAL HORIZONTAL
2F (HORTZONTAL)
WELDAXIS
HORIZONTAL-
4F (OVERHEAD)
I
l9
t
I
\
WeldingPositions- Groove(plate)
PLATESHOBIZONIAL PLATES
VERTICAL
3G PLATESVERTICAL PLATESHORIZONTAL
20
WeldingPositiona- Plpe
,-<.-<-\(----=! 5 prpEHoRrzo^nAL,RorArED.
- WELD FLAr(+1s.).
DEpostr
1n\ I ). 1-*.
-pW*- FILLERMErALAroRNEAR rHEroP
1G NOTATED
PIPEOR TUBEVERTICAL;NOT
ROTATED DURINGWELDING.
WELDHORIZONTAL (r15'1.
;
*'
- PiPe(contd)
WeldlngPositions
sGA-T--\+-
-@=N:=' rN-5=
(rls')i Nor RorArED
PIPEoR ruBEHoRlzoNrAL
WELDFLAT,
WELDING, VEBTICAL, OVERHEAD.
+tl U _i
\L----*----
DURING
RING
BESTRICTION
TESTWELD
PIPEINCLINED FIXED
(45'r5'); NOTROTATED
DUBINGWELDING.
22
'll32-'l Inch
Thicknessand Weightof SteelPlatesr
mm tb,tfi, Gauge Fractlon oeclmal mm tbfit2
Ga!ge Fractlon Decimal
Ln5 t7t32 0.531 t3.494 21.675
22 !32 0.031 oJ94
2.550 9l16 0.563 14.287 22.950
16 l^6 0.063 1.588
0.094 2.381 3.825 19t32 0.594 r5.081 24.225
13 3t32
5.100 5t8 0.625 1 5 . 8 7 5 25.500
ll 1/8 0.125 3.175
6.3',75 21t32 0.656 16.669 26.',1',15
5t32 0.156 3.969
,7 '7.650 tu16 0.688 t'7.46328.050
3l16 0.188 4.763
8.925 23t32 o.719 18.256 29.325
5 1t32 o.219 5.556
0.250 6.350 10.200 3t4 0.750 19.050 30.600
3 lt4
'7.t44 lr.4'75 25t32 0.781 19.844 31.875
9t32 0.281
'7.937 r2.750 t3^6 0.813 20.638 33.150
5/16 0.313
2',7132 2t.431 34.425
t!32 o_344 8.731 r4.oz5 0.844
0.375 9.525 15.300 7t8 0.875 22.225 35.700
3t8
0.406 1 0 . 3 1 9 t6.515 29t32 0.906 23.Ot9 36.9',t5
13t32
'7t16 17.850 15t16 0.938 23.813 38.250 I
0.438 11.112
o.469 1r.906 79.125 3y32 0.969 24.606 39.525
15t32
I 1.000 25.400 40.800
u2 0.500 12.700 24.4ffi
I
*:
24
BECERTAINBLADE FORCONVEXWELDS:USEELADEW|THSTNGLE
ARCAT
EDGEIS SQUABE APPROPRIATE
SIZE.FOBCONCAVE
I
WELDS:USEBLADE
WITHWELDEDPARTS, WITHDOUBLE
ARCATAPPROPRIATESIZE.
25
Commercial Pipe Sizes and Wall Thicknesses (asA-836 10and83619)
Nominal NominalWallThicknegsesin inchesfor
Plpe
Outslde Stan- sched. S c h e d . Sched. xx
Slze
Diam. Sched. Sched.
1osr datd2 40 xs3 Sched.
80 120 160 Strong
5s'
1/8 0.405 0.049 a.a68 0.068 4.495 0.095
1/4 0.540 0.065 4.488 0.088 4 . 1 1 9 0.119
3t8 0.675 0.06s a.a9I 0.091 0.126 0.126
lt2 0.840 0.065 0.083 0.109 0.109 0.t47 o.t4'l 0.188 0.294
3t4 1.050 0.06s 0.083 0 . 1 1 3 0 . 1 1 3 0.154 0.154 o.2t9 0.306
I 1.315 0.06s 0.109 0.133 0.133 0 . 1 7 9 0.179 0.250 0.358
t-1t4 1.660 0.065 0.109 0.110 0.140 0 . 1 9 1 0.191 o.250 0.382
r-1t2 1.900 0.065 0.109 0.145 0.145 4.240 0.200 0.28r 0.400
2 2.3',t5 0.065 0.109 4 . 1 5 4 0.154 4.218 0.218 0.344 0.436
2.875 0.083 0.120 4.243 0.203 4.276 a.276 o.375 0.552
3 3.5 0.083 0.120 0.216 o.2t6 0.304 0.300 0.438 0.600
3-lt2 4.0 0.083 0.120 0.226 o.226 0.318 0.318
0.083 0.120 0.237 0.231 0.337 0.337 0.438 0.531 o.674
5 0.109 0.134 0.258 0.258 0.375 0.375 0.500 0.625 0.750
6 6.625 0.109 0.134 0.284 0.280 a.$2 0.432 0.562 0.719 0-864
NOTES:
L Schedules 5sdd 1Ose availabteh cotusionresislantnareriak md Sch€dule10sn ako availablein ctrbon st€elin sizes12 in. andsnaller.
2. Thickn€s*s shown in rralrr re aho arailable in stainlesssreel,under the designaiion Schedule40s
3. Thic*nessesshown in ,alrr de aho available in stainle$ sreel,under the designalion Schedlle 80s
26
Materlalldentltication
Low Carbon Sieel M€d. Carbon Sle€l Hlqhcarbon sl€sl Hlqh Sulph|lr St€el
(Fa uapnencrest Strongly Maglelic StrongLy Magnetic Slrongly MaStretic Strongly Magnelic
\=r<
Conlinuous Chip
Oofa,--..",.tzZ=:
tlor b6r r$uts, lse at l6t 5,000
surf&e fet pd ninute on slinding
Y€llow Li.s Bnent Bu$
*"it!":ffi*'* I
Yellov Lin6 Spliss vdy Vay Cled Nmerous Srd
!-8 P'M') =
(ch sF p*Mii
21
Material ldentif iqalion (cont d)
Stalnl€ss Sle€l
Dull Grey Ligh! Grey
Dull Bright
Appeatancerest
A Sdd Mold
Q$ o-"*,,^' Bright
Brittle
Brighl Grey
Melts Slowly
rcl\'.'
rFor bst 6ults, us at l€osl 5,000
sufre feet per ninnte on grinding
/cn ARPM) : ^-
l----l-r
._
ir etrlm 3 Veadim-LongSpw-
4 -a/_
*H:[:i,:g,l:?"
28
n
Guidefor ManualOxytuelGas Cutilng UsingAcetylene
Materlal Culting Orlflce Approxlmate Manual
Thickness DrlllSlze Dlameter(in.) Pressureot Gas(psi) lravel Speed
(in) (centerhole) Acetylene Orygen (ln,/min.)
1/8 60 0.040 3 10 20 22
1t4 60 0.040 3 15 16-18
3/8 55 0.052 3 20 l,t-16
1/2 55 0.052 3 25 12-14
3t4 55 0.052 3f 10-12
53 0.060 35 8-11
l-t/2 53 0.060 40
2 49 0.073 45
49 0.073 5 50 5-6
4 49 0.073 5 55
5 0.082 5 60 3+
6 0.082 6 70
0.082 l
1, Ti!, drill or onfice diameler size will vdy with eeh tip according to nanufrctuer's specification.
30
;
Basicwelding Symbolsand Theil LocationSignificance
Edt
--_,, _-o___., e -
,-+
32
e
-+----'.
Locationol Elementsol a WeldingSymbol
FrNrsHsyrvnol\,-BPBY'"+if5fij,lT?'#tsi?J$EiE"
CoIVIOUBSYMBoL-\ \F ,/ aoor OpellNe; oEpTHoF F|LLING
WELD
GROOVE SIZE_I Y-- FORPIUGiNDaSLOTWELDS
// //
oFBEVEL
EprH
DEprH oR_.- _
srzE ':" ,/
X ,,-_!'ilEli""Jd.=,iio"r*."
,,-_'iiEl'r'"i*.liio"rnn.
TRENGTH
STRENGTH
:;ii*r!$ri#-,|"wELDS
WELDS
FoRCERTATN
cERrArN
*ur \. sweol
i{ / IE
rAlL(oMrrTED J | ,ttd EAI , .\
WHENREFERENCE
iii'riiirEeni-- I /
,/ ./
,"*r."r*"r
/ .- ] ,/
*ELD -J4
SYMBoL /AN) l/*"o*"o,u*."'"o
1 oj s"ors*r, I| i51.tr31i..iilF
"ur".*
sruD,PLUG,slor.
__
WELDS iriiiiiiiorrcrm
oRPRoJECTIoN I 6:i i-nEowsroeor
JOINT
ELEMENTSIN THIS AREA
REMATNAS SHOWNWHENTAIL
AND ARROWARE REVERSED
34
tErI-
@ 550 N.W. l,€fidnc kd l{ihi Firida 33126
I
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