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100% found this document useful (2 votes)

197 views263 pages

Libro de Trabajo de Procesos de Soldadura

Libro de trabajo de procesos de soldadura

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Jhonatan Paul Espinoza Timoteo

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Welding Processes

and Practices
Workbook

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August F. Manz
Eugene G. Hornberger

Printed by permission of the authors by the American Welding Society, 1998.

Copyright American Welding Society

Located, reviewed and reprinted in cooperation with the authors under the
AWS Product Development Committee as a service for quality-minded
fabricators.

This publication is designed to provide information in regard to the subject matter covered. It is made
available with the understanding that the publisher is not engaged in the rendering of professional
advice. Reliance upon the information contained in this document should not be undertaken without an
independent verification of its application for a particular use. The publisher is not responsible for loss
or damage resulting from use of this publication. This document is not a consensus standard, and is in
fact, the work of independent authors. Users should refer to the applicable standards when called for.

American Welding Society

@
Copyright American Welding Society
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Prefaee
The training of welders requires a great deal of individualized instruction. Often classes
are large and stretch the instructor?sability to devote enough attention to each student.
Welding instructors need instructional material that will reduce the amount of one-
on-one time required for each student. This workbook providesstudents with reference
material so that they will not need to approach the instructor on items already covered.
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Thus students can use the reference material for reinforcement of their skills.
The main purpose of this workbook is to present the student with a wide variety of
joint types and in avariety of positions, usinga selection of the more popular electrodes
used today.
The workbook does not purport to replace the instructor; the instructor must always
be the ultimate authority and reference for the student.
The angles and manipulationsfor the electrodes and torches will do the job properly.
Should the instructor have other preferences, they would certainly supersede those
presented here.
The hands-on Procedures are designed to aid the instructor,and to assist the student in
learningthe fundamentals of welding. They should also reduce the number of times the
student will have to go to the instructor with questions.
The Proceduresshould alsoassist the student in learningto follow written instructions
as well as to develop a sense of responsibility toward the job.
Most of the questionsstudents may havearecovered alongwith descriptivedrawings.
In most cases there i s further descriptiveand explanatoryinformation in the correspond-
ing lesson in the Welding Processes and Practices textbook. Each Procedure in the
workbook has been conveniently cross-referenced to its exact Section, Lesson, and
page number in the textbook. Lessons should first be studied in that text, then the
workbook should be used as a guide while performing the task.
Following the precepts of vocational education, it is suggested that the Procedure
sheets be used in conjunction with the instructor?s lecture and demonstration as
supportive material.

Copyright American Welding Society

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To the Student
Before you start, use the proper safety equipment and work efficiently at all times.
Everything you learn here will be helpful in other phases of your training. The good
habits you form will stay with you, but so will the bad ones. Do the best you can from the
beginning bad habits are difficult to break.
One of the more difficult things you must learn is to set your welding conditions
properly. In each Procedure you will be given a range of welding conditions for the
exerciseyou will be doing. You will have to find the point in that rangethat producesthe
best weld for you. This will come through practice.
It is important for a welder to be able to set the correct welding conditions for the
material type, size, thickness, or position. All these factors are important to know when
setting up the equipment. For this reason the welder must not only be able to set gas
pressures, amperages, voltages, or gas flows, they must be able to "read" the puddJeand
recognize the sound it makes when the conditions are correct. Through practice the
welder can recognizewhen the weldingconditions are proper by theappearanceof the
flame or the sound the arc makes and by the way the puddle reacts.

SAFETY REMINDERS

in addition to the safety reminders in the procedures, you should always remember to:

1. Pick up hot metal with tongs, pliers, or clamps. Never pick up hot metal with your
gloves or bare hands. Gloves used to pick up hot metal will quickly become stiff,
brittle, and unusable.
2. Cool all metal after welding.
3. Remove all welding stubs and wire from the area.
4. Leave the area clean for the next student.
5. Secure the welding equipment in the proper place at the end of the Procedure.

GENERAL MATERIAL AND EQUIPMENT

The general material and equipment you will need are listed at the beginning of each
section. Additional materials needed for specific Procedures are designed in the specifi-
cation boxes within each Procedure.

GENERAL INSTRUCTIONS

Throughout these Procedures you will be using a variety of equipment. When direct
current is called for, the electrode charge or polarity will be specified on the technique
sheet.

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Copyright American Welding Society

One final note before you start your hands-on training. The Procedures in this book
have been written for right-handed welders. Left-handed students should start at the
opposite end of the plate and reverse all the directions and angles given.
Welders should learn to work both from left to right and from right to left. in addition,
they should learn to weld toward and away from themselves. A proficient welder can
weld in any direction.
However, there is something very important to remember before you start: Namely,
your instructor is the expert. Go to your instructor whenever you have a problem. Do not
move on to a new Procedure before the instuctor has demonstrated that Procedure
(unless, of course, you have permission to do so).

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Copyright American Welding Society

Oxyacetylene Welding (OAW)of Carbon Steel 3

Procedure 1 Flat Beads Without Filler Metal 5
Procedure 2 Flat Beads with Filler Metal 7
Procedure 3 Flat Outside-Corner Joint 9
Procedure 4 Flat Outside-Corner Joint with Filler Metal 11
Procedure 5 Flat Square-Groove Butt Joint with Filler Metal 13
Procedure 6 Horizontal Outside-Corner Joint 15
Procedure 7 Horizontal Square-Groove Butt Joint 17
Procedure 8 Horizontal Fillet Joint Position 19

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Procedure 9 Vertical Outside-Corner Joint, Uphill Weld 21
Procedure 10 Vertical Outside-Corner Joint, Downhill Weld 23
Procedure 11 Vertical Square-Groove Butt Joint 25
Procedure 12 Vertical Fillet Joint 27
Procedure 13 Overhead Outside-Corner Joint 29
Procedure 14 Overhead Square-Groove Butt Joint 31
Procedure 15 Overhead Fillet Joint 33

Oxyacetylene Braze-Welding 35
Procedure 16 Running Flat Beads 37
Procedure 17 Flat V-Groove Butt Joint 39
Procedure 18 Horizontal T-Joint 41
Procedure 19 Horizontal Lap Joint Fillet 43
Procedure 20 Horizontal V-Groove Butt Joint 45
Procedure 21 Vertical T-Joint Fillet 47
Procedure 22 Vertical V-Groove Butt Joint 49

Oxyacetylene Welding of Pipe 51

Procedure 23 IG Position, Axis of the Pipe Horizontal 53
Procedure 24 2G Position, Axis of the Pipe Vertical 55
Procedure 25 5G Position, Axis of the Pipe Horizontal 57

Copyright American Welding Society

SHIELDED METAL ARC WELDING PROCESS 59

Shielded Metal Arc Welding of Plate 61

Procedure 26 Striking and Maintaining an Arc 63
Procedure 27 Welding Stringer Beads 65
Procedure 28 Running a Flat Pad of Stringers 67
Procedure 29 T-Joint Fillet, 1F Position, Stringer Beads
(E-601O or E-6011 Electrodes) 69
Procedure 30 T-Joint Fillet, 1F Position, Stringer Beads
(E-7014 or E-7024 Electrodes) 71
Procedure 31 Filling Craters at the End of Welds 73
Procedure 32 Square-Groove Butt Joint, 1G Position With Backup
Bar, Stringer Beads 75
Procedure 33 Outside-Corner Joint, 1G Position, Stringer
and Weave Beads 77
Procedure 34 Running a Horizontal Pad of Stringers 79

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Procedure 35 T-Joint Fillet, 2F Position, Multipass Stringers
(E-601O or E-6011 Electrodes) 81
Procedure 36 T-Joint Fillet, 2F Position, Multipass
Stringers (E-7024 Electrode) 83
Procedure 37 Single-Bevel Butt joint, 2G Position with
Backup Bar 85
Procedure 38 Open-Root V-Groove, Butt Joint, 2G Position 87
Procedure 39 T-Joint Fillet, 3F Position, Weave Beads, Uphill
(E-601O or E-601 1 Electrodes) 89
Procedure 40 T-Joint Fillet, 3F Position, Weave Beads, Uphill
(E-7018 Electrode) 91
Procedure 41 T-Joint Fillet, 3F Position, Stringer Beads, Downhill 93
Procedure 42 V-Groove Butt Joint, 3G Position with Backup
Bar, Uphill 95
Procedure 43 Open-Root V-Groove Butt Joint, 3G Position,
Stringer and Weave Beads 97
Procedure 44 T-Joint Fillet, 4F Position, Stringer Beads
(E-601O or E-6011 Electrodes) 99
Procedure 45 T-Joint Fillet, 4F Position, Stringer Beads
(E-7018 or E-7024 Electrodes) 101
Procedure 46 V-Groove Butt Joint, 4G Position with Backup Bar
(E-601O or E-6011 Electrodes) 103
Procedure 47 V-Groove Butt Joint, 4G Position with Backup Bar
(E-7018 Electrode) 105
Prooedure 48 Open-Root V-Groove Butt Joint, 4G Position 107

Copyright American Welding Society

Shielded Metal Arc Welding of Sheet Metal 109

Procedure 49 Welding an Outside-Corner Joint in the Flat or
Downhand Position 111
Procedure 50 T-Joint Fillet, 2F Position 113
Procedure 51 Lap Joint Fillet, 2F Position 115
Procedure 52 Outside-Corner Joint, 3G Position (E-60
Electrode) 117
Procedure 53 Outside-Corner Joint, 3G Position (E-60
Electrode) 119
Procedure 54 Lap Joint Fillet, 3F Position 121
Procedure 55 Lap Joint Fillet, 4F Position 123
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Procedure 56 Outside-Corner Joint, 4G Position 125

Procedure 57 Welding a Six-Sided Box, in the ZG,3G, and
4G Positions 127

Shielded Metal Arc Welding of Pipe 129

Procedure 58 Beveling Pipe to Prepare It for Tests 131
Procedure 59 Alignment, Fit-Up, and Tacking Procedure 133
Procedure 60 Welding Pipe in the 1G Position, with Its Axis in
the Horizontal Position 135
Procedure 61 Welding Pipe in the 2G Test Position, with Its
Axis in the Vertical Position (E-6010 or E-6011
Electrodes) 137
Procedure 62 Welding Pipe in the 2G Test Position, with Its Axis
in the Vertical Position (E-601O or E-6011
and E-7018 Electrodes) 139
Procedare 63 Welding Pipe in the 5G Position Uphill Passes
(E-601O or E-6011 Electrodes) 141
Procedure 64 Welding Pipe in the 5G Position First Pass
Downhill (E-601O or E-6011 Electrodes)
Second and Out Uphill (E-7018
Electrodes) 143
Procedure 65 Welding Pipe in the 5G Position Downhill Passes
(E-6010 or E-6011 Electrodes) 145
Procedure 66 Welding Pipe in the 6G Position Downhill Passes
(E-601O or E-6011 Electrodes) 147
Procedure 67 Welding Pipe in the 6G Position First Pass
Downhill (E-6010 and E-6011 Electrodes),
Second and Out Uphill (E-7018 Electrode) 149

GAS TUNGSTEN ARC WELDING PROCESS 151

G a s Tungsten Arc Weldhg of Carbon Steel 153

Procedure 68 Running a Flat Pad of Stringers 155

Copyright American Welding Society

Procedure 69 Outside-Corner Joint, 1 G Position 157

Procedure 70 T-Joint Fillet, 1 F Position 159
Procedure 71 V-Groove Butt Joint, 1 G Position 161
Procedure 72 Outside-Corner Joint, 2G Position 163
Procedure 73 T-Joint Fillet, 2F Position 165
Procedure 74 V-Groove Butt Joint, 2G Position 167
Procedure 75 Outside-Corner joint, 3G Position 169
Procedure 76 T-Joint Fillet, 3F Position 171
Procedure 77 V-Groove Butt Joint, 3G Position 173
Procedure 78 Outside-Corner Joint, 4G Position 175
Procedure 79 T-Joint Fillet, 4F Position 177
Procedure 80 V-Groove Butt Joint, 4G Position 179

Gas Tungshn Arc Welding of Aluminum 181

Procedure 81 Running a Flat Pad of Stringers 183
Procedure 82 T-Joint Fillet, 1 F Position 185
Procedure 83 Square-Groove Butt Joint, 1 G Position 187
Procedure 84 T-Joint Fillet, 2F Position 189
Procedure 85 Square-Groove Butt Joint, 2G Position 191
Prooedure 86 T-Joint Fillet, 3F Position 193
Procedure 87 Square-Groove Butt Joint, 3G Position 195
Procedure 88 T-Joint Fillet, 4F Position 197
Procedure 89 Square-Root Butt Joint, 4G Position 199

GAS METAL ARC WELDING PROCESS 201

Shor*-CircuitingArc Welding of Steel 203

Procedure 90 Running a Flat Pad of Stringer Beads 205
Procedure 91 T-joint Fillet, 1 F Position 207
Procedure 92 V-Groove Butt Joint, 1G Position 209
Procedure 93 T-joint Fillets, 2F Position 211
Procedure 94 V-Groove Butt Joint, 2G Position 213
Procedure 95 T-Joint Fillet, 3F Position, Upward Welding 215
Procedure 96 T-Joint Fillet, 3F Position, Downward Welding 217
Procedure 97 V-Groove Butt Joint, 3G Position with Backup Bar,
Upward Welding 219
Procedure 98 V-Groove Butt Joint, 3G Position,
Downward Weld ing 221

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Copyright American Welding Society

Procedure 99 T-Joint Fillet, 4F Position 223

Procedure 100 V-Groove Butt Joint, 4G Position 225

Spray Transfer Welding of Steel 227

Procedure 101 T-Joint Fillet, 1 F Position 229
Prooedure 102 V-Groove Butt Joint, 1G Position with Backup Bar 231
Procedure 103 T-Joint Fillet, 2F Position 233
Prooedure 104 V-Groove Butt Joint, 2G Position with Backup Bar 235

FLUX-CORED ARC WELDING PROCESS 237

Flux-Cored Arc Welding of Steel 239

Prooedure 105 Running Flat Pad of Stringers 241
Procedure 106 T-Joint Fillet, 1 F Position 243
Procedure 107 V-Groove Butt Joint, 1G Position with Backup Bar 245
Procedure 108 T-Joint Fillet, 2F Position 247
Procedure 109 V-Groove Butt Joint, 2G Position with Backup Bar 249
Procedure 110 T-Joint Fillet, 3 F Position 251
Procedure 111 V-Groove Butt Joint, 3G Position with Backup Bar 253
Procedure 112 T-Joint Fillet, 4F Position 255
Procedure 1 1 3 V-Groove Butt Joint, 4G Position with Backup Bar 257

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Copyright American Welding Society

OXYFUEL GAS
WELDING AND
BRAZING

Copyright American Welding Society

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Oxyacetylene W e l d i n g
(OAW) of Carbon Steel
The Procedures in this section of the workbook will aid you in developing your
skills in oxyfuel gas welding and brazing. You will use these skills as you advance to
other welding processes.
The relatively low heat needed to perform oxyfuel gas welding procedures permits
you to observe the weld puddle at close distance. Thus, you will learn how to better
manipulate the weld puddle.
Braze welding is a welding process used routinely in the repair of broken ma-
chinery. The Procedures presented in the latter part of this section will aid you in
developing these skills. It is important that you complete the Procedures in the or-
der that they are presented here. The sequence of the Procedures in the workbook
will ensure that you develop the necessary skills to master more and more complex
welding procedures.

GENERAL INSTRUCTIONS
For each of the procedures in this section, follow the steps listed below:

1. Assemble the oxyacetylene welding outfit according to the manufacturer’s instruc-

tions or the instructions of your teacher.
2. Select the correct tip size from the manufacturer’s chart and adjust the regulators
to the correct working pressure.
3. Check all connections with a leak detection fluid or soapy water to ensure
tightness.

Safety Note: Do not neglect this important step. Oxyfuel mixtures are highly
explosive and extremely flammable. Failure to check for leaks could result in serious
bodily injury and severe property damage.

4. Clean the surface of the plate you are going to weld on with a wire brush to
remove mill scale and oxides, then place it on the welding table.
5. Check the area around you and your welding table to make sure it is free of all
combustible materials.
6. Position yourself comfortably in front of your welding station. A standing position,
feet slightly apart, is best. This position allows maximum body movement to aid
in controlling the torch.

MATERIALS AND EQUIPMENT

For this section the material and equipment will be as follows:

1. Proper clothing 5. Pliers or tongs

2. Safety glasses and welding goggles 6. Spark lighter
with a number 4 or 5 lens 7. Wire brush
3. Leather gloves
4. Oxyacetylene torch, tips, and
regulators
3
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Copyright American Welding Society

- Direction of travel

FIGURE 1 1 -
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FIGURE 1-2
(From Welding Fundamentals and Procedures by Jerry Galyen, Garry Sear, and Charles A. Tuttle.
Copyright Q 1984 by John Wiley & Sons, Inc. Reprinted by permission of John Wiley & Sons, Inc.)

POSITION
Beads without filler metal Flat
ELECTRODE DIAMETER FLAME TYPE
None None Neutral
MATERIAL
1 pc. %ln X 3" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 1
Flat Beads W i t h o u t Filler Metal

(OBJECTIVE left for a right-handed person and toward the right

for a left-handed person.)
Upon completion of this procedure you should be able 3. Hold the torch there until a round puddle develops.
to weld beads in the flat position without filler metal. Use one of the side-to-side motions shown in Fig-
ure 1-1 to establish the puddle.
4. When the puddle has been established, progress at
Text Reference: Section II, Lesson 5 4 page 154. a uniform rate of travel toward the left (right for
left-handed welders) being careful to adjust the rate
of travel to obtain a bead of uniform width.
PROCEDURE 5. Continue to run beads until the plate i s filled up.
6. When the plate has cooled examine the bead appear-
1. Light the torch and adjust it to obtain a neutral flame. ance. (See Figure 1-2.)
Be sure your safety glasses and goggles are in place.
2. Lower the torch until the inner core of the flame is Safety Note: Do not handle the metal with bare
about Kz in. above the surface on the plate. The torch hands. It may be hot or have sharp edges that will burn
tip should be at a 40 to 50 degree angle pointing or cut your hand. Use your pliers or tongs to handle the
toward the direction of travel. (Pointing toward the metal.

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Copyright American Welding Society

FICURE 2-1

FIGURE 2-2 FIGURE 2-3

FIGURE 2-4
a
(From Weldin Fundamentals and Procedures by Jerry Calyen, Carry Sear, and Charles A.
Tuttle. Copyrig t 0 1984 by lohn Wiley & Sons, Inc. Reprinted by permission of john Wiley &
Sons,Inc.)

NAME POSITION
Beads with filler metal Hat
ELECTRODE DIAMETER FLAME TYPE
Carbon steel 5/31' Neutral
MATERIAL
1 pc. 3/32" X 3" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

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Copyright American Welding Society

Procedure 2
Flat Beads with Filler Metal

OBJECTIVE the puddle by dabbing it in the puddle as the torch

i s advanced along the sheet. Coordinate the rate of
Upon completion of this procedure you should be able travel and the addition of filler metal, paying attention
to weld beads in the flat position using filler metal. to maintain a uniform bead width and height.
4. When nearing the edge of the sheet gradually with-
Text Reference: Section II, Lesson 5 4 page 156. draw the flame and add filler metal to fill the crater.
5. Continue to run beads until the plate is filled up.
6. When the plate has cooled, examine the bead ap-
PROCEDURE pearance. (See Figure 2-4.)

1. Light the torch and adjust it to obtain a neutral flame. Note: Filler metals are classified by the American
Be sure your safety glasses and goggles are in place. Welding Society* in filler metal specifications. Filler metal
2. Lower the torch to the plate and establish a weld rods for gas welding range in diameter from 1/16 to % 6 in.
puddle. Hold the filler metal in your left hand. As the and are usually 36 in. in length. Mild steel welding rods
puddle develops, move the end of the filler metal to are often copper coated to inhibit rusting. The size of the
the leading edge of the puddle and allow the wire to rod you use will depend on the thickness of the metal
melt off and mix with the puddle. (See Figure 2-1.) to be welded and the position it is to be welded in. Too
Withdraw the wire slightly, keeping the end of the large a rod will cool the puddle, decreasing penetration
wire in the secondary flame envelope to protect it and fusion. A rod that is too small will cause excessive
. from the atmosphere. (See Figure 2-2.) Do not keep heat, resulting in too much penetration and too wide a
it too close to the flame or the end will melt and ball weld bead.
up. This large ball makes it very difficult to add filler
metal to the puddle. (See Figure 2-3.)
3. Continue to add filler metal to the leading edge of *American Welding Society, 550 N.W. Lejeune Road, Miami, FL 331 35
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Copyright American Welding Society

m Tack we'ds

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FIGURE 3-1

FIGURE 3-2

NAME POSITION
Comer weld without filler Flat
ELECTRODE DIAMETER FLAME TYPE
None None Neutral
MATERIAL
2 pcs. )/31" X 1%" X 6" carbon steel
'PASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

Copyright American Welding Society

Procedure 3
Flat O u t s i d e - C o r n e r Joint

OBJECTIVE Regulate your speed of travel so the bead has an even

width. Too rapid a travel speed will not allow the
Upon completion of this lesson you should be able to bead to form. Too slow a travel speed will cause an
weld a flat corner joint without filler metal. excessively large puddle that will fall through, causing
a large hole.
Text Reference: Section II, Lesson 5 4 page 157. 5. Continue along the joint until you reach the end.
When you reach the end continue your weaving
motion and gradually lift the flame away from the
PROCEDURE surface until the puddle solidifies.
6. After the weld cools, clean it with your wire brush
1. Light the torch and adjust it to obtain a neutral flame. and examine it.
Be sure your safety glasses and goggles are in place.
2. Tack the two pieces together as shown in Figure 3-1. Observe, as you practice, that the tip to work distance
3. Lower the torch to the joint so the inner cone is about can be used as an aid to control the weld puddle. If the
1/16 in. above the surface of the joint. Move in a slight puddle becomes too large, increase the flame to puddle
circular motion until you establish a puddle. Observe distance to cool off the puddle. If you get too close the
the puddle and make sure you melt the growe faces sparks and spatter that come off of the weld puddle can
and the root of the joint. enter the tip and clog it, causing backfires or backflashes.
4. Continue using one of the weaving motions you have Also be sure to set the correct gas pressures. Excessive
learned. Make sure that the puddle forms behind pressure will cause a strong flame that will make weld
the flame to complete the weld. (See Figure 3-2.) puddle difficult to control.

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Copyright American Welding Society

FIGURE 4- 1
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NAME POSITION
Corner weld with filler Flat
ELECTRODE DIAMETER FLAME TYPE
Carbon steel '/Zu Neutral
MATERIAL
2 p. X 1 %" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Sinde Weave

Copyright American Welding Society

Procedure 4
Flat Outside-Corner Joint with Filler Metal

OBJECTIVE melt all areas of the joint, including the root. This will
determine your penetration. Be careful not to allow
Upon completion of this lesson you should be able to the torch to remain in one spot too long or you will
weld flat corner joints using filler metal. develop a puddle so large it will fall through. The
resulting hole is extremely difficult to repair. You must
watch the puddle carefully to make sure the surfaces
Text Reference: Section II, Lesson 5 4 page 158.
of the groove and the root are welded, otherwise you
will not achieve full penetration.
4. Progress along the joint adding filler metal as you
PROCEDURE learned earlier, make sure that you obtain complete
penetration and watch that your bead width and re-
1. Light the torch and adjust it to obtain a neutral flame. inforcement are uniform.
Be sure your safety glasses and goggles are in place. 5. Weld the complete joint, be careful to withdraw the
2. Tack the two pieces together as shown in Figure 4-1. flame slowly at the end of the joint so you do not
3. Lower the torch to the joint and establish a puddle. melt the end. While withdrawing the flame, add filler
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Carefully note when you establishthe puddle that you rod to the puddle to fill the crater.

Copyright American Welding Society

4 k- The root opening should be

equal to the thickness of the sheet

FIGURE 5-1

FIGURE 5-2

qAME POSITION
Flat butt with filler Flai

ELECTRODE DIAMETER FLAME TYPE

Carbon steel ?/un Neutral
WTERIAL
2 pcs. 3/dX 3" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

Copyright American Welding Society

Procedure 5
Flat Square=GrooveButt Joint with
Filler Metal

OBJECTIVES 2. Lower the torch to the joint and establish a puddle.

To ensure penetration use the keyhole technique.
Upon completion of this lesson you should be able to The keyhole technique involves allowing the puddle ,

weld flat butt joints. to penetrate through the joint until a keyhole (see
Figure 5-2) is established.
Text Reference: Section II, Lesson 5A; page 159. 3. Once you have established a keyhole begin adding
filler metal to the leading edge of the puddle, be
careful to control rate of travel along the joint and rate
PROCEDURE of filler metal addition to produce an even, consistent
bead.
1. Tack the two pieces together as shown in Figure 5-1.

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Copyright American Welding Society

OAW

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FIGURE 6-1

NAME POSITION
Open corner Horizontal
ELECTRODE DIAMETER FLAME TYPE
Carbon steel Neutral
I MATERIAL
2 DCS. 3/32'
W2"

X 1 i/2" X 6" carbon steel 1

PASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

Copyright American Welding Society

Procedure 6
Horizontal Outside4orner Joint

OBJECTIVE your travel speed to produce a bead of consistent

width with even ripples.
Upon completion of this lesson you should be able to 5. When you reach the end of the joint gradually lift
weld open corner joints in the horizontal position. the flame away from the surface until the puddle
solidifies.

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Text Reference: Section II, Lesson 5B; page 159. 6. Set up another horizontal corner weld as shown in
Figure 6-1. Begin the weld as in Step 2, but this time
add the filler metal to the puddle as you progress
PROCEDURE along the joint. Make sure you melt the filler metal
completely and mix it with the weld puddle thor-
1. Light the torch and adjust it to obtain a neutral flame. oughly before advancing the flame along the joint.
Be sure your safety glasses and goggles are in place. 7. Allow the plate to cool. Clean it, then examine it for
2. Tack the two pieces together and position as shown joint penetration and face appearance.
in Figure 6-1.
3. Lower the torch to the joint so the tip of the inner
core is about 1/16 in. above the surface of the joint. Safety Note: If you force cool your welds by im-
Move the flame in one of the weave patterns you mersing them in water be sure to wear your gloves and
have learned until you establish a puddle. stand off to the side to prevent steam burns to your hands
4. Continue the weld using the weave pattern. Regulate or face.

Copyright American Welding Society

FIGURE 7-2

NAME POSITION
Square groove butt Horizontal
ELECTRODE DIAMETER FLAME TYPE
Carbon steel '/d Neutral
-~
I MATERIAL ~ I
2 pcs. 3/51" X 3" X 6" carbon steel

Single String

Copyright American Welding Society

Procedure 7
Horizontal Square-Groove Butt Joint

OBJECTIVE 3. Position the torch so that the tip is pointing up at

about a 10-degree angle. (See Figure 7-2.) The flame
Upon completion of this lesson you should be able to angle will help to control the weld puddle to provide
weld square-groove butt welds in the horizontal position. even reinforcement and to prevent undercut at the
toe of the weld on the top side of the joint.
4. If the puddle becomes too large and begins to sag,
Text Reference: Section II, Lesson 5B; page 160. you can do two things.
a. You can add less filler metal and work the puddle
you have with the flame.
PROCEDURE b. You can move the flame farther away from the
plate. This will reduce the amount of heat put into
1. Tack the two pieces together as shown in Figure 7-1. the joint.
2. Position the plate so that the weld joint is in the 5. Complete the joint being careful to fill the crater as
horizontal 2G position. you complete the weld.
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

FIGURE 8- 1
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Heat will conduct away from the joint in the

bottom sheet, causing the top to heat more
quickly

Directing the flame toward the bottom

sheet will make the melting more even

FIGURE 8-2

NAME
Fillet weld
I POSITION
Horizontal
ELECTRODE DIAMETER FLAME TYPE
Carbon steel %ln Neutral
MATERIAL
2 pcs. 3/wnX 3" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single String

Copyright American Welding Society

Procedure 8

Horizontal Fillet Joint Position

OBJECTIVE 2. Lower the torch to the joint and establish a puddle.

As shown in Figure 8-2, you must angle the torch
Upon completion of this lesson you should be able to differently to obtain equal melting at the joint.
weld fillet welds in the horizontal position. 3. Add filler rod as you progress along the joint. Check
that both legs and the root are being fused, the bead
Text Reference: Section II, Lesson 56; page 160. width is even, and the face is flat or slightly convex.
Weld both sides.

PROCEDURE
1. Tack the two pieces together as shown in Figure 8-1.
Tack both sides.
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

in. tacks,
w e n d s and middle

--161 in.

FIGURE 9-1

\
FIGURE 9-2

NAME POSITION
Open corner Vertical up
ELECTRODE DIAMETER FLAME TYPE
Carbon steel %ln Neutral
~

MATERIAL
2 pa. 3/32" X 1 %" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

Copyright American Welding Society

Procedure 9
Vertical Outsidel Corner Joint, Uphill W e l d

OBJECTIVE 3. Move the tip to the joint and position the torch as
shown in Figure 9-2.
Upon completion of this lesson you should be able to 4. Establish a puddle, observing that the side walls are
weld an open-corner joint vertically up. molten to the root of the joint.
5. When a puddle is established, add the filler wire to
the leading edge of the puddle. (See Figure 9-2.) Add
Text Reference: Section il, Lesson 5C; page 161.
the wire as needed. Do not use a continuous feed.
6. Use a side-to-side weave and progress vertically up,
taking care to keep the bead width uniform and the
PROCEDURE contour even.
7. Progress to the top of the joint, then gradually pull
1. Light the torch and adjust it to obtain a neutral flame. away the torch, adding filler wire to build up the
Be sure your safety glasses and goggles are in place. crater.
2. Tack the two pieces together and position as shown 8. When the plate has cooled clean it, examine it for
in Figure 9-1. joint penetration and face appearance.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
FIGURE 10-1

FIGURE 10-2

VAME POSITION
Open cornet Vertical down
ELECTRODE DIAMETER FLAME TYPE
Carbon steel %zu Neutral
MATERIAL
2 pa. %zu X 1 %" X 6" carbon steel
?ASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

Copyright American Welding Society

Procedure 10
Vertieal OutsidemCorner Joint,
Downhill W e l d

OBJECTIVE speed that is too fast will result in only partial melting of
the joint. if this occurs, the metal will not flow behind
Upon completion of this lesson you should be able the flame to form a completed weld.
to weld an open corner joint in thevertical down position.
5. Use a side-to-side motion to help the weld form.
Text Reference: Section il, Lesson 5C; page 162. If you need more control over the weld puddle,
increase the torch angle in order to use the flame
to help support the puddle.
PROCEDURE 6. Complete the downhill progression using a weaving
motion until the joint i s complete.
1. Tack the two pieces together and position as shown 7. Tack two more pieces together as shown in Figure
in Figure 10-1. 10-1.
2. Move the tip to the joint and position the torch as 8. Establish a puddle as you did in Step 3, but this time
shown in Figure 10-1. as you begin the downhill progression begin adding
3. Establish a puddle, be careful to make sure the side filler metal as shown in Figure 10-2.
walls are melted completely to the root of the joint. 9. Complete the weld being careful to watch your filler
4. Begin moving downward at a rate of speed that will wire addition and travel speed to provide an even,
ensure a complete weld. consistent bead.
10. Upon completion of the welds clean them and ex-
Caution: A travel speed that is too slow will result in amine them for root penetration and face appear-
a large puddle that will drop out leaving a hole. A travel ance.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

> Tacks

*Root opening should be up to half

the thickness of the sheet used

FIGURE 11-1

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FIGURE 11-2

NAME POSITION
Square-groove butt Vertical up
ELECTRODE DIAMETER FLAME TYPE
Carbon steel HZ" Neutral
MATERIAL
2 pn. %2" X 3" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

Copyright American Welding Society

Procedure 11
Vertioal SquaremGroove Butt Joint

OBJECTIVE dle until you see the keyhole that 'indicates complete
penetration has been obtained.
Upon completion of this lesson you should be able to 3. When you achieve the desired penetration begin
weld square-groove butt joints in the vertical position. adding filler metal and progress upward. (See Fig-
ure 11-2.) Use one of the weaving motions you have
Text References Section II, Lesson 5C; page 162. learned to make sure the puddle fuses to both sides
of the joint.
4. Progress upward at an even rate of travel, while
adding filler metal to produce a bead of even width
PROCEDURE with good contour and appearance.
5. End the weld being sure to taper off at the end to fill
1. Tack two pieces together and position as shown in the crater and complete the joint.
Figure 11-1.
2. M i v e the torch to the bottom of the groove and es- Caution: Craters are often the source of cracks and
tablish a weld puddle. Continue to develop the Pud- blisters due to inadequate fill.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

sides
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

FIGURE 12-1

-Back plate ,

FIGURE 12-2

NAME POSITION
Fillet Vertical up
ELECTRODE DIAMETER FLAME TYPE
Carbon steel Jh" Neutral
MATERIAL
%1" X 3"X 6" carbon steel
l'~%P X 1 %"X 6"carbon steel
PASSES BEAD TIME (CEE INSTRUCTOR)
Single Weave

Copyright American Welding Society

Procedure 12
Vertical Fillet Joint

OBJECTIVE Note: Extreme care must be taken so that melting

occurs all the way into the root of the joint. The side
Upon completion of this lesson you should be able to walls will melt first, but do not begin adding filler metal
weld vertical fillet welds. until the root is molten.

Text Referenee. Section II, Lesson 5C; page 163. 3. Begin the vertical progression, adding filler metal as
shown in Figure 12-2, keeping the rate of travel and
PROCEDURE filler metal addition even so an even bead i s de-
posited.
1. Tack the assembly together and position it as shown 4. Apply a ‘/4 in. leg fillet on both sides of the joint as
in Figure 12-1. indicated by the welding symbol.
2. Position the torch as shown in Figure 12-2 and es- 5. When you have completed the welds, clean them and
tablish a puddle. examine them.
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

FIGURE 13-1

FIGURE 13-2

NAME POSITION
Comer weld Overhead
ELECTRODE DIAMETER FLAME TYPE
Carbon steel 3/d Neutral
MATERIAL
2 pcs. 3/32" X 1 %" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 1 3

Overhead OutsSdemCorner Joint

OBJECTIVE 2. Bring the torch to the joint and establish a puddle.

Look for the keyhole indicating complete melting.
Upon completion of this lesson you should be able to 3. Use the weave technique most comfortable for you
weld overhead outside-corner joints. and begin progressing along the joint evenly.
4. Fuse the entire joint looking for complete penetration
Text Reference: Section II, Lesson 50; page 164. and even bead width.
5. Tack two more pieces together as shown in Figure 13-1
and again establish a puddle.
PROCEDURE 6. When a puddle has been established begin adding
filler metal as shown in Figure 13-2.
1. Tack the two pieces together and position as shown 7. When you have completed the beads clean them and
in Figure 13-1. examine them.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

FIGURE 14-2

NAME POSITION
Sauare-Prroove weld Overhead
ELECTRODE DIAMETER FLAME TYPE
Carbon steel Y3Z1 Neutral
MATERIAL
2 pn. %Z" X 3" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 14
Overhead Square-Groove Butt Joint

OBJECTIVE 2. Bring the torch to the plate and establish a puddle;

be careful to obtain the keyhole. Position the torch
Upon completion of this lesson you should be able to as shown in Figure 14-2.
weld overhead square-groove butt joints. 3. Add filler metal as shown in Figure 14-2. Pay attention
to bead width and surface eontour.
Text Reference: Section II, Lesson 5D; page 164.
Note: The flame can be used to aid in controlling the
PROCEDURE puddle.

1. Tack the two pieces together and position as shown 4. Complete the joint and clean and examine it.
in Figure 14-1.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Tack both sides I

FIGURE 15-1

FIGURE 15-2

NAME POSITION
fillet weld Overhead
ELECTRODE DIAMETER FLAME TYPE
Carbon steel Neutral
MATERIAL
1 pc. v3Z" X 3" X 6" carbon steel
1 pc. %zu X 1 %" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 15
O v e r h e a d Fillet Joint

OBJECTIVE Note: By now you have observed that in T-joints, the

side walls become molten much quicker than the root.
Upon completion of this lesson you should be able to The natural tendency is to begin adding filler metal to
weld overhead fillets. avoid excessive side wall melting. Doing so usually re-
sults in incomplete root penetration, since the puddle will
Text Referenee: Section II, Lesson 5D; page 165. bridge across between the two members of the joint, and
not reach the root. Do not begin adding the filler metal
until the root of the joint has begun to melt.
PROCEDURE
3. Continue along the joint using the torch and filler
1. Tack the two pieces together and position as shown metal, positions shown in Figure 15-2. Use one of
in Figure 15-1. the weave-bead techniques you have learned in the
2. Bring the torch to the joint and establish a puddle; be earlier lessons.
careful to develop the molten puddle to the root of 4. Weld the other side of the joint. When you have
the joint. completed the welds, clean and examine them.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Provided by IHS under license with AWS Licensee=IHS Subs and Mgrs /IHSINTL003, User=GCN, serPemex
No reproduction or networking permitted without license from IHS Not for Resale, 09/13/2005 16:49:30 MDT
Oxyacetylene
Braze-W e l d i n g
Braze-welding may be defined as a process by which metals are joined using a filler
metal that melts above 840 degrees F. but below the melting point of the base metal.
Unlike brazing the’ filler metal is not drawn into the joint by capillary action. The
filler metal is deposited in layers. The filler metal wets the surface of the base metal,
but does not mix with it as in fusion welding. The surfaces to be joined must be
clean and a flux must be used. The flux is applied usually by one of two methods.
In the first method the end of the brazing rod is heated slightly in the flame, then
inserted into a container of dry granulated flux. Some of the flux will adhere to the
warmed filler rod, and will provide the necessary fluxing action for the braze-weld.
In the second method, the filler metal may be purchased with a flux coating. In this
case flux addition to the puddle is continuous.

GENERAL INSTRUCTIONS
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The following steps are necessary to complete the procedures in this section:

1. Grind the surface of the plate to remove mill scale. The surfaces to be joined by
braze-welding must be clean or a good bond will not be achieved.
2. Assemble the oxyacetylene welding outfit according to the manufacturer’s instruc-
tions or the instructions of your teacher.
3. Select the correct tip size from the manufacturer’s chart and adjust the regulators
to the correct working pressure.
4. Check all connections with a leak detection fluid or soapy water to ensure
tightness.
5. Clean the surface of the plate you are going to weld on with a wire brush to
remove mill scale and oxides, and then place it on the welding table.
6. Check the area around you and your welding table to make sure it is free of all
combustible materials.
7. Position yourself comfortably in front of your welding station. A standing position,
feet slightly apart, is best. This position allows maximum body movement to aid
in controlling the torch.

MATERIALS AND EQUIPMENT

For this section the material and equipment will be as follows:

1. Proper clothing
2. Safety glasses and welding goggles with a number 4 or 5 lens
3. Leather gloves
4. Oxyacetylene torch, tips, and regulators
5. Pliers or tongs
6. Spark lighter
7. Wire brush
a. Brazing rod with Y32 in. diameter (flux coated or with a can of flux)
35
Copyright American Welding Society
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No reproduction or networking permitted without license from IHS Not for Resale, 09/13/2005 16:49:30 MDT
38 OXYFUEL GAS WELDING AND BRAZING
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

FIGURE 16-1

NAME POSITION
Running beads Flat
ELECTRODE DIAMETER FLAME TYPE
Brazing rod %Zu Neutral or slightly oxidizing
MATERIAL
1 pc. %" X 6" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

Copyright American Welding Society

Procedure 1 6
Running Flat Beads

OBJECTIVE plate is at the proper temperature the metal will im-

mediately wet the surface of the plate.
Upon completion of this lesson you should be able to
braze-weld beads in the flat position. Note: The term “wet”or “wetting” can be defined as the
ability of the filler metal, using the proper flux, to coat the
Text Referenoe: Section II, Lesson 6A; page 167. surface you desire to join without causing that surface to
become molten.

PROCEDURE 6. Manipulatethe flame to work the filler metal so it wets

the surface and gains the desired buildup and bead
1. Light the torch and adjust it to obtain a reducing width. Heat control is important. Insufficient heat will

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
flame. Be sure your safety glasses and goggles are in not allow the braze metal to wet the surface or flow
place. In braze-welding you should avoid any chance properly. Excessive heat will cause the braze metal to
of contamination in the area you intend to join, since flow excessively and not allow it to build up. You can
this will make it very difficult for the braze metal to control the amount of the heat you apply by varying
weld the metal properly. For this reason it is best the distance between the torch and the plate.
to adjust the flame to obtain a neutral or slightly 7. Continue the bead to the end of the plate. Because
oxidizing flame. the plate will become very hot, it is a good idea to
2. Lower the torch so the inner cone is just above the quench the plate after every bead. This will also help
surface of the plate. remove the flux from the bead.
3. Use a circular motion to heat the plate to a dull red. 8. Clean the bead and examine it. Be sure to wear your
4. Bring the brazing rod to the surface and melt off a bit safety glasses when you remove the flux. Chip the
of the rod with the flame. (See Figure 16-1 .) flux and wire brush it thoroughly.
5. Use the flame to manipulate the braze metal. If the 9. Fill the plate with beads and examine them.

Copyright American Welding Society

FIGURE 17-1

I . ,...
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

FIGURE 17-2

UAME POSITION
V-groove butt Flat
!LECTRODE DIAMETER FLAME TYPE
Brazing rod %ln Neutral or slightly oxidizing
VIATERIAL
2 pcs. '14" X 3" X 6" carbon steel, with a 30-degree bevel on
one 6 in. side
'ASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

Copyright American Welding Society

Proeedure 1 7
Flat V-Groove Butt Joint
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OBJECTIVE proper temperature has been reached, begin adding

braze metal. Observe that the braze metal wets
Upon completion of this lesson you should be able to through to the root of the joint. When this occurs
braze-weld flat V-groove butt joints. begin the first pass being sure to wet all the joint sur-
faces.
4. Complete the first pass, be careful to obtain a concave
Text Reference: Section II, Lesson 6 4 page 167.
weld face.
5. Complete the joint, adding passes two and three as
shown in Figure 17-2.
PROCEDURE 6. Clean the plate thoroughly and examine it. If your
weld is done properly you will observe filler metal
1. Grind the surfaces to be joined. that has penetrated through the root of the joint and
2. Tack the assembly together as shown in Figure 17-1. has wet all the surfaces. The face of the weld should
3. Heat the metal to a dull cherry color. When the be smooth and have even ripples.

Copyright American Welding Society

FIGURE 18-1

NAME POSITION
T-fillet Horizontal
ELECTRODE DIAMETER FLAME TYPE
Brazhg rod %lm Neutral or slightly oxidizing
MATERIAL
1 pc. %I" X 3" X 6" carbon steel
1 pc. HI"X 1 YI"X 6" carbon steel
~ ~~~~ ~

PASSES BEAD TIME (SEE INSTRUCTOR)

Single Weave

Copyright American Welding Society

Procedure 18
Horizontal T-Joint

OBJECTIVE 2. Tack the two pieces together and position them as

shown in Figure 18-1.
Upon completion of this lesson you should be able to 3. Heat both sides of the joint to a dull cherry color and
braze-weld horizontal T-joints. add filler metal.
4. Use one of the weave motions you have learned to
Text Reference: Section II, Lesson 66; page 168. work the puddle to ensure it wets all the surfaces to
the root of the fillet. Remember to use the flame to
work distance to control the heat input.
PROCEDURE 5. Complete both sides of the joint, and clean and ex-
amine it.
1. Grind or sand the areas to be braze-welded.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

I
I
v
Concentrate flame on the
bottom plate
I

Tack both ends on both sides

FIGURE 19-1

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

NAME POSITION
Lap fillet Horizontal
ELECTRODE DIAMETER FLAME TYPE
Brazing rod %a" Neutral or slightly oxidizing
MATERIAL
2 pa. %a" X 3" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

Copyright American Welding Society

Procedure 19

Horizontal Lap Joint Fillet

OBJECTIVE 3. Heat the joint to a dull cherry color and add filler
metal. Remember to concentrate the flame on the
Upon completion of this lesson you should be able to lower plate to balance the heat in the joint.
braze-weld horizontal lap fillets. 4. Use one of the weaving motions to work the puddle
to ensure wetting on all areas of the joint.
Text Reference: Section II, Lesson 6B; page 168. 5. Concentrate on keeping the fillet small, with the leg
of the fillet not exceeding the thickness of the sheet.
This will not be easy, as the flux will spread out and
PROCEDURE clean an area considerably larger than the immediate
joint area. Use the flame to contain the filler metal to
1. Grind or sand the areas to be welded. the immediate joint area.
2. Tack the two pieces together and position as shown 6. Weld both sides of the joint and clean and examine
in Figure 19-1. it.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

FIGURE 20-1
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

NAME POSITION
V-groove butt Horizontal
ELECTRODE DIAMETER FLAME TYPE
Brazing rod 3/31" Neutral or slightly oxidizing
MATERIAL
2 pcs. %" X 3" X 6" carbon steel with a 30-degree bevel on
one 6-in. side
PASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

Copyright American Welding Society

Procedure 20
Horizontal VmGroove Butt Joint

OBJECTIVE toward the upper piece to direct the filler metal to

the upper surface.
Upon completion of this lesson you should be able to
braze-weld horizontal V-groove butt joints. Remember: The puddle will be very fluid and tend to
run down toward the lower piece. Push the metal toward
Text Reference: Section II, Lesson 6 6 page 169. the top piece and withdraw the torch to allow the metal to
cool and remain in place.

PROCEDURE 5. Do not attempt to complete the joint in one pass.'Put

several layers in, ending with a convex face surface
1. Grind or sand the areas to be welded. with a smooth surface and even ripples.
2. Tack the two pieces together and position as shown 6. Clean ,the plate and examine it. If you have properly
in Figure 20-1. spaced the root opening and paid attention to ensure
3. Heat the joint to a dull cherry color and add filler filler metal wetting of all the joint surfaces, you will
metal. see a line of braze metal protruding through the root
4. Use a weaving motion on the torch. Direct the flame and joining both root surfaces.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

filler wire

FIGURE 2 1- I

NAME POSITION
T-fillet Vertical
ELECTRODE DIAMETER FLAME TYPE
Brazing rod '/'P Neutral or slightly oxidizing
MATERIAL
1 pc. %1" X 3" X 6" carbon steel
1 pc. %P X 1 %" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

Copyright American Welding Society

Procedure 21
Vertical T-Joint Fillet

OBJECTIVE filler metal. Make sure the joint is wet with the filler
metal to the root.
Upon completion of this lesson you should be able to 4. Pull away the torch and allow the filler metal to freeze
braze-weld vertical T-joint fillets. and form a shelf on which you can continue to build
the vertical bead.
Text Reference: Section II, Lesson 6C; page 170.

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5. Observe that torch manipulation is very important in
the vertical position. The puddle i s very fluid and can
easily become uncontrollable due to excessive heat.
PROCEDURE The torch flame has enough stiffness to move the
puddle. Proper manipulation of the torch will turn
1. Grind or sand the areas to be braze-welded. this into an advantage. (See Figure 21 - 1 .)
2. Tack the two pieces together and position as shown 6. Complete the fillet on both sides. (it will be necessary
in Figure 21 -1. to cool the joint between sides.) Clean the welds and
3. Heat both sides of the bottom of the joint and add examine them.

Copyright American Welding Society

1 .
ricin.
4b- 4
T0

i
r Joint preparation

Tack both ends

Torch angle and
filler wire

FIGURE 22- 1

I 3
FIGURE 22-2

NAME POSITION
V-b- Vertical
ELECTRODE DIAMETER FLAME TYPE
Brazing rod 3/32. Oxidizing
MATERIAL
2 pcs. %“ X 3” X 6”carbon steel with a 30-degree bevel on
one Lin. side
-~ ~~ ~~

PASSES BEAD TIME (SEE INSTRUCTOR)

Single Weave

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 22
Vertical V-Groove Butt Joint

OBJECTIVE have been wet by the filler metal. This includes the
groove faces and root.
Upon completion of this lesson you should be able to 4. Manipulate the torch to control the amount of heat
braze-weld vertical V-groove butt joints. put into the plate. One of the weaves you have
learned will help to ensure the puddle covers the
Text Reference: Section II, Lesson 6C; page 170. joint. Withdrawing the torch will help to keep the
plate cool. If the plate becomes too hot the braze metal
puddle will becometoo fluid and will fall from the joint.
Use the shelf technique you have learned in the earlier
PROCEDURE lessons of this chapter.
5. Weld the joint in the two passes. (See Figure 22-2.)
1. Grind or sand the areas to be braze-welded. Pay particular attention to the side walls, or groove
2. Tack the two pieces together and position as shown faces of the joint. If you keep the puddle too cool, or
in Figure 22-1. allow the weld face to become too convex, you may
3. Heat the joint until it is a dull cherry color and begin trap slag in these areas.
adding filler metal. Observe that all areas of the joint 6. After completing the joint, clean and examine it.
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Oxyacetylene Welding
of Pipe
Pipe welders need special skills to weld pipe successfully. As a pipe welder you
will need to change position continually to maintain the correct angle as you weld
around a joint. This requires great flexibility. Good vision is needed to focus on the
weld three dimensionally. Sometimes access to a particular pipe i s limited and you
may have to work with the aid of a mirror.
The procedures in this section will introduce you to techniques that will help you
become a successful pipe welder.

GENERAL INSTRUCTIONS
1. Find a working stance that i s both comfortable and secure; you will need both
hands free to weld pipe.
2. Position yourself so that you have access to the joint and can move the torch and
filler metal freely as you make the weld.
3. Maintain a relatively low-heat flame so that you can control the puddle.

MATERIALS AND EQUIPMENT

For this section the material and equipment will be as follows:

1.Welding goggles, number 5 or 6 lens

2.Safety glasses
3.Grinding goggles
4.Soapstone
5.Wraparound
6.Hand grinder or sander
7. Chipping hammer
8. Ballpeen hammer
9. Half-round bastard file, 10 in.
10. Wire brush

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Copyright American Welding Society

90'

1G position

FIGURE 23- 1

FIGURE 23-2

Single pass

Multiple passes

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FIGURE 23-3

NAME POSITION
V-butt Flat
ELECTRODE DIAMETER FLAME TYPE
Carbon steel W1" Neutral
MATERIAL
2 pa. pipe approximately 3 in. diameter X 3 in. long
PASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

Copyright American Welding Society

Procedure 23
16 Position, Axis of the Pipe Horizontal

OBJECTIVE puddle will again want to run downhill. To control the

contour and width of the bead, you may try one or a
Upon completion of this lesson you should be able to combination of the following techniques.
weld pipe in the flat 1G position. a. Alter the flame to pipe distance.
b. Change the torch angle and use the flame to
Text Reference: Section II, Lesson 7 4 page 172. control the puddle.
5. When you reach the 11 o?clockpositiontaper off your
weld. Do this by moving the inner cone away from the
crater and allowing it to solidify. Be carefulto keepthe
PROCEDURE crater in the flame?ssecondary envelope to prevent it
from oxidation while it is cooling down.
1. Tack the assembly together and position the pipe flat 6. Rotate the pipe to move the 11 o?clock position to a
with the axis of the pipe horizontal. (See Figure new position at 2 o?clock.
23-1.) Support the pipe so you can turn it for welding. 7. Bring the flame to a point ahead of the crater and
You may support it by a piece of angle, or internally on reestablisha keyhole while melting the crater. When
a rod. this is done begin welding toward the 11 o?clock
2. Weld the pipe from the 2 o?clockto the 11 o?clock pos¡tion.
position. (See Figure 23-2.) Establish a puddle before 8. Repeat Steps 1 through 8 until the pipe is welded.
adding filler metal. Look for the keyhole, which will 9. Dependingon the diameter and wall thickness of the
indicate root penetration. pipe, it may be necessary to use a multiple pass
3. When a keyhole has been established, begin adding technique. See Figure 23-3 for examples of multiple
filler metal. Use one of the weave techniques you pass methods.
have learned. 1O. When you are finished clean the pipe and examine it.
4. As you weld from 2 to 1 1 o?clock,you will notice that You should see evidence of root penetrationand root
the bead will change in relation to its location on the reinforcementaround the entire insidecircumference
pipe. At 2 o?clock the puddle will want to run of the pipe. The outside surface or face of the weld
downhill, at 12 o?clock the root will want to sag should have an even reinforcement,a constant width,
toward the inside of the pipe, and at 11 o?clock the and a surface with fine ripples.

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Copyright American Welding Society

i
2G position

FIGURE 24-1

-
Single pass

Multiple passes

FIGURE 24-2

NAME POSITION
V-butt Horizontal
ELECTRODE DIAMETER FLAME TYPE
Carbon steel 3/32" Neutral
MATERIAL
2 pcs. pipe approximately 3 in. diameter X 3 in. long
PASSES BEAD TIME (SEE INSTRUCTOR)
Single Weave

Copyright American Welding Society

Procedure 24
26 Position, Axis o f the Pipe Vertical

OBJECTIVE ensure proper root penetration. Add filler wire and

begin the weld. Observe that as with the horizontal
Upon completion of this lesson you should be able to plate, groove weld, the puddle will want to sag. Build
weld pipe in the vertically fixed (2G) position. the weld from the bottom up, using the bottom as a
shelf to support the rest of the weld.
Text Reference: Section II, Lesson 7A; page 173. 3. During welding, you may rotate the pipe about its axis
but you may not turn it end for end. Use the same
technique you learned in the last lesson to start and
PROCEDURE stop your weld.
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4. Depending on the wall thickness of the pipe you may

1. Tack two pieces of pipe approximately 3 in. diameter use single or multiple pass techniques. (See Figure
by 3 in. long, together and position as shown i n Figure 24-2.)
24-1. 5. When you have completed the weld, clean the pipe
2. Begin the puddle using the keyhole technique to and examine it.

Copyright American Welding Society

FIGURE 25- 1

Second

FIGURE 25-2

NAME POSITION
V-butt Horizontal-fixed
ELECTRODE DIAMETER FLAME TYPE
Carbon steel %ln Neutral
MATERIAL
2 pa. pipe approximately 3 in. diameter X 3 in. long ~

PASSES BEAD TIME (SEE INSTRUCTOR)

Single Weave

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Copyright American Welding Society

Procedure 25
5G Position, Axis of the Pipe Horizontal

OBJECTIVE 12 o’clock position. (See Figure 25-2.) Begin the first

weld at about the 7 o’clock position and begin weld-
Upon completion of this lesson you should be able to ing vertical up around the pipe. Use the keyhole tech-
weld pipe in the horizontal fixed (5C) position. nique before adding filler metal.
3. Observe that the weid puddle will act differently in
relation to its position on the pipe. Use one or a
Text References Section II, Lesson 7A; page 174.
combination of the techniques you learned previously
to control the puddle.
4. When stopping and restartingthe welds be sure to use
PROCEDURE the methods you learned earlier. It will be necessary
to stop and start frequently to reposition yourself and
1. Tack two pieces of the pipe approximately 3 in. di- the torch.
ameter by 3 in. long, together and position as shown 5. Depending on the thickness of the pipe it may be
in Figure 25-1. necessary to use a multiple pass technique.
2. To ensure a good weld in the 5C position the weld 6. When you have finished the weld, clean and exam-
must be over lapped by going beyond the 6 and ine it.
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

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Shielded Megal Arc
W e l d i n g of Plate
Shielded metal arc welding is a welding process widely used in industries involving
manufacturing with metals. The skills you develop in shielded metal arc welding will
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serve as a foundation upon which you can build a mastery of more complex welding
procedures.
Shield metal arc welding, or stick welding, involves the use of electrodes. Electrodes
are manufactured to weld a wide range of metals. The Procedures in this section will
guide you through the steps in welding carbon steel using various electrodes in all
of the common welding positions. A number of electrodes are specified so that you
become familiar with their characteristics and gain experience in handling them.

GENERAL INSTRUCTIONS
Throughout the procedures in this section you may use either an AC or DC welder,
depending on their availability. When a DC welder is used, the polarity will be
indicated on the procedure sheet.
The lessons have been written for the right-handed student. However, left-handed
students should not have any trouble. They should start at the opposite end of a plate
and reverse the right-hand electrode drag and push angles.
All welders should learn to weld both from right to left and left to right. In addition,
they should also learn to weld toward and away from themselves. Proficient welders
can weld in any direction.

MATERIALS AND EQUIPMENT

For this section the material and equipment will be as follows:

1. Welding shield
2. Safety glasses
3. Protective leathers and gloves
4. Chipping hammer and wire brush

61
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FIGURE 26-I

FIGURE 26-2

Start motion
Establish the arc

FIGURE 28-3

NAME POSITION
Striking an arc Flat
ELECTRODE DIAMETER AMPERAGE
E-601O %t" 110-170 DCEP
or
E-6011 %ZW 110-170ACor DC
MATERIAL
1 pc. %" X 4" X 8"carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
None None

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Copyright American Welding Society

Procedure 26
Striking and Maintaining an Arc

OBJECTIVE 5. Lower your shield, then bring the electrode down and
to the right using a swinging motion, like striking a
Upon completion of this lesson you should be able to match. (See Figure 26-3.)
strike and maintain an arc. 6. When the electrode contacts the plate, it will strike
an arc. When this happens, raise the electrode slightly
Text Reference: Section Ili, Lesson 5A; page 219. to about %6 in. (See Figure 26-3).
i. immediately lower the electrode to reduce the arc
gap. The distance between the tip of the electrode and
the workpiece should be approximately the thickness
PROCEDURE of the electrode core wire, Xz in. (See Figure 26-3).
8. Do not lift your shield, but break the arc by snapping
1. Wire brush the welding surface of the plate. The axis the electrode up to the left. The power supply cannot
of the weld will be as shown in Figure 26-1. provide the correct arc current to a long arc. As
2. Secure the workpiece clamp and adjust the welding you increase the arc length the current i s decreased.
current. DC current only can be used with E-6010 There will be some arc length that causes the arc to
electrode. Either AC or DC can be used with E-601 1 extinguish suddenly. When this happens, restart the

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electrode. This statement holds true throughout the arc exactly as you did the first time. Continue to strike,
book. and strike the arc until the electrode burns down to
3. Place the electrode in the holder at a 90-degree angle. approximately 2 in.
(See Figure 26-2.) 9. The electrode melts with each start. It gets shorter
4. Hold the electrode at approximately a 30-degree and you must constantly feed the electrode toward
angle off the perpendicular about 1 in. above the the puddle. If you do not lower the electrode, the arc
left-hand edge of the plate. gap will increase, and the arc will go out.

Copyright American Welding Society

FIGURE 27-1 FIGURE 27-2

Direction of travei
1

f -'to-- Bead width

FIGURE 27-3

AME POSITION
- strinner
Weldinn . , beads Flat
.ECTRODE DIAMETER A M PERAGE
E-601O '/e" 75-1 1O DCEP
or
E-6011 '/a" 75-11O AC or OC
'ATERIAL
1 pc. Ve" X 4" X 8" carbon steel
4SSES BEAD TIME (SEE INSTRUCTOR)
None None

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Copyright American Welding Society

Procedure 27
W e l d i n g Stringer Beads

OBJECTIVE 8. Strike the arc on the left side of the plate. Tilt the
electrode holder slightly to the right. The electrode
Upon completion of this lesson you should be able to should point at about a 1 O to 15 degreeanglefrom the
weld flat stringer beads. vertical into the puddle. This is commonly called the
lead or drag angle. (See Figure 27-3.)
Text Reference: Section 111, Lesson 5 4 page 220. 9. Maintain an arc length of about Ye in. and keep the
width of the puddle to 2 to 2Y2 times the diameter of
the core wire and approximately 3/32 in. in height to 5/16
PROCEDURE in. wide. (See Figure 27-4.)
10. Run the stringer bead for about 3 in.
1. Wire brush the welding surface of the plate.
2. The plate must be welded with the axis as shown in Note: Examine the stringer for evenness of the ripples,
Figure 27-1. width, and height. Chip the slag away and wire brush
3. Attach the workpiece clamp and adjust the power thoroughly before continuing.
supply as directed.
4. Use a clamp to hold your workpiece in place.
5. Make sure the workpiece cable is securely attached. 11. Strike another arc about 3% in. to the right of the weld
6. Place the electrode in the holder ata 90-degree angle. puddle crater at the end of the stringer.Then move the
(See Figure 27-2.) arc directly over the crater. it should be a slightly long
7. Assume a comfortable position, with your left elbow arc. Hold it in position for a moment. Then close the
resting on the table. Place your right hand, the one arc gap to normal and proceed as before.
with the electrode holder, in the palm of your left 12. Continue in the same manner, but start the next
hand. Do not grip the holder tightly. If you do, you will stringer Y2 in. below the first. Completely cover the
tire quickly and your hand will become unsteady. plate.

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Copyright American Welding Society

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
FIGURE 28-1 FIGURE 28-2

Electrode drag
10-5"

FIGURE 28-3
b FIGURE 28-4

FIGURE 28-5

VAME POSITION
Welding a pad of stringer beads ~ ~~ ~~
Flat
ELECTRODE DIAMETER AMPERAGE
E-601O '/a" 75-110 DCEP
or
E-6011 '/a" 75-11O AC or DC
MATERIAL
1 DC. H"X 4" X 10" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Stringer

Copyright American Welding Society

Procedure 28
Running a Flat Pad of Stringers

OBJECTIVE Note: Do not attempt to use the "C" motion until the
instructor demonstrates it.
Upon completion of this lesson you should be able to
run a flat pad of stringers.
8. Clean the stringer thoroughly using the chipping
hammer and the wire brush.
Text Reference: Section 111, Lesson 5 4 page 223. 9. The next bead should overlap about one-third to
one-half of the first bead. Use a drag angle of 10
PROCEDURE to 15 degrees.
10. Use the angles mentioned above for this bead and
1. Wire brush the welding surface of the plate. all the remaining beads in this assignment. Strike the
2. The plate must be welded with the axis as shown in arc at the left side of the plate. Hold the electrode
Figure 28-1. so that the edge of the coating that is farthest from
3. Secure the workpiece and the workpiece clamp. you is pointed at the nearest edge of the first bead.
4. Adjust the welding current. (See Figure 28-5.)
5. Make sure that the electrode is held firm in the 11. In Figure 28-5, notice the angle of the electrode with
electrode holder, at a 90-degree angle. relation to first bead and the surface of the plate.
6. Start at the left side of the plate, about Yi in. from 12. Strike and hold a long arc. Then proceed along the
the top edge. (See Figure 28-2.) Use about a 10 to closest edge of the first bead. Make sure that you
15 degree drag angle. (See Figure 28-3.) limit the motion of the electrode. The stringer should
i. Strike and hold a slightly long arc until a puddle not be wider than 2 to 22'9 times the diameter of the
begins to form. Then shorten the arc length and core wire.
move steadily to the right. Use a "C" motion. (See 13. The second stringer must cover about one-third to
Figure 28-4.) With a "C" motion the bottom swing one-half of the first one, as shown in Figure 28-2.
of the electrode moves further to the right than the 14. Continue to weld stringer beads in this manner.
top portion. Pause slightly at the top of the "C."Then Cover the entire plate. Then cool the plate and ex-
move down, out and back somewhat faster. amine it.

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Copyright American Welding Society

&
FIGURE 29-1 FIGURE 29-2

1st bead
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Whipping motion

"C" motion

FIGURE 29-3 FIGURE 29-4

~~ ~ ~

NAME POSITION
T-fillet Flat
ELECTRODE DIAMETER AMPERAGE
E-601O 'hm 75-110 DCEP
or
E-6011 '/en 75-110AC or DC
~~ ~~~~ ~ ~

MATERIAL
1 pc. 3/e" X 4"X 12"carbon steel
2 pn. VawX 1 3/4" X 12"carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Stringer

Copyright American Welding Society

Procedure 29

T=Joint Fillet, 1F Position, Stringer Beads

(E-6010or E-6011 Electrodes)

OBJECTIVE plate. Then inspect it for undercut and unevenness

of height or width. Undercut may be caused by too
Upon completion of this lesson you should be able to long an arc, too high a current, wrong electrode
weld flat fillets. angle or manipulation, or too fast a rate of travel.
7. Overlap a second stringer bead on the first one. Run
Text Reference: Section III, Lesson SA, page 224. half on the first bead and half on the side of the
workpiece farthest from you. Use a 1O to 15 degree
angle and a 15 to 20 degree work angle. This will
PROCEDURE cause the metal to flow up the side of the workpiece.
One-half of the bead should be on the plate and the
1. Remove all slag, rust, or mill scale from the weld other half covering about one-half of the first bead.
surface of the plates. (See Figure 29-4.) Using this angle you will find that
2. Tack the three plates as shown in Figure 29-1. Be the molten metal flows or washes up the side of the
sure that there is little or no space between surfaces. plate that the electrode i s pointed toward.
Make sure that the plates are perpendicular to each 8. Clean the weld thoroughly. Run another stringer with
other. the electrode pointed toward you, at about a 15
3. Position the practice piece as shown in Figure 29-2. to 20 degree angle. This bead should cover about
4. Be sure that the workpiece and the work lead are one-half of the last stringer and flow up the side
secure. of the plate. The complete weld should be flat or
5. With the electrode perpendicular to the joint run a slightly convex and have legs of equal size.
stringer from left to right. Maintain an electrode drag 9. Repeat the task, this time use the joint opposite the

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
angle of 10 to 15 degrees. Use either a whipping one you just welded.
motion or the "C" motion as in Figure 29-3. 1O. Complete two of the joints and save two for the next
6. Chip and wire brush the bead thoroughly. Cool the lesson.

Copyright American Welding Society

Whipping motion

"C" motion

FIGURE 30-1 FIGURE 30-2

Hold a long arc

Lower the

Start by tapping
against the plate
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Direction of travel
------I
FIGURE 30-3 FIGURE 30-4

FIGURE 30-6

\IAME POSITION
T-fillet Flat
.LEORODE DIAMETER AMPERAGE
E-7014 '/a" 110-160 AC or DCEP
or %ln 150-21 O
E-7024 '/B. 110-160 AC or DC
%ln 150-21 O
AATERIAL
Use the two joints lefi over from Procedure 29
'ASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Stringer

Copyright American Welding Society

Procedure 30
T-Joint Fillet, 1F Position, Stringer Beads
( E 4 0 1 4 or E l 1 0 2 4 Electrodes)

OBJECTIVE 10. Drag the first pass along the root of the joint. Keep
the electrode perpendicular to the workpiece. Use
Upon completion of this lesson you should be able to a drag angle of approximately 30 degrees. Strike the
weld a pad of stringer beads in the 1F position. arc by tapping the tip of the electrode in the groove
of the workpiece to break the coating off the tip. (See
Text Reference: Section 111, Lesson 5A; page 225. Figure 30-3.)
11. When the arc starts, hold a long arc for a moment.
Then shorten the arc length until the coating on the
PROCEDURE right-hand side of the electrode touches the metal,
at a 30-degree lead angle. (See Figure 30-4.) Weld
1. Wire brush the surfaces to be welded. at a travel speed that gives the proper bead width for
2. Position the practice piece as shown in Figure 30-1. the electrode diameter used.
3. Make sure the workpiece clamp and the workpiece 12. Be sure you maintain the correct drag angle. If you
are secure. reduce the drag angle too much, the electrode can
4. Adjust the welding current. stub out.
5. Weld the first joint with E-7014 electrodes. Use a 13. Continue, as with the E-7014 electrode, using the
drag angle of 1O to 15 degrees, as you did with the same side angles.
E-6010 and E-6011 electrodes. But you do not need 14. After you have welded the first three stringers, cover
to use the "C" motion (see Figure 30-2); just move the over the weld with a weave bead. Increase the arc
electrode along the joint without any movement other current setting and with the same electrode angles
than forward travel. strike the arc on the left. Then move to the right,
6. After each pass chip and wire brush thoroughly. weaving the electrode from side to side. (See Fig-
Although slag from the E-7014 electrode comes off ure 30-2.) Pause slightly at the sides to minimize
easily, it often sticks to tiny crevices, especially in the undercut.
corners or toes of the weld. 15. Part of the next weave bead should cover slightly
7. Pay close attention to the edges or toes of the weld. more than half of the previous bead, while the rest
Make sure you are not leaving any undercut. If you of the bead washes up the side of the joint. (See
are, slow down. Use a lower rate of travel. Make sure Figure 30-5.)
you are not holding too long an arc. 16. Part of the next weave bead should cover about
8. Place the second joint in the same position as the one-third of the previous bead, while the rest of the
first. Use the E-7024 electrodes. bead washes up the opposite side of the joint. (See
9. The E-7024 electrode is a heavily coated iron pow- Figure 30-5.) Continue to run beads in this manner.
der electrode. Because of this, it can be dragged Make sure they are laced together, the same as you --`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

along the joint with the coating touching the metal did with stringer beads.
being welded. This prevents it from stubbing out.

Copyright American Welding Society

I *
Direction of travel

FIGURE 31 1 - FIGURE 31-2

-
Change electrode angle
and reverse direction

Direction of travel

FIGURE 31-3 FIGURE 3 1-4

\IAME POSITION
Filling craters Flat
iLECTRODE DIAMETER AMPERAGE
E-6010 Va" 75-125 DCEP
or
E-601 1 '/a" 75-125 AC or DC
V\ATERIAL
1 pc. %" X 4" X 12" carbon steel
'ASSES BEAD TIME (SEE INSTRUCTOR)
MUkiDle Stringer

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Copyright American Welding Society

Procedure 3 1
Filling C r a t e r s at the End of W e l d s

OBJECTIVE 7. Hold a normal arc on the crater until it is filled to thé

same height as the bead. Then continue the stringer.

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Upon completion of this lesson you should be able to Stop every few inches and repeat the process on
fill craters properly. the new crater. This will give you practice with this
method.
8. When you reach the end of the plate, reverse the
Text Reference: Section III, Lesson 5A; page 226. direction of travel. Raise the electrode slowly to keep
the same arc length as you weld up and over the
finished bead. Weld back over the bead for 2'9 in.
PROCEDURE Hold a close arc, then stop welding. Use a 10- to
15-degree push angle. (See Figure 31 -3.) If you burn
1. Wire brush the surface of the plate. á hole though the weld, or the weld metal spills over
2. Position the plate as shown in Figure 31-1. and runs off the end of the plate, you either moved
3. Secure the plate and attach the workpiece clamp. too slowly or carried too long an arc. Practice this
4. Adjust the welding current. method until you can do it well.
5. Start at the left. Run a short stringer, about 2 or 3 in. 9. Another method of crater filling is to break the arc
Stop. Then clean the weld. about 2 in. from the end of the plate. Clean the bead.
6. Strike another arc about 1 in. ahead of the crater. Then start at the right side of the plate and weld back
Then movethe arc on top of the crater. See Figure 3 1 -2. toward the crater with the electrode pointing into the
Whenever you strike an arc, it leaves a hard spot in the puddle at a drag angle of about 15 to 30 degrees. (See
metal. When you begin ahead of the crater, the hard Figure 31-4.) Weld over the crater of the bead and
spot is covered over by the bead and is eliminated. break the arc slowly or with a slight circular motion.

Copyright American Welding Society

Tacks

[---fT-;l-1
E-4 IC
16 tf
FIGURE 32-1 FIGURE 32-2

$7' 45'

FIGURE 32-3 FIGURE 32-4

NAME
Square-groove butt
1 POSITION Flat
ELECTRODE DIAMETER AMPERAGE
E-7024 1/31" 180-250 AC or DC
MATERIAL
1 pc. K" X 2" X 8" carbon steel
2 pcs. 3h" X 3" X 8" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Stringer

Copyright American Welding Society

Procedure 32
Square-Groove Butt Joint, 1G Position with
Backup Bar, Stringer Beads

OBJECTIVE i . Place the electrode in the holder at a 45-degree

angle. (See Figure 32-3.)
Upon completion of this lesson you should be able to 8. Fill the two fillets with three stringer beads. (See
weld square-groove butt joints with a backup bar in the Figure 32-4.)
flat position. 9. Hold the electrode at approximately 30 to 45 de-
grees from the surface of the plate with a drag angle
Text Reference: Section 111, Lesson 5A; page 227. of about 30 degrees. Drag it along the bottom leg of
the joint. The electrode coating should touch both
the backup bar and the vertical leg. (See Figure 32-4.)
PROCEDURE 1O. Move along steadily. Make sure the bead covers both
legs of the joint equally.
1. Clean all slag, rust, mill scale, and other dirt from the 11. Clean and run the second bead with the electrode.
parts to be welded. Hold the electrode about 15 degrees off the perpen-
2. Tack weld the pieces as shown in 32-1. It is impor- dicular as in Figure 32-4.
tant that you have as good a fit as possible. Be sure 12. Remove the slag from the weld deposit. Run the third
that there are no spaces between the parts. bead with the same electrode angle used with the
3. Position the test piece as shown in Figure 32-2. first bead. (See Figure 32-4.) Pay close attention to
4. Make sure the work clamp and the test piece are the top, or leading edge of the upper plate. Watch
securely fastened. the top edge. of the puddle. Make sure that you do
5. Adjust the welding current. not cut down the top edge. The fillet is not complete
6. Make sure your tack welds are at least % in. long if you do not cover the entire vertical leg.
and are placed according to Figure 32-1. If the tacks 13. Weld the other fillet in the same manner.
are not strong enough or in the proper places, the 14. Fill in the remainder of the joint with either the
plates may distort and make the test more difficult stringer bead or the weave method. (See Figure
to pass. 32-5.)

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Weld axis /
Keyhole

FIGURE 33-1 FIGURE 33-2

FIGURE 33-3 FIGURE 33-4

I NAME Outside corner

1 POSITION
Flat
ELECTRODE DIAMETER AMPERAGE
E-601O '/a" 75-125 DCEP
or
E-6011 '/aU 75-1 25 AC or DC
MATERIAL
2 pcs. K uX 2" X 12" carbon steel
2 spacers, X 3/4" X 5" long
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Stringer and weave

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 33
Outside-Corner Jolnt, 1G Position, Stringer
and W e a v e Beads

OBJECTIVE the left side of the joint. When you reach the end
of the tack, pause until a keyhole appears. (See
Upon completion of this lesson you should be able to Figure 33-2.)
weld open root outside-corner joints in the flat position 7. When the keyhole appears, whip the electrode fore-
using stringer and weave beads. ward and slightly up one side of the joint. (See Fig-
ure 33-3.1 This motion of whipping out and away
from the puddle allows the molten metal to cool and
Text Reference: Section 111, Lesson 5 4 page 228.
freeze. Otherwise it would fall through the root and
cause excessive melt through.
8. As the filler metal solidifies, return the electrode
PROCEDURE to the foreward edge of the keyhole. Hold it there
until it fills the keyhole and another keyhole opens.
1. Clean all the parts to be welded. Continue whipping the arc across the entire joint,
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

2. Use the spacers to position the pieces. Then tack adding a dab of metal each time.
weld the two pieces together to form a 90-degree 9. The second pass should be a stringer bead. Make
angle as in Figure 33-1. Be sure the space along the sure you fuse both sides of the joint at the toes into
entire joint is even. the edges of the weld. (See Figure 33-4.)
3. Remove the spacers and place the weldment in po- 10. The third pass is a weave bead. Pause slightly at the
sition. (See Figure 33-1.) sides for proper fusion. (See Figure 33-3.)
4. Make sure the workpiece clamp and workpiece are 11. The final pass is also a weave bead. Use the motion
securely fastened. Adjust the welding current. shown in Figure 33-3.
5. The tacks must be at least 1 in. long or the root 12. Watch out for excessive overlap. Avoid extra weld
opening may close up as you weld the first pass. metal hanging over the edge of the joint.
6. Hold the electrode perpendicular and use a drag 13. The completed weld should have a slightly convex
angle of 10 to 15 degrees. Weld over the tack at (outwardly curved) appearance.

Copyright American Welding Society

line

FIGURE 34-1 FIGURE 34-2

?!
5"-15"

- top view
FIGURE 34-3 - 15"

FIGURE 34-4

Whipping
Whipping motion.

C motion
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

NAME POSITION
Pad of stringers Horizontal
I ELECTRODE
E-601O
DIAMETER
'/a" I AMPERAGE 75-125 DCEP
or
E-6011 '/a0 75-125 AC or OC
MATERIAL
1 pc. 3/an X 6"X 6"carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

Copyright American Welding Society

Procedure 34
Running a Horizontal Pad of Stringers

OBJECTIVE 4. Adjust the welding current.

5. Place the electrode in the holder. Clamp it at a 45-

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
Upon completion of this lesson you should be able to degree angle as shown in Figure 34-3.
weld a pad of stringers in the horizontal position. 6 . Start at the left side of the plate. Hold the electrode
'
pointing upward at about a 5- to 15-degree angle.
Text Reference: Section 111, Lesson 58; page 230. Use a 1O- to 15-degree drag angle as shown in Figure
34-4.
7. Move to the right with a slight whipping motion. You
PROCEDURE can also use the "C" motion. Each of these motions
gives the molten puddle a chance to cool slightly.
1. Be sure the edges of the plate are clean,.then wire This helps it solidify and keeps it from sagging. When
brush the surface of the plate.
using the "C" motion, do not forget to pause at the
2. Draw a line across the plate with the soapstone. Place
upper left part of the "C." (See Figure 34-5.)
the line Y2 in. from the bottom edge of the plate as
8. The second stringer, and all that follow, should cover
in Figure 34-1.
the top third of the bead below it. This keeps the weld
3. Position the plate as in Figure 34-2 with the line at
surface even in height, without valleys or low spots.
the bottom.

Copyright American Welding Society

+/<SMAW

FIGURE 35-1

30-45"

Work angle
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

FIGURE 35-2 FIGURE 35-3

NAME POSITION
Fillet Horizontal
ELECTRODE DIAMETER AMPERAGE
E-601O '/a" 75-125 DCEP
or
E-6011 '/a" 75-125 AC or DC
MATERIAL
1 pc. Van X 4" X 12" carbon steel
2 pcs. VE? X 1 %" X 12" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

Copyright American Welding Society

Procedure 35
TmJoint Fillet, 2F Position, Multipass
Stringers (El6010or E-6011 Electrodes)

OBJECTIVE 6. Hold the electrode at about a 30- to 4.5-degree angle

off the bottom plate as in Figure 35-2. Use a 5- to
Upon completion of this lesson you should be able to 15-degree drag angle for the first pass. Fill the crater
weld horizontal fillets. at the end of the bead.
7. Hold the same electrode angles with the second
Text Reference: Section tit, Lesson 58, page 230. bead. Point the tip of the electrode so it is partially
on the plate and partially on the first bead as shown
in Figure 35-2. Slightly more than half of the filler
PROCEDURE metal should be on the stringer bead.
8. For the third stringer lower the electrode angle to
1. Remove all slag and other impurities from the plates. between 10 and 20 degrees, as in Figure 35-2. Use
Clean the area to be welded. a whip or "C" motion. Undercut can be reduced if
2. Tack the plates to form a cross as shown in Fig- you whip properly or pause at the upper left side of
ure 35-1. Do not hold the metal in place with your the puddle when using the "C" motion.
gloves. Use some scrap metal or a clamp to position 9. Clean and inspect the last bead for undercut. Weld
the plates. three more stringers over the first three passes to
3. Position the weldment as in Figure 35-1. complete the joint. See the bead sequence in Fig-
4. Adjust the welding current. ure 35-3.
5. Place the electrode in the holder with a 45-degree 1o. Clean your weldment and inspect it. Then weld one
angle. more joint.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

q+<SMAW

FIGURE 36-1

a FIGURE 36-2
1st a n d 2nd
30-45"

3rd, 10-20'

Work angle

;iil
FIGURE 36-3

1 NAME
Fillet
1 POSITION
Horizontal
ELECTRODE DIAMETER AMPERAGE
E-7024 '/a" 140-1 90 AC or DCEP
MATERIAL
Use the two joints left over from Procedure 35
PASSES BEAD TIME (SEE INSTRUCTOR)
Muitide String

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 36
T=Joint Fillet, 2F Position, Multipass
Stringers (E-7024Electrode)

OBJECTIVE the center of the joint-clean the crater area. Then

complete the stringer.
Upon completion of this lesson you should be able to 5. Pay very close attention to the electrode angles. Be
weld horizontal fillets with iron powder electrodes. sure you do not change angles during stopping and
starting.
Text Referenoe: Section 111, Lesson 5B; page 231. 6. Watch your travel speed. It must be steady if the
bead width is to remain constant.
7. Be sure the legs of the weld are of equal length.
PROCEDURE 8. Hold the same electrode angle with the second bead.
Point the tip of the electrode so it is partially on
1. Position the assembly in the position shown in Fig- the plate and partially on the first bead as shown in
ure 36-1. Figure 36-2. Slightly more than half of the filler metal
2. Place the E-7024 electrode in the holder at a 45- should be on the stringer bead.
degree angle. 9. For the third stringer, lower the electrode angle to
3. Adjust the welding current. between 10 and 20 degrees as in Figure 36-2.
4. Run a stringer bead from left to right. Use a drag IO. Complete the joint using the bead sequence shown
technique. Hold the electrode at about 30- to 45- in Figure 36-3.
degrees to the bottom plate, (see Figure 36-21, with 11. Complete the last unwelded joint using the same six-
a drag angle of about 30 degrees. Stop welding at bead technique.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
FIGURE 37-1 FIGURE 37-2

L
\
\ 10 to20:

FIGURE 37-3 FIGURE 37-4

\IAME POSITION
Single bevel butt Horizontal
!LEORODE DIAMETER A M PERAGE
E-7018 '/a" 115-1 65 AC or DCEP
V\ATERIAL
1 pc. 3/a" X 1 %" X 8" carbon steel
2 pcs. 3/8" X 3" X 8" carbon steel
'ASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 37
Single-Bevel Butt Joint, 26 Position with
Baekup Bar

OBJECTIVE spacing. The electrode should penetrate deeply into

the bottom plate and wash up on the backup bar as
Upon completion of this lesson you should be able to shown in Figure 37-4.
weld a single-bevel butt joint with a backup bar in the 8. Clean the first bead thoroughly. Then run the second
horizontal position. bead over the remaining root area and the beveled
plate. Use an electrode work angle of about 10
to 20 degrees upward into the root as shown in
Text Referenee: Section 111, Lesson 5B; page 232. Figure 37-3. For good fusion be sure to burn into the
top plate, the remaining root space, and first bead as
shown in Figure 37-4.
PROCEDURE 9. Clean the second bead thoroughly. Cover it with
two stringers or one wide stringer depending on the
1. Flame cut and grind a 45-degree bevel, on the long width of the first bead. Stringers at the bottom plate
edge of one plate. must be made with an electrode angle of about 45
2. Remove all slag, mill scale, and so on from the area degrees if you are to get deep penetration. (Refer to
to be welded on all three plates. Figures 37-3 and 37-4.)
3. Fit and tack the plates as shown in Figure 37-1. Tack 10. All other stringers, until the last pass, should be at
at the ends of the joint. about a 10- to 20-degree upward angle. Follow the
4. Position the test piece as in Figure 37-2. The weld- bead sequence shown in Figure 37-4. The exception
ment may not be moved until all welding is com- to this is stringer 5 that requires the same angle as 1
pleted. and 3.
5. Secure the weldment and workpiece clamp. 11. The next to last layer beads numbers 5, 6, and 7
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

6. AC or DCEP. Adjust the welding current. in Figure 37-4 should be about 1/16 in. below the
7. For the first pass hold an electrode work angle of surface of the plate.
about 45 degrees as shown in Figure 37-3. Use a 12. All the stringers in the finish pass beads numbers 8
drag angle of about 20 to 30 degrees. Do not let to 1 1 in Figure 37-4 may be put in with an electrode
the puddle cover more than one-half of the root angle of about 1O- to 15-degree upward angle.

Copyright American Welding Society

Spacers

Tacks long

FIGURE 38- 1 FIGURE 38-2

Pre position

FIGURE 38-3

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
C motion

FIGURE 38-4 FIGURE 38-5 FIGURE 38-6

NAME POSITION
Open-root butt Horizontal
~~ ~

ELECTRODE DIAMETER AMPERAGE

E-601O '/a" 75-1 25 AC or DCEP
or
E-6011 '/a" 75-125 AC or DC
UATERIAL
2 spacers %z" X %" X 5"
2 pcs. %" X 4" X 8" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

Copyright American Welding Society

Procedure 38
Open-Root V-Groove, Butt Joint, 2G Position

OBJECTIVE 8. AC or DCEP. Adjust the welding current.

9. After setting your heat on scrap metal, start the weld
Upon completion of this lesson you should be able to bead on the left. Use an electrode angle of about 5 to
weld open-root butt joints in the horizontal position. 10 degrees upward into the root. (See Figure 38-5.)

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
Use a 10- to 15-degree drag angle.
10. Pause at the end of the tack until a keyhole appears.
Text Reference: Section 111, Lesson 5B; page 233.
11. When the keyhole appears, whip the electrode for-
ward and down onto the wall of the lower bevel.
Without stopping make a slight "C" motion and re-
PROCEDURE turn to the keyhole. As you do this the puddle so-
lidifies. The whipping allows the puddle to cool. It
1. Use a hand cutting torch or mechanical flame cutter keeps the keyhole small and stops the puddle from
to bevel one of the long edges of each plate. Cut the spilling out the back of the joint.
bevel at a 30-degree angle. This makes a 60-degree 12. With a little practice you will master this technique.
included angle as in Figure 38-1. if you pause too long in the puddle, you will "blow
2. Remove all slag, mill scale, and foreign matter by through or spill the molten metal out of the rear of
grinding or sanding. the joint. If you move too fast, you will not penetrate
3. Grind or file a Kz in. root face on each beveled edge the joint properly.
as shown in Figure 38-1. 13. The second pass is a stringer bead. Make it with the
4. Lay the plates, face down, on a flat surface with the "C" motion. Take care to pause at the upper left
two spacers in place as in Figure 38-2 (top view). hand portion of the "C" shown in Figure 38-6.
5. Tack the two plates as indicated in Figure 38-2. 14. Finish the remainder of the joint with stringers as
6. Remove the spacers and preposition the plates as in shown in Figure 38-5. Do not forget to leave about
Figure 38-3. a 1/16 in. space between the face of beads number 3
7. Position the plate as in Figure 38-4; secure the plate and 4, the next to last pass, and the surface of the
and workpiece clamp. plate.

Copyright American Welding Society

FIGURE 39- 1 FIGURE 39-2

JI-
I
Axis Of we'd

FIGURE 39-4

FIGURE 39-3 P

a-43
FIGURE 39-5 FIGURE 39-6

~ ~

NAME POSITION
T-joint fillet Vertical
ELECTRODE DIAMETER AMP ERAGE
E-601O '/a" 75-125 AC or DCEP
or
E-6011 '/ern 75-125 AC or DC
MATERIAL
2 pcs. H"X 4" X 8" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 39
T m J o i n t Fillet, 3F Position, W e a v e Beads,
Uphill (E16010or Em601 1 Electrodes)

OBJECTIVE at point 1. (See Figure 39-6.) Pause slightly to allow

the metal to form a puddle. When the puddle forms,
Upon completion of this lesson you should be able to move the electrode slowly to point 2 on the right
weld vertical fillets. side. Pause again to allow any undercut to fill in.
Then whip the electrode to point 3 slightly above the
Text Referenoe: Section III, Lesson 5C; page 235. center of the puddle. As the weld puddle changes
color, return the electrode to point 4. Pause again
while the undercut fills in, then slowly move across
PROCEDURE to point 5. Repeat the motions on the left as shown
by points 6, 7, and 8. As you continue the sequence,
1. Prepare, clean, and tack the plates to form a T-joint remember the electrode i s always returned to the
as in previous lessons. (See Figure 39-1.) side where it left the puddle.
2. Place the electrode in the holder at a 45-degree
angle as shown in Figure 39-2. Use this electrode Note: Always hold a long arc on both the upstroke and
position for all vertical welds. the down stroke so you do not deposit any metal during
3. Set your welding current on a piece of scrap metal the electrode motion.
in the vertical position.
4. Position the joint so the weld axis is vertical as in 10. If the center of the weld is too high or if it sags, you
Figure 39-3. are moving too slowly across the face of the weld.
5. Adjust the welding current. Move faster.
6. Position yourself so the electrode is centered be- i 1. If the center of the weld is too low or has holes, you
tween the two plates as in Figure 39-1. Point the are moving too fast across the face. Move slower.
electrode slightly upward, at a 1O to 15 degree an- 12. Move with a rhythm. Always pause at the sides of
gle as in Figure 39-4. the groove.
7. First pass: Strike the arc at the bottom of the joint 13. As the electrode moves from side to side, make sure
where the two plates meet. Hold the arc until the you stop with the electrode coating at the edge of
puddle is approximately '/4 to 3'16 in. wide where it the previous pass. The puddle will flow out past the
joins the two plates. Whip the electrode up and to edge and provide the correct pass width.
the right as in Figure 39-5. Hold a long arc as you 14. Finish the second pass in this manner; repeat the
move out of the puddle and as you drop back into it. sequences for the third pass. The finish of the third
8. As the electrode drops back into the puddle, hold pass should not exceed five electrode diameters in
a normal length arc. Pause slightly and whip out of width.
the puddle again. 15. Inspect for unevenness, undercut, holes, and bead
9. Second pass: Start at the left side of the weld groove contour.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

FIGURE 40-1 FIGURE 40-2

E-
JI-
I
Axis Of we'd

10-15"

FIGURE 40-4

FIGURE 40-3

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

FIGURE 40-5 FIGURE 40-6

NAME POSITION
T-joint fillet Vertical
ELECTRODE DIAMETER AMPERAGE
E-7018 '/aR 115-165 AC or DCEP
MATERIAL
2 pa. %* X 3" X 12" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Mu1tipIe Weave

Copyright American Welding Society

Procedure 40
T=Joint Fillet, 3 F Position, Weave Beads,
Uphill (E4018 Elecúrode)

OBJECTIVE 8. Pause at each side and watch for the weld puddle
to sag in the center. If sag is present:
Upon completion of this lesson you should be able to a. Reduce the amperes,
weld vertical fillets using low hydrogen electrodes. b. Increase the travel speed, or
c. Hold a closer arc
Text Reference: Section 111, Lesson 5C; page 236. 9. Second pass: Clean the first bead; then strike the arc
on the bottom center of the groove. Move quickly
to the lower left edge of the first pass.
PROCEDURE 10. Pause until the puddle forms. Then move the elec-
trode steadily to the right, drawing the puddle along.
1. Prepare, clean, and tack plates to form a T-joint as 11. Pause on the right when the edge of the electrode

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
shown in Figure 40-1. reaches the edge of the weld. The puddle will flow
2. Place the electrode in the holder at a 45-degree out another 3/32 in. to Ya in.
angle as shown in Figure 40-2. 12. Use either the basic weave or the alternate weave
3. Position the joint so the weld axis is vertical as in shown in Figure 40-6.
Figure 40-3. 13. Third pass: Weave another bead over the second
4. Adjust the welding current. pass. Cover slightly more than one-half of the right
5. Hold the electrode midway between the two plates side of the weld. Watch for undercut on the right
as in Figure 40-1. Point the electrode slightly upward, side of the weld.
at about a 0- to 5-degree angle, as in Figure 40-4. 14. Weave the fourth bead on the left side. Cover the plate
6. First pass: Begin at the bottom of the joint. Start the from the second pass and overlap about 94’ in. of the
arc with a tapping motion. This breaks the coating plate from the third pass. Be careful of undercut, both
covering the end of the electrode. on the left side and where this bead joins the other
7. Weave the electrode from side to side, advancing bead. Do not weave wider than three times the
upward slightly to keep the bead progressing. (Refer electrode diameter.
to Figure 40-5.) The bead should only be about 356
in. wide.

Copyright American Welding Society

-
FIGURE 4 1 1

FIGURE 41-2 ' FIGURE 4 1-3

4AME POSITION
T-joint fillet Vertical down
LECTRODE DIAMETER AMPERAGE
E-601O '/a" 75-125 DCEP
or
E-6011 '/a" 75-125 AC or D C
AATERIAL
2 pcs. 3/8" X 4" X 8" carbon steel
'ASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Proeedure 41
T-Joint Fillet, 3 F Position, Stringer
Beads, Downhill

OBJECTIVE the tack and until the end of the tack is reached. Hold
a fairly long arc.
Upon completion of this lesson you should be able to 5. When you pass the tack, gently push the electrode
weld vertical down fillets. into the root. The electrode should touch the work-
piece.
6. Slowly drag the electrode down the joint making sure
Text Reference: Section 111, Lesson 5C; page 237. that the electrode angle remains the same.
7. If the slag begins to run ahead of the puddle, you must
either increase your electrode angle and use the force
PROCEDURE of the arc to hold back the slag or increase your travel
speed.
1. Position the weldment as shown in Figure 41-1. 8. Run additional stringer beads using the bead se-
2. Adjust the welding current. quence shown in Figure 41 -3. Clean thoroughly be-
3. First pass: Point the electrode directly into the center tween passes.
of the joint. Use an upward angle of about 15 to 30 9. Complete the joint. Clean and examine it, then weld
degrees as shown in Figure 41 -2. the second side using the same technique and bead
4. Strike the arc and weave down until you pass over sequence you used on the first side.
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

FIGURE 42-1 FIGURE 42-2

FIGURE 42-3

rlAME POSITION
V-groove butt Vertical up
:LECTRODE DIAMETER AMPERAGE
E-7018 '/a" 90-1 50 DCEP
or
5/32" 110-230 DCEP
AATERIAL
1 pc. 114" X i " X 12"carbon steel
2 pcs. %" X 3" X 12"carbon steel
'ASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 42
V=Groove Butt Joint, 36 Position with
Backup Bar, Uphill

OBJECTIVE 5. Using a i/s in. electrode for the root pass begin at the
bottom of the joint and establish a shelf on which to
Upon completion of this lesson you should be able to begin the vertical up bead.
weld vertical v-groove joints using a backup bar. 6. Begin the root bead using a slight weave. Hesitate on
the sides of the groove to make sure the weld does
not undercut the sides of the groove.
Text Reference: Section 111, Lesson 5C; page 237.
,. Using the bead sequence shown in Figure 42-3 put
in the first two layers with %I in. electrodes, put in
the third layer with 5/32 in. electrodes. This should
PROCEDURE bring the weld just below flush, with the surface of
the plate. Complete the reinforcement with the i/s in.
1. Put a 30-degree bevel on one 12 in. side of each electrode being especially careful on the sides to hes-
plate. itate enough to fill the joint and eliminate undercut.
2. Tack the assembly as shown in Figure 42-1. 8. Cool and clean the plate. Examine it for uniform
3. Position the joint as shown in Figure 42-2. width, even ripples, and absence of undercut along
4. Adjust the welding current. the sides of the weld.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

FIGURE 43-1

Electrode
angle

FIGURE 43-3 FIGURE 43-4 FIGURE 43-5

P
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

FIGURE 43-6 FIGURE 43-7

JAME POSITION
V-groove butt Vertical up
LECTRODE DIAMETER AMPERAGE
E-601O '/eR 75-125 DCEP
or or
E-6011 '/e" 75-1 25 AC or DCEP
AATERIAL
2 spacers 3/31"
2 pn. '/e" X 5" X 12" carbon steel
'ASSES BEAD TIME (SEE INSTRUCTOR)
MuItipIe String and weave

Copyright American Welding Society

Procedure 43
Open-Root V=GrooveButt Joint, 36 Position,
Stringer and Weave Beads

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
OBJECTIVE 9. Start the arc on the bottom tack. Hold the arc at
the beginning of the root opening until a keyhole
Upon completion of this lesson you should be able to appears. Use an electrode angle 1O to 15 degrees as
weld open-root vertical-butt joints. shown in Figure 43-5.
10. First pass: Move the electrode upward in a slight
Text Reference: Section 111, Lesson 5C; page 238. whipping motion then return to the keyhole. Pause
there until the keyhole fills and another opens above
PROCEDURE it. Continue to whip uphill.
11. If the keyhole does not appear, you are:
1. Bevel the long side of the plates with a 30-degree a. Moving upward too rapidly
angle. This provides a final included angle of 60 b. Do not have sufficient arc current to penetrate
degrees. c. Do not have the proper root opening
2. Remove the scale on the intended weld areas by 12. if the keyhole i s too large, you are:
grinding or sanding. a. Moving upward too slowly
3. File a K 2 in. root face land or shoulder o n each b. Have the current set too high
bevel. c. Holding too long an arc
4. Fit it up with a y32 in. root gap and tack at each end 13. Clean the plate and run the second pass. Start at
as shown in Figure 43-1. the bottom of the joint. Hold a normal arc and weld
5. Preposition the plates slightly as in Figure 43-2 so uphill using either the weave shown in Figure 43-6,
you can fit a Ya in. electrode beneath the joint. or the triangle motion shown in Figure 43-7. Pause
6. Position the joint at a comfortable height in the at the sides to eliminate undercut.
position shown in Figure 43-3. 14. The next to last pass should be W Zto % n.i, below the
i . Adjust the welding current. plate surface. This gives you a guide for the last pass.
8. Check your welding condition on scrap so that you 15. The final pass must be about 1/16 in. above the surface
can easily whip the electrode uphill as in Figure of the plate. Excess reinforcement can create a stress
43-4. riser or notch that can lead to weld failure.

Copyright American Welding Society

sMAw% SMAW

FIGURE 44- 1 FIGURE 44-2

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
-10"

FIGURE 44-3 FIGURE 44-4

NAME POSITION
Fillet Overhead
ELECTRODE DIAMETER AMP ERAGE
E-601O '/aR 75-125 DCEP
or or
E-6011 '/a" 75-125 AC or DCEP
MATERIAL
1 pc. Ya" X 4" X 12" carbon steel
2 pcs. Va" X 1%" X 12" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 44
T=Joint Fillet, 4F Position, Stringer Beads
(Eœ6010 or El601 1 Electrodes)

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OBJECTIVE 6. Strike the arc and hold a fairly long arc. Begin a
stringer and weld over the tack using the "C" motion.
Upon completion of this lesson you should be able to When the end of the tack is reached, shorten the
weld fillets in the overhead position. arc. Then complete the stringer pass using the "C"
motion. Pause at the upper left of the "C" to fill in
the undercut. Direct the arc at the overhead plate as
Text Reference: Section 111, Lesson 5D; page 240.
shown in Figure 44-4.
7. Clean the plate after the first pass thoroughly. Use a
5- to 1O-degree work angle as in Figure 44-4. Run the
PROCEDURE next stringer so it covers about YE in. of the vertical
plate and about two-thirds of the first stringer.
1. Wire brush the intended weld area of the plate. 8. Clean the plate and run the third stringer. Use a 5-
2. Tack the plates together as shown in Figure 44-1. to 10-degree work angle, as shown in Figure 44-4,
3. Position the practice piece in the fixture as in Fig- favoring the top plate. About one-half to two-thirds of
ure 44-2. Be sure the workpiece and workpiece bead 2 should be seen. The legs of the weld should
clamp are secure. be equal with the face of the weld at a 45-degree
4. Adjust the welding current. angle to the plate surface.
5. Place the electrode in the holder as shown in Fig- 9. Cool and clean the joint. If it is satisfactory, weld a
ure 44-3. Use a 30-degree work angle off the vertical third layer. The third layer should have three beads
plate as shown in Figure 44-4. Work with a drag angle as shown in Figure 44-4. Clean the joint thoroughly
of approximately 1O degrees. after each bead.

Copyright American Welding Society

FIGURE 45-1

FIGURE 45-2

5 3rd
-10”

FIGURE 45-3

NAME POSITION
Fillet Overhead
~

ELECTRODE DIAMETER AMPERAGE

E-7018 ‘/aU 115-1 65 AC or DCEP
MATERIAL
Use the two joints from Procedure 44
PASSES
MdtiDk!
BEAD
Strine
I TIME (SEE INSTRUCTOR)

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 45
T=Joint Fillet, 4 F Position, Stringer Beads
(E4018or E 4 0 2 4 Electrodes)

OBJECTIVE an arc as possible, without stubbing out, and com-

plete the stringer. Move the electrode along, pulling
Upon completion of this lesson you should be able to steadily, using the "C" motion. But never allow the tip
weld overhead fillets using low hydrogen electrodes. of the electrode to leave the puddle. "Play" the arc
on the overhead plate by pausing slightly at the top
left of the "C" motion.
Text Reference: Section 111, Lesson 5D; page 241. 6. Clean thoroughly. Use the slag hammer to remove the
slag, then brush the joint thoroughly. After brushing
inspect carefully for any slag you might have missed.
PROCEDURE The slag left by low hydrogen electrodes is sometimes
difficult to remove, especially if there is an undercut
1. Clamp the practice plates in position as shown in area where it can adhere.
Figure 45-1. Be sure the workpiece and workpiece 7. Run the second stringer, using the same electrode
clamp are secure. angles as with the first pass. Cover about two-thirds
2. Adjust the welding current. of the first pass and about Ya in. of the vertical plate
3. Place the electrode in the holder as shown in Fig- as shown in Figure 45-3.
ure 45-2. Strike an arc using the tapping method. Start 8. Clean thoroughly and run the third stringer. Use a
the first bead at the left side of the joint with the elec- work angle of 5 to 1O degrees off the vertical plate as
trode at a 30-degree work angle off the vertical plate shown in Figure 45-3. About one-half to two-thirds of
as in Figure 45-3. Use a drag angle of approximately the second stringer should be uncovered. The weld
1O degrees. legs should be equal. The face of the weld should
4. Hold a slightly long arc and weld over the tack using make a 45-degree angle with the plate surfaces.
the "C" motion. Make sure that you do not oscillate 9. Run a third layer, consisting of three stringers as
excessively or leave the puddle. shown in Figure 45-3.
5. When the end of the tack is reached, hold as short 10. Complete the T-bar assembly for more practice.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

P
*/<SMAW 1'
-
4
60'
FIGURE 46- 1 FIGURE 46-2
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FIGURE 46-3 FIGURE 46-4

YAME POSITION
V-groove Overhead
ELECTRODE
E-601O
DIAMETER
Va"
I AMPERAGE
75-125 DCEP
or
E-6011 Van I 75-125 AC or DCEP
MATERIAL
%" X 3"X 12" carbon steel
:rban x 1 */z* x 12" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 46
VmGroove Butt Joint, 4 6 Position with
Backup Bar ( E m 6 0 1 0 or Em601 1 Eleatrodes)

OBJECTIVE 45. Start at the left side of the joint. Hold the elec-
trode perpendicular to the plate. Use a drag angle
Upon completion of this lesson you should be able to of approximately 20 to 35 degrees as shown in Fig-
weld overhead grooves with a backup bar. ure 46-3.
4. Advance the electrode along the joint in a straight line
Text Reference: Section III, Lesson 5 D page 241. using a slight weave to ensure both sides of the joint
are welded. Keep the arc short and travel speed even.
5. Clean the bead thoroughly. Pay attention to the toe
PROCEDURE of the weld. All slag must be removed from this area.
6. Complete the remainder of the joint with stringer
1. Put a 30-degree bevel on one 12 in. side and tack beads using a bead sequence as shown in Fig-
the plates together as shown in Figure 46-1. Position ure 46-4. Pay particular attention that the toe of the
them as shown in Figure 46-2. weld fuses into the other beads and base metal. Make
2. Adjust the welding current. sure the final layer finishes up with a maximum rein-
3. Place the electrode in the holder as in Procedure forcement of 3/32 in.
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

60'

FIGURE 47- 1 FIGURE 47-2

___---_-----_ --
Direction of travel
* ' , L
I I

-3 5" I
FIGURE 47-3 FIGURE 47-4

NAME POSITION
V-groove Overhead
ELECTRODE DIAMETER AMPERAGE
E-7018 '/aR 115-165 DCEP
MATERIAL
2 pcs. %" X 3" X 12" carbon steel
1 oc. %" X 1 1h" X 12" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 47
V-Groove Butt Joint, 46 Position with
Backup Bar (E4018Electrode)

OBJECTIVE line at an even travel speed, using a slight weave

ensuring both sides of the joint are properly fused. Do
Upon completion of this lesson you should be able to not use a whipping motion when using low hydrogen
weld overhead grooves using low hydrogen electrodes. electrodes. Doing so will cause porosity.
5. Clean each bead thoroughly being careful to ensure
Text Reference: Section 111, Lesson 5D; page 242. the toe of the weld is thoroughly cleaned and free
of slag. Any remaining slag will become trapped in
subsequent beads.
PROCEDURE
Note: The bead appearance of the low hydrogen
1. Put a 30-degree bevel on one side and tack the plates electrode is considerably smoother and more even than
together as shown in Figure 47-1. Position them as the surface obtained with E-601 O or E-6011 electrodes.
shown in Figure 47-2.
2. Adjust the welding current. 6. Complete the joint using stringer beads with a bead
3. Start at the left side of the joint. Hold the electrode sequence as shown in Figure 47-4. Keep the second
perpendicular to the plate using a drag angle of 20 to to last layer (beads 4, 5, and 6 ) slightly below flush
35 degrees. (See Figure 47-3.) so the reinforcement will not exceed Y32 in. when
4. Advance the electrode along the joint in a straight finished.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

8
75"

FIGURE 48-1 FIGURE 48-2

Penetration or
melt through
I I

4th pz

1st
and 2nd
passes

FIGURE 48-3 FIGURE 48-4

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

NAME POSITION
V-groove Overhead
ELECTRODE DIAMETER AMPERAGE
E-601O ven 75-125 DCEP
E-7018 '/a" 115-1 65 DCEP
MATERIAL
2 pcs. 1h" X 5" X 10" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 48
Open=RootV=GrooveButt Joint, 443 Position

OBJECTIVE 4. Hold a very close arc. Push the electrode slightly

through the keyhole. This will force the molten metal
Upon completion of this lesson you should be able to pile up on the top side of the joint (approximately
to weld overhead open-root groove welds using low to 3h2 in. in height).
hydrogen electrodes. 5. Clean the first pass thoroughly. Run a stringer by
drawing the electrode along the joint for the second
Text Reference: Section til, Lesson 5D; page 242. pass. Use E-7018 electrodes for this and the rest of
the passes. Make sure the arc is running fairly “hot.”
The heat i s needed to burn out any wagon tracks or
PROCEDURE deep grooves at the weld toes. Stay in the puddle.
6. The third layer will be made with two stringers.

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1. Be sure that the bevel angle and root face are pre-
pared according to Figure 48-1. Clean all intended Remember: Favor the toe area of the weld. Point the
weld areas and tack the plates as shown i n Fig- electrode slightly in the direction you want the metal to
ure 48-1. flow toward, (See Figure 48-3.)
2. Position the test piece as shown in Figure 48-2. Be
sure the test piece and workpiece clamp are secure. 7. Complete the remainder of the joint using the stringer
Adjust the welding current. method. Be careful of producing undercut or exces-
3. Use the E-601O electrode and a drag angle of approx- sive reinforcement on the finish pass. See Figure 48-4
imately 1O degrees to whip in the first pass. Make sure for the bead sequences and amount of weld rein-
that you open a keyhole. Keep it open along the en- forcement.
tire length of the joint.

Copyright American Welding Society

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
Welding sheet metal, especially that below 16 gauge, is extremely difficult with the
shielded metal arc welding process. Thin sheet metal i s better suited for welding by
the gas metal arc, the gas tungsten arc, and the oxyacetylene processes. Cas metal
arc welding is a fast and economical process. Cas tungsten arc welding, although
slower, has the ability to produce exceptionally sound welds in the “hard to weld”
metals such as stainless steel, aluminum, magnesium, titanium, copper, and so on.
The oxyacetylene process is an old standby; however, it lacks the speed needed
for most types of production welding. This method also increases the heat input and
causes the metal to warp.
A skilled shielded metal arc welder can successfully weld some sheet metal gauges.
However, 16 gauge i s the thinnest that can be welded successfully without too much
distortion or burn-through.

GENERAL INSTRUCTIONS
joint preparation and fit-up are of great importance in sheet metal welding. Slight
openings in fillet joints or butt-joint faces will cause the arc to burn away the sheet
metal edges during the welding operation. It is important to observe the following
instructions as you complete each procedure in this section:

1. Shear or saw all metal to be joined. Flame cutting is a poor choice. Even if the
welder is skillful enough to eliminate the slag from the cutting operation, the metal
will warp from the heat. A good fit-up is difficult, if not impossible, to obtain with
warped sheet metal.
2. Tacks on sheet metal should be close together. Depending on the gauge of the
metal and the type of joint, they should be placed no more than 1 to 1 % in. apart.
Tacks that are farther apart will allow the joint to open from the heat making it
difficult to weld the joint.
3. Know your electrodes; choose the proper one for the job.

MATERIALS AND EQUIPMENT

For this section the material and equipment will be as follows:

1. Welding shield
2. Safety glasses
3. Protective leathers and gloves
4. Chipping hammer and wire brush
5. Personal welding equipment
6. Pliers
7. E-6013 electrodes, Y,, in. diameter

109
Copyright American Welding Society
Provided by IHS under license with AWS Licensee=IHS Subs and Mgrs /IHSINTL003, User=GCN, serPemex
No reproduction or networking permitted without license from IHS Not for Resale, 09/13/2005 16:49:30 MDT
110 SHIELDED METAL ARC WELDING PROCESS

FIGURE 49-1 FIGURE 49-2

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

FIGURE 49-3 FIGURE 49-4

FIGURE 49-5

NAME POSITION
Corner joint Flat
ELECTRODE DIAMETER AMP ERAGE
E-6013 3/d 45-90 DCEN
MATERIAL
2 pa. 16 gauge X 2" X 10" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single String

Copyright American Welding Society

Procedure 49
Welding an Outside-Corner Joint in the
Flat or Downhand Position

OBJECTIVE joint with a perpendicular work angle as in Figure

49-3. Use a 5- to 10-degree drag angle as shown in
Upon completion of this lesson you should be able to Figure 49-4. The electrode can also be dragged along
weld outside corner joints in sheet metal. in contact with the metal, However, the electrode
drag angle must be increased to approximately 25
to 30 degrees.
Text Reference: Section 111, Lesson 6 4 page 245.
7. Stop midway along the joint. Remove the slag and
inspect the bead. It should be slightly convex with no
overlap at the toes of the weld. It should be free of
PROCEDURE surface holes and slag inclusion. Figure 49-5 shows
the desired bead profile.
I . Adjust the welding current on 16-gauge scrap sheet. 8. If the face of the bead is convex and there i s overlap,
2. Tack the two pieces of sheet metal to form the open- there is too much filler metal. This happens when
corner joint shown in Figure 49-1. Tacks on sheet your rate of travel is too slow, your heat is set too
metal differ from those used on plate. Sheet metal high, or you have too much drag angle. If the bead is
tacks should be small; they are no larger than arc flat or concave, there is too little metal. This happens
strikes. Apply them by striking and maintaining an arc when your rate of travel is too fast or your amperage
for two or three counts and then break the arc. is too high. If the bead is high, just sitting on top of the
3. After tacking, secure the weldment as shown in Fig- joint, your amperage is too low. Change your welding
ure 49-2. conditions accordingly.
4. Remove all slag from the tacks and wire brush the 9. After your make the necessary adjustments, pick up
intended weld areas. the weld at the crater. Hold a long arc to start, then
5. Place the electrode in the holder at a 90-degree angle. complete the joint, Inspect as before and continue to
6. Starting at the highest point of the joint, strike the arc weld practice pieces until you can produce accept-
and hold a normal arc gap. Move steadily along the able welds.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

t+- 10 or i 2 gauge

B Bubble tacks

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
FIGURE 50-1 FIGURE 50-2

FIGURE 50-3 FIGURE 50-4

FIGURE 50-5

IAME POSITION
T-joint fillet Horizontal
I LECTRODE DIAMETER AMPERAGE
E-6012 '/aR 80-140 AC or DCEN
MATERIAL
2 pcs. 10 or 12 gauge X 2" X 10" carbon steel
'ASSES BEAD TIME (SEE INSTRUCTOR)
Single String

Copyright American Welding Society

Procedure 50
T-Joint Fillet, 2F Position

OBJECTIVE i. Clean the slag left by the tacking procedure and start
at the left side. Place the electrode in the holder, at a
Upon completion of this lesson you should be able to 45-degree angle as you did when welding horizontal
weld horizontal fillets on sheet metal using an E-6012 fillets on plate. The electrode work angle should be
electrode. between 30 and 45 degrees as shown in Figure 50-4.
Use a 1O- to 15-degree lead or drag angle.
Text Referenoe: Section 111, Lesson 6B; page 246. 8. Maintain a puddle slightly larger than the electrode
diameter (maximum H6 in.), by holding a close arc
with the electrode pointed into the heel of the joint.
PROCEDURE Favor the bottom piece slightly.
9. You can either hold a close arc or drag the electrode.
1. Adjust the welding current. If you drag the electrode, touch the leading edge of
2. Adjust the current on 1O- or 12-gauge sheet metal. the coating to the surface of the joint. Watch the
3. Clean the intended weld areas. upper trailing edge of the puddle. If it does not fill
4. Fit-up the two pieces to form a T-joint as in Fig- in completely, you should travel slower. Otherwise,
ure 50-1. Make sure the vertical piece is perpendic- the vertical leg will be undercut.
ular. 10. When you reach the halfway point, stop. Clean the
5. Place one tack at each end as in Figure 50-2. Place weld and remove the slag. Examine the bead to
smaller tacks between the end tacks, at about 1 in. be sure you are fusing both pieces. The weld face
intervals. These tacks are sometimes referred to as should be at a 45-degree angle. The legs should be
bubble tacks. They should be round and slightly equal and the surface flat or slightly convex. (See
larger in diameter than the electrode. Figure 50-5.)
6. Secure the tacked pieces in position as shown in 11. Restart the arc using the same electrode, and com-
Figure 50-3. Tilt it, up to 15 degrees in the direction plete the weld.
of travel. This will let you weld faster and reduce the 12. When you have completed the weld, cool and clean
chance of undercut. it thoroughly. Then weld the other side.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

16 g a . 1 tacks

FIGURE 5 1 1 - FIGURE 5 1-2

P, 45" approx

FIGURE 51-3 FIGURE 51-4

NAME
Lao-¡oint fillet
I POSITION
~ ~~
Horizontal
ELECTRODE DIAMETER AMPERAGE
E-6013 %lm 45-90 AC or DCEN
MATERIAL
2 pcs. 16 gauge X 2" X 10" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single String

Copyright American Welding Society

Procedure 51
Lap Joint Fillet, 2F Position
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

OBJECTIVE 6. Start at the left side of the joint. The electrode work
angle should be approximately 45 degrees as shown
Upon completion of this lesson you should be able to in Figure 51-3. Use about a 10- to 15-degree lead
weld sheet metal lap joints in the horizontal position. or drag angle. Maintain the puddle slightly larger than
the legs of the joint.
Text Reference: Section 111, Lesson 6B; page 247.
Note: Do not burn away an excessive amount of the toe
PROCEDURE at the top of the vertical leg.

1. Adjust the welding current. 7. Pull the puddle, with a uniform width, along the entire
2. Clean all intended weld areas. Then tack the two length of the joint. With a K2 in. diameter electrode
pieces on the ends as shown in Figure 51-1. it is very difficult to keep the weld small enough for
3. Make sure there are no openings along the joint and metal of this thickness. If you have too much trouble,
place bubble tacks as in Figure 51-2. The closely try using 1/16 in. diameter electrodes.
spaced tacks will keep the joint from opening up as 8. Check the completed weld for surface holes, slag
the weld progresses. inclusion, and discontinuities, including spaces left
4. Secure the tacked pieces in position as in Figure 51-2. unwelded. The weld should be completed in a single
You may tilt the pieces slightly (a maximum of 15 pass. it should have equal legs and a flat or slightly
degrees) toward the direction of travel. If you do, convex face as shown in Figure 51 -4.
welding will proceed at a slightly faster pace and you 9. Cool and clean the sample. Then weld the opposite
will minimize the chance of undercut. side.
5. Remove the slag left by the tacking procedure and
place the electrode in the holder at a 45-degree angle.

Copyright American Welding Society

10-124ga.-

FIGURE 52-1
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

FIGURE 52-2

10-20"
Drag angle

FIGURE 52-3

VAME
Corner ioint
~~~ ~~~
1 POSITION
- ~
Vertical
-~ ~

i LECTRODE DIAMETER AMPERAGE

E-6011 3/32" 40-80 DCEN
MATERIAL
2 pcs. 10 or 12 gauge X 2" X 10"carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single String

Copyright American Welding Society

Procedure 52
O u t s i d e = C o r n e rJofnt, 36 Position
(El6011 Electrode)

OBJECTIVE 6. Start at the top of the joint. Strike an arc and move
steadily toward the bottom using about a 10- to
Upon completion of this lesson you should be able to 20-degree drag angle as shown in Figure 52-3. Point
weld outside-corner joints in the vertical position. the electrode straight into the joint.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
7. As you follow the groove it may be necessary to
Text Reference: Section III, Lesson 6C; page 248. weave the electrode slightly from side to side. This
will fuse the toes of the weld. If the puddle is wide
PROCEDURE enough, the weaving is not necessary.
8. Hold a fairly long arc. Do not be concerned by any
1. Adjust the welding current. flux that moves ahead of the puddle. Whatever flux
2. Tack weld the joint as in Figures 52-1 and 52-2. is present will be light, and it will have no effect on
Place the tacks 1 to 1 % in. apart. Be sure there are the advancing weld.
enough tacks; otherwise the joint will open during 9. Concentrate on completing the weld without stop-
welding. ping. If a pause is necessary, be sure to clean the
3. Secure the weldment in the 3G vertical position as crater area thoroughly before continuing.
in Figure 52-2. 10. The contour of the weld can range from a flat face
4. Remove all slag from the tacking procedure and to slightly convex face.
clean the intended weld area. The welding will be 11. You can continue to practice this joint by adding
from the top of the joint toward the bottom. pieces to the weldment. Be sure to clean all plate
5. Place the electrode in the holder at a 45-degree edges and intended weld areas before you begin.
angle. (See Figure 52-1.)

Copyright American Welding Society

10-12"ga.
-k

FIGURE 53-1

FIGURE 53-2

FIGURE 53-3

VAME POSITION
Corner joint Vertical
!LECTRODE DIAMETER AMPERAGE
E-6013 '/a" 80-130 DCEN
víATERIAL
2 pcs. 1O or 12 gauge X 2" X 1O" carbon steel
'ASSES BEAD TIME (SEE INSTRUCTOR)
Single String

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 53

Outside-Corner Joint, 36 Position

(E-6013 Electrode)

OBJECTIVES 7. Using the downhill technique drag the electrode

downward using a slight weaving motion if neces-
Upon completion of this lesson you should be able to sary. Spread the weld pool to cover the entire joint.
weld vertical corner joints using E-601 3 electrodes. 8. Do not oscillate the electrode excessively. Excessive
oscillation will cause the weld to be too wide. The
Text Reference: Section 111, Lesson 6C; page 249. weld width should be slightly more than the joint
width.
PROCEDURE 9. if the slag runs ahead of the molten puddle, you
should stop. Chip the weld at the crater, clean it,
1. Adjust the welding current. and start over.
2. Clean all intended weld areas.
3. Fit-up and tack two pieces to form an outside-corner Remember: Hold a long arc when restarting.
joint as in Figures 53-1 and 53-2. Make sure the Completely fill in the crater before continuing the
pieces are at a right angle, as indicated. Place a tack bead.
at each end and enough tacks in between to keep the
joint from opening during the welding procedure. 10. Experiment a little with the length of the arc. Try a
Clean the slag left by the tacking procedure. short length arc and a medium arc. Note the differ-
4. Secure the weldment in position as shown in Fig- ence, then use the arc length you feel is the best
ure 53-2. for you. This holds true for electrode angles. Some
5. Place the electrode in the holder at a 45-degree angles improve the appearance of the weld and the
angle. ease with which it is welded.
6. Start to weld from the top. Aim the electrode straight
into the joint. The drag angle should be between 1O
and 25 degrees as shown in Figure 53-3.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

4 La.
FIGURE 54-1
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

FIGURE 54-2

FIGURE 54-3

NAME
~~ ~~ ~
Lao ioint
-~~
I POSITION
~
Vertical
ELECTRODE DIAMETER AMPERAGE
E-6013 %Zu 45-90 DCEN
MATERIAL
2 pcs. 16 gauge X 2" X 1 O" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single String

Copyright American Welding Society

Procedure 54
Lap Joint Fillet, 3F Position

OBJECTIVE Start at the top of the joint using a 10- to 20-degree

drag angle, a work angle of 20 to 25 degrees, off the
Upon completion of this lesson you should be able to vertical edge of the overlapping sheet as shown in
weld vertical lap joints on sheet metal. Figure 54-3.
6. Use the drag technique. Hold a fairly short arc. The
Text Reference: Section III, Lesson 6C; page 249. puddle should be large enough in diameter to fuse
the entire joint.
7. Favor the surface of sheet 2 (see Figure 54-3). Watch
PROCEDURE the left side of the puddle closely and make sure it
fuses the leading edge of sheet 1. if you move too
1. Adjust the welding current. slowly or weave excessively, you will burn away the
2. Fit-up and tack the joint on the ends as in Figure 54-1. leading edge of sheet 1. This is not acceptable.
Place enough tacks between the ends so the joint will 8. It is very difficult to obtain a finished weld with equal
not open from the heat of the welding. legs on thin sheet metal while using a k i n . diameter
3. Remove all slag from the tacking procedure and clean electrode. A better electrode choice would be 1/16 in.
all intended weld areas. diameter. If 1/16 in. electrodes are available, use them
4. Secure the weldment as shown in Figure 54-2. The to practice this joint.
direction of welding will be downward, from the top 9. Usually the leg of the fillet on sheet 2 is slightly longer.
of the joint. This is acceptable as long as the other leg is fused
5. Place the electrode in the holder at a 45-degree angle. properly.

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Copyright American Welding Society

16 gauge

FIGURE 55-1 FIGURE 55-2

a-
FIGURE 55-3
180'
Leading edge

1o -20"
Work angle

FIGURE 55-4

NAME POSITION
Lap joint Overhead
ELECTRODE DIAMETER AMPERAGE
E-6013 3/31" 45-90 DCEN
MATERIAL
4 pcs. 16 gauge X 2" X 10"carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single String

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Copyright American Welding Society

Procedure 55

Lap Joint Fillet, 4F Position

OBJECTIVE held at a 10- to 20-degree work angle off the vertical

face of the joint as shown in Figure 55-4.

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Upon completion of this lesson you should be able to 6. Favor the horizontal surface, making sure the leading
weld overhead lap joints on sheet metal. edge and the vertical leg are fused. Do not burn the
leading edge of the bottom sheet back more than
Text Referenoe: Section III, Lesson 6D; page 250. approximately 1/16 in.
7. Use a slight "C" motion, or the whipping method, to
control the puddle. Do not overweld by making too
PROCEDURE wide a bead. Do not pile excess weld metal on the
surface. Guard against burn through in the last few
1. Adjust the welding current. inches.
2. Tack the weldment in the position shown in Fig- 8. Clean, cool, and examine the joint for appearance
ure 55-1. Clean the tacks and all intended weld areas. and soundness. The weld contour should be flat or
3. Secure the plates in the 4F position as shown in slightly convex.
Figure 55-2. 9. Weld the remaining three fillets as indicated by the
4. Place the electrode in the holder as shown in Fig- symbol in Figure 55-2. "Typ" means all joints of the
ure 55-3. type indicated should be welded the same. Weld two
5. Start at the left side of the joint with the electrode joints using DCEN and two using alternating current.

Copyright American Welding Society

710 gauge or 12 gauge

FIGURE 56-1 FIGURE 56-2

FIGURE 56.3 FIGURE 56-4

NAME POSITION
Corner joint Overhead
ELECTRODE DIAMETER AMPERAGE
E-6012 ’/a” 80-140 DCEN
MATERIAL
4 pcs. 10 or 12 gauge X 3” X 10”carbon steel’
PASSES BEAD TIME (SEE INSTRUCTOR)
Single String

Copyright American Welding Society

Procedure 56
Outside=Corner Joint, 4 6 Position

OBJECTIVE 5. Start welding at the left side of the joint. Use a drag
angle of 5 to 15 degrees as shown in Figure 56-3.
Upon completion of this lesson you should be able to Use a work angle perpendicular to the joint as shown
weld outside-corner joints in the overhead position. in Figure 56-4.
6. Make sure the puddle covers the entire joint, over-
Text Reference: Section 111, Lesson 6D; page 251. lapping the toes slightly. The metal edges will melt
and become part of the joint.
PROCEDURE 7. Use the drag technique or a slight whipping motion
to weld the joint. Make sure you obtain complete
1. Adjust the welding current-alternating current or fusion. The weld metal should not penetrate through
direct current either polarity, however, direct current to the opposite side of the joint. Hold a medium arc
electrode negative is preferred, DCEN. length.
2. Tack the weldment in the position shown in Fig- 8. Maintain the electrode drag angle to about the last
ure 56-1. Clean away the slag and all intended weld 1 '/z in., then you may have to switch to a push angle
areas. of 5 to 10 degrees. This is illustrated in Figure 56-3.
3. Secure the weldment in the 4G position as shown This is necessary only if the joint is overheating and
in Figure 56-2. there is a possibility of melt through.
4. Place the electrode in the holder as in the previous 9. Clean, cool, and examine the weld for defects.
lesson. 10. Check for proper bead contour (see Figure 56-4).
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Copyright American Welding Society

FIGURE 57- 1 FIGURE 57-2

axis

FIGURE 57-3 FIGURE 57-4 FIGURE 57-5

I FIGURE 57-6 FIGURE 57-7

NAME POSITION
Six-sided box All Dosition ~

ELECTRODE DIAMETER AMPERAGE

E-6011 3/31" 40-80 AC or DCEN
E-6011 Va" 75-125 AC or DCEN
E-6013 %ln 45-90 AC or DCEN
E-6013 '/a" 80-1 30 AC or DCEN
MATERIAL
2 pcs. 10 gauge X 6" X 8" carbon steel
2 pa. 10 gauge X 6" X 10" carbon steel
2 pcs. 10 gauge X 8" X 10" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single String

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Copyright American Welding Society

Procedure 57

W e l d i n g a Six-Sided Box, in the 26,343,

and 4 6 Positions

OBJECTIVE 4. Tack side pieces 5 and 6 to form a hollow box as in

Figure 57-2.
Upon completion of this lesson you should be able to 5. Tack top piece 4 to complete the box as in Fig-
weld a variety of joints using different electrodes to weld ure 57-2. Check to be sure all the joints are fit prop-
a closed-sheet metal box. erly. There should be no openings. Use the smaller
diameter electrode to tack weld all corners for ap-
proximately YI in. on each side of the vertical joint.
Text Reference: Section 111, Lesson 6E; page 252. This is shown in Figure 57-3.
6. Clean all the tacks and the intended weld areas.
Place the weldment in position as in Figure 57-4.
PROCEDURE It must remain fixed in this position until all welding
is completed.
1. Adjust the welding current as follows: 7. Weld the four vertical joints. Use YE in. diameter
E-6011 electrodes on DCEN and the downhill tech-
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nique. Start on the tack at the top, slightly to one side

Electrode diameter Ampere of the joint, as in Figure 57-5. Finish the same way at
Welding current Range
the bottom of the joint. This will allow you to over-
(AC or direct current lap the connection with the remaining welds. It will
electrode negative) also help eliminate poor connections at the junction
E-6011 K2 in. 40 to 80
of the welds. The contour of all welds is shown in
E-6011 Y8 in. 75 to 125
Figure 57-6.
E-6013 Kz in. 45 to 90 8. After welding all four vertical joints using this proce-
E-6013 YE in. 80 to 130
dure clean and weld the bottom joint. Use the Y8 in.
diameter E-6013 electrode on DCEN. The work an-
Be sure all sheets are joined at a right angle. Use a try gle of the electrode should be approximately 30 to
square to aid in positioning them. Clean all joints as 40 degrees off the vertical leg as in Figure 57-7.
in previous lessons. Maintain a close fit throughout. 9. Complete the box by welding the top joint with
2. Use a Kz in. electrode for the tacking procedure. the '/s in. diameter E-6011 electrode on DCEN. The
Use the ballpeen hammer to close the joint open- work angle should be approximately 45 degrees off
ings. the horizontal leg of the joint. (See Figure 57-7.)
3. Tack end pieces 1 and 2 to the bottom piece 3 as 10. Clean all welds and allow to cool. Examine for any
in Figure 5 7- 1. defects.

Copyright American Welding Society

The Procedures in this section will introduce you to the fundamentals of shielded
metal arc welding of pipe. You will find the welding of pipe a new challenge that
involves dexterity and a sharp perception of welding in three dimensions. A successful
pipe welder exhibits exceptional ability to concentrate on the weld puddle as he or
she guides the arc around the joint, all the while maintaining the proper electrode
angle. You may find that some pipe welding situations will involve the use of mirrors
due to inaccessibility to the pipe because of location of the pipe.
Complete the Procedures in this section in the sequence in which they appear.
Only by masteringthe basic techniques of pipe welding will you be able to success-
fully advance to more complex welding procedures.

GENERAL INSTRUCTIONS
The Procedures in this section will introduce you to techniques instrumental in
becoming a successful pipe welder. You will need to review those skills involved in
the procedures on oxyacetylene welding of pipe, presented earlier in the workbook.

MATERIALS AND EQUIPMENT

For this section the material and equipment will be as follows:

1. Welding goggles, number 5 or 6 lens

2. Safety glasses
3. Grinding goggles
4. Soapstone
5. Wraparound
6. Handgrinder or sander
i. Chipping hammer
8. Ballpeen hammer
9. Half-round bastard file, 10 in.
10. Wire brush

129

Copyright American Welding Society

FIGURE 58-1

Direction >o
travel

FIGURE 58-2

NAME POSITION
Pipe preparation Flat
ELECTRODE DIAMETER A M PERAGE
None
MATERIAL
1 pc. 4" or 6" schedule 40 pipe
PASSES BEAD TIME (SEE INSTRUCTOR)
None None

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Copyright American Welding Society

Procedure 58
Beveling Pipe to Prepare It for Tests

OBJECTIVE 9. Start the cut Y4 in. from the line, between the line
and the scrap end of the pipe. After piercing the
Upon completion of this lesson you should be able to metal, make a cut to the line and begin to move
prepare pipe for welding. along it slowly. Make sure you hold the torch tip at
30 degrees. The torch tip must always point at the
Text Reference: Section III, Lesson 7 4 page 254. center of the pipe.
10. When you reach the limit of travel (12 or 12:30),
move the torch tip away from the line toward the
PROCEDURE end of the pipe, opening a small hole before you
release the cutting oxygen lever. This will give you a
1. Hammer the surface of the pipe slightly. Make sure new starting point when you resume the cut. It also
you remove heavy rust deposits on the inside and eliminates gouging the bevel when you start the next
outside surfaces. cut.
2. Wire brush all loose residue and scale from the 11. Rotate the pipe counterclockwiseand make the sec-
surfaces of the pipe. ond cut. Continue to rotate the pipe after each cut
3. Set up the oxy-fuel flame cutting unit you will use until the full bevel is completed.
to prepare the pipe. 12. Tap the feather edge of the bevel lightly with the
4. Using a wraparound, draw a line with the soapstone, ballpeen hammer. Try to remove as much of the slag
about Y4 in. from the end of the pipe. (Make sure you as possible. If the slag cannot be removed, you were
use a well-sharpened soapstone.) moving too slow or your flame was set too high. Use
5. Place another line about 4 in. from the first. a chipping hammer to remove the remainder of the
6. If the pipe is long enough, and a pipe beveler is slag.
available, make cuts on both lines. If a pipe beveler 13. Place the beveled pipe section in the vise. Then sand
is not available, use a hand torch. or file the remaining slag and scale from the beveled
7. if a hand torch is used, hold the torch at a 30-degree surface.
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angle, with the torch tip within YE in. or less from the 14. Use a sander or a file to remove the feather edge
surface of the pipe (see Figure 58-1). and form a root face.
8. Right-handedstudents should start cutting at approx- 15. Use the file to finish the root face. Do not forget
imately the 1O o’clock position. Then cut clockwise, to file all scale from outside of the pipe next to the
stopping a little after 12 o‘clock as shown in Fig- beveled edge. Then use the rounded side of the file
ure 58-2. Do not attempt to make cuts longer than to clean inside the pipe.
from 1O to 12:30. Left-handed students start at 2 and 16. After you have completed the bevel, cut off the pipe
cut counterclockwise toward 12 o’clock. along the second line.

Copyright American Welding Society

FIGURE 59-1 FIGURE 59-2

3rd
tack

a
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FIGURE 59-3 FIGURE 59-4

JAME
Pipe fit and tack
I POSITION
Flat
ELECTRODE DIAMETER AMPERAGE
E-6010 '/aR 75-125 DCEP
or
E-6011 '/BR 75-1 25 AC or DCEP
MATERIAL
2 pcs. 4" or 6" schedule 40 pipe from procedure 58
2 spacers HP X Va" X 6"
1 DC. 3"or 4" channel 12" long
~~

PASSES BEAD ITME

(SEE INSTRUCTOR)
None Tark

Copyright American Welding Society

Procedure 59
Aligrnment, FitlUp, and Tacking Procedure

OBJECTIVE spacers cannot move. This will keep the root gap
the same throughout the joint.
Upon completion of this lesson you should be able to fit i. Place the first tack at 12 o’clock as shown in Fig-
and tack pipe. ure 59-3. All tacks should be approximately % in.
long.
Text Reference: Section 111, Lesson 7A; page 255. 8. Remove the spacers and place them or wedges at 4
and 8 o’clock as shown in Figure 59-4. If you place
them too deep into the root gap, it will be difficult
PROCEDURE to remove them. Rotate the pipe so you can tack the
joint at 6 o’clock.
1. Check to make sure that the outside surfaces of the 9. Place the second tack at 6 o’clock as shown in
pipes do not have any heavy coating or slag on them. Figure 59-3, then remove the spacers.
2. Tack or clamp the channel iron to a work table as 1O. Check to determine if the spacing at 3 and 9 o’clock
shown in Figure 59-1. are equal. If not, use the feather wedge just below
3. Adjust the welding current. 3 or 9 o’clock to even the spacing. Then place a
4. Set the two pieces of pipe on the toes of the chan- tack just above the wedge. Remove the wedge. Then
nel iron with the root faces almost touching as in place it in the joint, on the opposite side, and tack
Figure 59-2. weld just above the wedge.
5. Place the two spacers between the root faces. Place 11. Examine the joint. If the gap is not evenly spaced
one vertically, to run between 1O and 1 1 o’clock and all around the pipe, or if the pipe i s misaligned,
8 and 7 o’clock as shown in Figure 59-3. cut the tacks out with a hacksaw and start from the
6. The pipes must be pressed firmly together so the beginning.

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Copyright American Welding Society

__
Axis
/T
, 60"
ig
FIGURE 60-1 FIGURE 60-2

Axis Rotate
clockwise

Start
6

FIGURE 60-3 FIGURE 60-4

r& rnax.

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reinforcemeril

L-g max. penetration

FIGURE 60-5

rlAME POSITION
Pipe weld Flat
LECTRODE DIAMETER AMPERAGE
E-601O '/a" 75-125 DCEP
or
E-6011 '/an
~~
75-125 AC or DCEP
UIATERIAL
2 pcs. 4" or 6" schedule 40 pipe
'ASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

Copyright American Welding Society

Procedure 60
W e l d i n g Pipe in the 16 Position, with Its
Axis in the Horizontal Position

OBJECTIVE 7. Utilize the whipping method, as in welding plate

in the vertical position, to run the first pass uphill.
Upon completion of this lesson you should be able to Use an electrode to push an angle 5 to 15 degrees
weld pipe one-quarter turn at a time. upward as in Figure 60-3. Whip upward, taking care
not to scar the surface of the pipe on either side
Text Reference: Section 111, Lesson 7B; page 257. of the V-groove. Stop when 1 o’clock is reached as
shown in Figure 60-4. Clean thoroughly.
8. Turn the pipe clockwise toward you one-quarter of a
PROCEDURE turn. Then proceed in the same manner until the first
pass is completed. Be sure to start the next electrode
1. Prepare, fit, and tack the pipe. slightly below the crater.
2. Secure the pipe with its axis in the horizontal posi- 9. The second pass (hot pass) and third pass (cover
tion as shown in Figure 60-1. pass) can be welded with either the triangle motion
3. Adjust the welding current. or the alternate weave, as in vertical plate welding.
4. Place the electrode in the holder, as in Figure 60-2. Take care to pause at the sides of the joint. Burn
Use a 90- or 45-degree angle away from the end of out any entrapped slag and fill in any undesirable
the holder. undercut.
5. Position yourself so you are at a 90-degree angle to 1O. Follow the same bead sequence. Adhere to the max-
the pipe. Be sure you are comfortable. imum root and face reinforcement as shown in Fig-
6. Strike the arc, on the bevel, at approximately 3 ure 60-5.
o’clock. Carry it down to 4 o’clock. Pause long 11. When you make the connection on completing the
enough for the root faces to melt away and a keyhole pass, be sure to overlap slightly. Break the arc by
form. Then reverse your electrode direction. slowly drawing it away from the puddle.

Copyright American Welding Society

32
60"
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FIGURE 61 1 - FIGURE 61-2

Start -

FIGURE 61-3 FIGURE 61-4

FIGURE 61-5

NAME POSITION
Pipe weld Horizontal
ELECTRODE DIAMETER AMP ERAGE
E-601O '/0" 25-125 DCEP
or
E-6011 '/e" 75-1 25 AC or DCEP

Copyright American Welding Society

Procedure 61

Welding Pipe in the 26 Test Position, with

Its Axis in the Vertical Position (E-6010 or
El601 1 Electrodes)

OBJECTIVE carry the arc onto the lower beveled surface. When
you return to the keyhole, wash the metal into the
Upon completion of this lesson you should be able to root, then pause just long enough to fill the keyhole
weld pipe in the 2G position with E-601O or E-601 1 and reopen it again.
electrodes. 10. Make sure that you hold a long arc when starting a
new electrode. This heats the metal where you left
off welding so that you get the desired penetration
Text Reference: Section 111, Lesson 7C; page 259. when you enter the keyhole. You must obtain 100
percent penetration at these connections. Otherwise,
you will leave voids or unwelded spaces. These will
PROCEDURE cause a weld to fail in service or during the testing
procedure.
1. Prepare the pipe and fit and tack. 11. Clean the root pass thoroughly. Then run a stringer
2. Secure the pipe so its axis i s vertical as in Figure wide enough to cover the root pass. Make sure
61-1. the weld toes are fused properly to prevent slag
3. Adjust the welding current. inclusions or undercut.
4. Once the test has started the pipe may not be moved 12. The next pass consists of stringers 3 and 4 as shown
for any reason until the welding is completed. This in Figure 61-5. These two stringers will be similar
is standard procedure when taking tests of this type. to those used in welding plate in the horizontal
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

5. Place the electrode in the holder, at a 90- or 45- position. Weld the lower stringer first.
degree angle, as in Lesson 78.
6. The work angle of the electrode should be about Remember: Only two-thirds of the lower stringer
5 to 10 degrees below center of the joint as in should be visible when the pass is completed.
Figure 61-2.
i. Use a slight drag angle of 5 to 10 degrees from the 13. The last pass consists of stringers 5, 6, and 7 as
axis of the pipe as shown in Figure 61 -3. shown in Figure 61-5. If you used heavy beads on
8. Strike an arc and get a keyhole started. If the upper the previous passes, this pass may not be necessary.
root face burns away excessively, decrease the elec- 14. Apply the three stringers as in horizontal plate weld-
trode work angle. You can do this by raising your ing. Be careful to avoid undercut on the top edge.
hand and reducing the angle. You can use a slight push angle on the last stringer
9. As shown in Figure 61-4 use the whipping motion to if undercut is a problem.

Copyright American Welding Society

3--

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32
60"

FIGURE 62-1 FIGURE 62-2

' 1 Wagon tracks (voids or

slag not removed by
the "hot pass")

of travel
' L Wagon tracks burned
out by properly applied
hot pass

FIGURE 62-3 FIGURE 62-4

FIGURE 62-5

\]AME
Pipe weld
I POSITION
Horizontal
!LEORODE DIAMETER AMPERAGE
E-601O ven 75-125 DCEP
or
E-6011 l/e" 75-125 AC or DCEP
E-7018 '/e. 115-1 65 DCEP
4ATERIAL
2 pcs. 4" or 6" schedule 40 pipe
'ASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

Copyright American Welding Society

Procedure 62

Welding Pipe in the 26 Test Position, with Its

Axis in the Vertical Position (E16010 or
E1601 1 and El7018 Electrodes)

OBJECTIVE 8. Clean the weld area thoroughly. Change over to the

E-7018 electrode. Increase the amperage slightly as
Upon completion of this lesson you should be able to recommended and try the arc on scrap metal.
weld pipe in the 2C position using E-6010 or E-60îf 9. Strike an arc. Change to a drag angle of 5 to 15
electrodes for the root pass, and E-7018 electrodes for degrees, but use the same work angle as in Figure 62-
the fill pass. 2. Hold a short arc and do not whip out of the
puddle. just move the electrode along at a steady
rate and pull the puddle with it.
Text Reference: Section Ili, Lesson 7C; page 260.
10. The electrode may be oscillated, or moved slightly
within the confines of the puddle. Keep the oscilla-
tions to a minimum, however.
PROCEDURE 11. This second pass is a stringer bead. Pay close atten-
tion; keep the crater deep enough and hot enough
1. Prepare the pipe and fit and tack. to fuse the sides of the joint and the root pass thor-
2. Adjust the welding current. oughly. Welders sometimes call this “burning out the
3. Secure the weldment in the 2C position as shown wagon tracks” with the “hot pass.” This is illustrated
in Figure 62-1. in Figure 62-4.
4. Place the E-6010 or E-601 1 electrode in the elec- 12. Clean the weld thoroughly. Paying close attention to
trode holder at a 45-degree angle. removing any slag that may remain at the toes of the
5. Assume a comfortable position. Lean against the pipe weld. Cover this pass with at least two more stringers
or balance yourself. as in Figure 62-5.
6. Strike an arc on the beveled surface and move 13. Clean each pass carefully. Be sure to hold normal
quickly down into the root gap. Hold the elec- arc lengths on restarts. The arc should be struck Yz
trode with a 20- to 30-degree drag angle and a 0- in. ahead of the crater and slowly moved back to
to 10-degree work angle, upward into the root, as the crater. This will reweld the arc strike areas as the
shown in Figures 62-2 and 62-3. weld progresses.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
7. Obtain penetration and complete the root pass. Hold 14. The last stringer is critical. Watch the upper left-hand
a long arc on restarts. Be sure to “burn in” when edge of the puddle to be sure that you are filling in
making the connection. all undercut.

Copyright American Welding Society

60"

FIGURE 63-1 FIGURE 63-2

Side 2
B root opening-7I_ r$! reinforcement

5- angle

drag angle T-g reinforcement

FIGURE 63-3 FIGURE 63-4

NAME
Pioe weld
I POSITION
Horizontal fixed
ELECTRODE
E-601O
or
DIAMETER
'/aR I AMPERAGE 75-125 DCEP
E-6011 '/aR 75-1 25 AC or DCEP
MATERIAL
2 pa. 4" or 6" schedule 40 pipe
2 soacers Hz"X W" X 6"
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 63

W e l d i n g Pipe in the 5 6 Position Uphill Passes

(E-60 1O or E-60 1 1 Electrodes)

OBJECTIVE Remember: Maintain the slight push angle until you

reach between the 1 and 2 o’clock position. At this point
Upon completion of this lesson you should be able to switch to a 5- to 15-degree drag angle, continue welding
weld pipe in the 5-G position. until 12:30 as in Figure 63-3.

Text Reference: Section III, Lesson 7D; page 261. 11. Clean and inspect the weld. Move to side two of
the pipe. (See the weld progression shown in
Figure 63-2.) Now make the second bead.
PROCEDURE
1. Prepare, fit, and tack the pipe. Remember: Hold a long arc when overlapping starts
2. Secure the pipe in the 5G (horizontal fixed) position and stops on the first bead. Clean and inspect the second
as in Figure 63-1. Choose a height that will allow you bead.
to reach the top and bottom of the joint comfortably.
3. Adjust the welding current. 12. Return to side two. Start the second pass (third bead)
4. Place the electrode in the holder at a 90- or 45- by welding uphill as shown in Figure 63-2. Use the
degree angle, whichever is more comfortable for weave method. You can start by moving the elec-
you. trode from side to side; then continue unless the
5. Get into as comfortable position as possible. Lean puddle becomes too fluid. If that is the case, switch
your shoulder or upper arm against the pipe. to the triangle motion. The triangle motion may be-
6. Strike an arc on the bottom beveled surface at about come necessary in the area of 8 to lO o’clock. Main-
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

the 6:30 position. Weld counterclockwise through tain the electrode drag and push angles as shown in
the 6 o‘clock position, up the side one of the pipe. Figure 63-3. Clean and inspect the bead.
This i s shown Figure 63-2. 13. Move to side one. Start bead four and complete the
i. Use an electrode work angle of 90 degrees and a second pass. Hold a long arc on the starts and stops.
drag angle of about 5 to 15 degrees as shown in Clean and inspect the completed pass. See the bead
Figure 63-3. sequence shown in Figure 63-4.
8. Maintain a constant drag angle. Hold a close arc, 14. Start the final (cap) pass on side two. Begin at ap-
similar to the drag technique, but without the elec- proximately 6 o’clock and weld uphill to 12 o’clock
trode touching the pipe. Keep the arc visible while using the weave technique. Keep the weld width
you whip the bead uphill toward 5 o’clock. Keep the complete and the reinforcement to a minimum. (See
keyhole open. Figure 63-4.)
9. At slightly past 5 o‘clock switch from a drag to a 5- 15. Weld side one of the cap pass. Make sure to overlap
to 15-degree push angle. Continue to weld upward at 6 and 12 o‘clock.
as shown in Figure 63-3. 16. Clean and examine your weld for undercut, gas
io. Use the same whipping technique as in vertical pockets, slag holes on the surface, penetration,
welding of the grooves in plate. width, and reinforcement.

Copyright American Welding Society

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

JQ?
ofAxis
pipe

FIGURE 64-1
-
32
60"

FIGURE 64-2
Side 1

&' root opening -1k I

typ. reinforcementJ

FIGURE 64-4

VAME POSITION
Pipe weld Horizontal fixed
ELECTRODE
E-601O
DIA M ETER
lha
I AMPERAGE
75-125 DCEP

UATERIAL
lha
1/81 I 75-1 25 AC or DCEP
115-1 65 DCEP

2 pcs. 4" or 6" schedule 40 pipe

2 spacers %6" X 5/8" X 6"
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

Copyright American Welding Society

Procedure 64
W e l d i n g Pipe in the 5 6 Position First Pass
Downhill (El6010 or E l 6 0 1 1 Electrodes)
Second a m d Out Uphill (E17018Electrodes)

OBJECTIVE drag angle. As shown in Figure 64-3, weld downhill.

7. Stop just past 6 o?clock, as shown in Figure 64-2.
Upon completion of this lesson you should be able to Clean the bead and move to side two. Complete
weld pipe in the 5G position. the second downhill root pass. Be sure to properly
overlap the first bead.
8. Second pass and out use E-7018 low hydrogen elec-
Text Reference: Section III, Lesson 70; page 262.
trodes. Use a drag angle of 1O to 15 degrees. Start
the third bead somewhere near 5 to 7 o?clock, taking
care to overlap and tie in the connection between
PROCEDURE the two root beads. Weld upward on side two. Use
a slight weave. Take care not to leave the puddle or
1. Prepare and fit the pipe as in previous lessons. oscillate excessively.
2. Secure the pipe in the 5G (horizontal fixed) position 9. As the weld passes 7 o?clock, gradually change from
as in Figure 64-1 at a comfortable welding height, to a drag angle of O to 5 degrees. Continue until 10
reach the top and bottom of the joint. o?clock is reached. Then switch to a drag angle of
3. Adjust the welding current. 1O to 1 5 degrees. Stop at about 12 o?clock.
4. Place the electrode in the holder at a 90- or 45- 10. Clean and move to side one. Weld the fourth bead
degree angle, whichever is more comfortable for uphill. Hold a long arc on the starts and stops to
you. make good tie in connections.
5. As in lesson 63, get into as comfortable position as 11. After cleaning use uphill beads to weld the finish
possible. Strike an arc on the beveled surface. Begin , pass. Start on side one. Do not weave the pass
at about 11:30 position as shown in Figure 64-2. any wider than Y32 in. past the edge of the bevels.
Weid clockwise, using the downhill technique as As shown in Figure 64-4 keep the reinforcement
shown in Figure 64-3. to approximately Y32 in. Beads with low hydrogen
6. Keep the electrode work angle at 90 degrees to electrodes should be no wider than three electrode
the surface of the pipe. The drag angle should be diameters. If the groove i s wider than this, it would
from 10 to 25 degrees, depending on the amount of be better to finish the joint with stringers.
penetration you obtain. if the drag angle is too large, 12. Cool and clean the completed weld. Examine for
stop and increase your amperage. This will give you undercut, surface defects, bead shape, width, and
more penetration and reduce the required electrode appearance of the weld and reinforcement.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

60"

FIGURE 6s-1 FIGURE 65-2

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
10-25" drag angle
, j t ra tS

S
Direction

FIGURE 65-3
Q P
1
W
Side 1 6 root opening -It+

typ. reinf0rcement-J

FIGURE 65-4
I

NAME POSITION
Pipe weld Horizontal fixed
ELECTRODE DIAMETER AMP E RAGE
E-601O Ihn
E-6011 V8"
E-601O 5/31"
E-6011 5/32"

MATERIAL
2 pcs. 4" or 6" schedule 40 pipe
2 macers %6" X Va" X 6" ___

PASSES BEAD TIME (SEE INSTRUCTOR)

Multiple Weave

Copyright American Welding Society

Procedure 65
Welding Pipe in the 5 6 Position Downhill
Passes (El601O or E1601 1 Electrodes)

OBJECTIVE 6. Clean the bead and weld side two of the root pass
as shown in Figure 65-2. Be sure you are obtaining
Upon completion of this lesson you should be able to the correct melt through or penetration.
weld pipe in the 5C position. 7. Start the second pass at the top of side two. The
electrode angles remain the same as on the root
Text Reference: Section 111, Lessson 70; page 263. pass, except the drag angle can be reduced to zero
between 7 o’clock and the bottom on side two, and
5 o’clock and the bottom on side one.
PROCEDURE 8. Clean weld bead three and complete the second
pass by welding bead four on side one as in Fig-
1. Prepare and fit the pipe as in previous lessons. ure 65-2. Be sure to overlap at the start and stop.
2. Secure the pipe in the 5G (horizontal fixed) position, 9. Clean the second pass thoroughly, then examine
as shown in Figure 65-1. Use a comfortable height it for evenness of deposit. You should have de-
so you can reach both top and bottom of the joint. posited the same amount of weld metal through-
3. Adjust the welding current. out the entire joint. Then finish off with a cap pass
4. Place the electrode in the holder at a 90- or 45- using the E-6010 or E-6011 X2 in. electrode. (See
degree angle, whichever is more comfortable for Figure 65-4.)
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you. 10. Frequently the weld i s shallow between 2 to 4 and

5. Assume a comfortable welding position. Drag the 8 to 10 o‘clock. Then, as shown in Figure 65-2, you
first pass downhill, on side one. Weld from 11:30 to must run short beads between these points. These
approximately6 o’clockand asshown in Figures 65-2 extra beads are shown as 3r/, and 4i/2 in Figure 65-2.
and 65-3. Maintain a 90-degree workangle and 10- to These beads will allow you to weld a uniform finish
25-degree drag angle. pass around the entire joint.

Copyright American Welding Society

20-30" drag

Side 2 9 Side 1
Direction
of travel
7 6 5
3"
52 stop
60'

FIGURE 66-1 FIGURE 66-2 FIGURE 66-3

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Reinforcement

FIGURE 66-4 FIGURE 66-5

NAME POSITION
Pipe weld 45 degree incline 6G
I ELECTRODE
E-601O
DIAMETER
1/8" I 75-125 DCEP
or
E-6011 '/a" 75-125 AC or DCEP
MATERIAL
2 pcs. 4" or 6" schedule 40 pipe
2 spacers Kz"X Van X 6"
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

Copyright American Welding Society

Procedure 66
Welding Pipe in the 66 Position Downhill
Passes (E16010 or E1601 I Electrodes)

OBJECTIVE the electrode is inside the joint, a harsh sound i s

heard. This sound i s the best indication that you are
Upon completion of this lesson you should be able to obtaining penetration.
weld pipe in the 6G position. 11. When you reach the end of the root opening at the
bottom of the pipe, pull out to a normal arc length.
Continue to weld until you overlap the first bead at
Text Reference: Section III, Lesson 7E; page 265. least Y4 in.
12. Clean the pass thoroughly before you start the sec-
ond, or "hot pass." (Use your chipping hammer, the
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

PROCEDURE saw blade, and wire brush.) Begin on side one. Start
welding somewhere between 12 and 1 o'clock. Be
1. Prepare and fit the pipe as in previous lessons. sure to stagger the starts and stops.
2. Secure the pipe in the 6G position as shown in 13. For the hot pass, and all other passes, the electrode
Figure 66-1. Use a height that is comfortable for you drag angle should be between 10 to 20 degrees.
to reach. Also, you should always aim the electrode at a point
3. Adjust the welding current. slightly off the center of the pipe as in Figure 66-2.
4. Place the electrode in the holder at a 90-degree This amount of electrode angle tends to push the
angle. molten pool in the direction you wish. it also gives
5. Position yourself as in previous lessons. you better control of the weld deposit.
6. Strike the arc on the beveled surface of the joint, 14. The hot pass not only deposits filler metal, it "burns
between 11:30 and 12 o'clock. Use a drag angle of out" any trapped slag in the toes of the root pass.
20 to 30 degrees to the surface of the pipe as shown Make sure you set the current high enough so the arc
in Figure 66-2. Maintain this angle for the entire first melts the crown of the root pass. When the puddle
pass. is concave and fluid, you probably are obtaining a
7. Maintain a work angle between O to 10 degrees off good bead. Use a slight weaving motion as shown
the perpendicular as shown in Figure 66-3. The angle in Figure 66-4.
you use will be determined by the way the root faces 15. Do not pause as long at the joint sides as in uphill
melt. Both root faces may melt evenly, or one may welding. Pausing will cause the center of the weld
tend to melt faster and burn away. If one face melts to sag; however, you should pause long enough to
faster, angle the electrode toward it. This forces weld fuse the toes of the joint properly.
metal into the area so the joint may fuse uniformly. 16. Repeat this on side two. Remember to overlap at
8. As you weld keep a constant pressure on the elec- least Y4 in. at the start and end of the preceding pass.
trode. Keep lowering your hand and the electrode 17. The next pass will be comprised of two stringer
holder. This maintains the proper drag angle as the beads as shown in Figure 66-5. Run the first one on
electrode burns away while you move along the the lower part of the joint. Use the same electrode
changing contour of the pipe. Do not burn the elec- manipulation as you used for the hot pass.
trode any shorter than 2 % to 3 in. it may overheat 18. Do not start both stringers at the same point.
and cause the electrode to stick to the joint. Stringers must start and stop on a staggered basis.
9. Before starting a second electrode the completed Watch out for undercut on the upper stringer.
portion of the weld should be thoroughly cleaned. 19. Clean the pass completely. Finish the joint with a
One electrode should be enough for you to com- three stringer cap pass as shown in 66-5.
plete the first pass, from 11:30 to 6:30.
1o. Start the second half of the root pass on the opposite The number of passes required to complete the pipe
side of the pipe, side 2. Overlap the first bead by joint depends on the wall thickness and size of the
approximately % in. Hold a long arc until the root stringers. Sometimes you can complete the joint by de-
opening is reached. Then force the electrode gently positing a root pass, a hot pass, and a cap pass of two
into the joint until the arc almost disappears. When stringers.

Copyright American Welding Society

Side 2
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60"

FIGURE 67-1 FIGURE 67-2 FIGURE 67-3

FIGURE 67-4 FIGURE 67-5

NAME POSITION
Pipe weld 45 degree incline 6C
ELECTRODE
E-601O
or
E-6011
DIAMETER
Va"

'/a"
I AMPERAGE
75-125 DCEP
75-1 25 AC or DCEP
E-7018 w 115-116 DCEP
MATERIAL
2 pa. 4" or 6" schedule 40 pipe
2 spacers '116" X Va" X 6"
PASSES BEAD TIME (SEE INSTRUCTOR) ,

MUkiDk Weave

Copyright American Welding Society

t Procedure 67

Welding Pipe in the 643 Position First Pass

Downhill (E-6010 and E-601 1 Electrodes),
Second and Out Uphill (E-7018 Electrode)

OBJECTIVE hydrogen electrode puts more filler metal in the de-

posit than E-601O or E-601 l electrodes. This means
Upon completion of this lesson you should be able to it will take fewer passes to fill the joint.
weld pipe in the 6G position. 7. Start the second pass near the bottom of the pipe,
between 5 and 6 o’clock. Run a stringer bead toward
the top of side 2. Use a slight weaving motion as
Text Reference: Section III, Lesson 7E; page 266. shown in Figure 67-4. Do not oscillate the electrode
excessively. Do not whip or remove the electrode
from the puddle at any time. Use an electrode drag
PROCEDURE angle of O to 5 degrees.
8. Clean the bead thoroughly, using the slag hammer
1. Prepare and fit the pipe as in previous lessons. and wire brush. Remember that the slag formed by
2. Secure the pipe in position as shown in Figure 67-1. low hydrogen electrodes is difficult to remove. It is
3. Adjust the welding current. almost impossible to burn out with the next pass.
’ 4. Drag the first pass with E-6010 or E-601 1 electrodes.
Make sure to use the electrode angles indicated in
9. Weld the other side of the pipe. Be careful of the
overlap at both the start and stop. Follow the bead
Figures 67-2 and 67-3. sequence shown in Figure 67-5.
5. Clean the first pass thoroughly, then switch to E- 10. The finish pass is run with stringer beads three and
7018 electrodes. Adjust your amperage on scrap four. The lower stringer should be welded first. Use
plate. the same electrode angles and electrode motion as
6. The iron powder in the coating of the E-7018 low before. Be sure to stagger the starts and stops.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

W e l d i n g of
Carbon Steel
In the following procedures you will develop your skills in gas tungsten arc welding.
You will learn the fundamental techniques by welding on carbon steel. Carbon steel is
readily available and is considerably less expensive than stainless steel or aluminum.
In later sections, you will weld aluminum, using much of what you learned on
carbon steel. If you master gas tungsten arc welding of carbon steel and aluminum,
you will be able to weld other materials with just a little additional instruction and
practice.

GENERAL INSTRUCTIONS
The welding procedures will specify amperage ranges. If your equipment has re-
mote amperage control foot pedal capabilities you may wish to use it, however, it is
not required. You will find many cases in industry where foot pedals cannot be used
because of the position or size of the weldment. It would be good to practice welding
without remote current control so you will be better prepared for these situations.
High frequency will be specified for ease in starting the arc. The arc can be initiated
by using a touch start technique, but this i s not a preferred method since it often
results in causing a small portion of the end of the tungsten to break off and remain in
the weld. The type of torch you use will depend on the equipment available in your
shop. Air-cooled torches are limited in capacity. Water-cooled torches are preferred.

1. Use both hands when welding with filler wire addition, and one foot when using
remote amperage control pedals.
2. Find a comfortable working stance. Remember it is difficult to produce sound
quality welds if you are'in an awkward or uncomfortable position.
3. Hold a short and steady arc. This means holding the torch as steady as possible.
Few of us are steady enough to do that freehand. You should look for some way
to support the hand you use to hold the torch while welding. Hold the torch in a
way that is most comfortable to you. Some hold the torch as they would a pencil,
while others hold it like an electrode holder.
4. Hold the filler wire between your thumb and forefinger with 1 O to 12 in. sticking
out.

MATERIALS AND EQUIPMENT

For this section the material and equipment will be as follows:

1. Welding shield with appropriate filter lens

2. Safety glasses
3. Short cuff leather gloves
4. Appropriate welding clothing
5. Wire brush
6. Pliers 153
Copyright American Welding Society
Provided by IHS under license with AWS Licensee=IHS Subs and Mgrs /IHSINTL003, User=GCN, serPemex
No reproduction or networking permitted without license from IHS Not for Resale, 09/13/2005 16:49:30 MDT
154 GAS TUNGSTEN ARC WELDING PROCESS

FIGURE 68-1 FIGURE 68-2

Too fast, too cold, or both7

ia)

FIGURE 68-4

FIGURE 68-3 FIGURE 68-5

,
NAME POSITION
Pad of stringers Flat
ELECTRODE DIAMETER 1 FILLER WIRE
2% thoriated tungsten %6' 3h" diameter E-70s-3
(pointed) or
V32"

MATERIAL
1 pc. V4" X 3" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

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Copyright American Welding Society

Procedure 68
Running a Flat Pad of Stringers

OBJECTIVE holding the torch in such a manner that you can roll
the torch in your hand to contact the workpiece and
Upon completion of this lesson you should be able to establish an arc.
weld a pad of stringers. 6. Establish a weld puddle holding the torch perpen-
dicular to the plate pointing toward the direction of
Text Reference: Section IV, Lesson 4A; page 308. travel. (See Figure 68-1 .)
i. Bring the filler metal close to the puddle and add the
wire to the front edge of the puddle. (See Figure.68-
PROCEDURE 2.) Be careful not to touch the filler wire to the ,
tungsten. This will cause the wire to melt onto the
1. Adjust the welding current direct current electrode tungsten, contaminating it. If this happens you will
negative, 90 to 150 amperes. High frequency start have to stop and regrind your tungsten.
1O to 15 CFH argon, '/z in. gas cup. 8. Add the filler metal a dab at a time to the leading
2. Grind or sand the surface to be welded to remove edge of the puddle. Move the wire back and move
any mill scale or rust. the torch forward to advance the puddle continu-
3. Position the plate flat. Hold the GTAW torch in your ing this technique to weld a straight bead. (See Fig-
right hand and position the torch just above the plate ure 68-3.) Keep the end of the filler metal within the
on the right-hand side of the plate. Grasp the filler protective gas shield. if you withdraw the filler wire
metal between your thumb and forefinger in your from the gas shield, the hot end will oxidize in the air
left hand, allowing approximately 10 to 12 in. to and cause contaminants to enter the weld puddle.
protrude through your fingers. 9. Continue progressing at an even travel adding filler
4. Energize the torch. This can be done by turning wire regularly to produce a straight bead with even
on the power supply, turning on a torch switch width and height. Use a slight circular motion to
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

or depressing a remote control foot switch. if the spread the puddle and assure that the sides of the
equipment is available use all three techniques to puddle fuse into the base metal. (See Figure 68-4.)
practice starting the arc. in future lessons we will 1O. When you break the arc either to reposition yourself
just say strike the arc. or because you have finished the bead, be sure to
5. Slowly lower the torch and establish an arc. If you keep the torch over the puddle for a period of time
have high frequency it will cross the gap between to allow the postflow gas purge to protect the weld
the tungsten electrode and the workpiece. This will from oxidation while it i s still hot.
allow the current to begin to flow. When the arc i s 11. Continue to weld stringer beads, overlapping the
established the high frequency will stop. if you do beads so that the bead your arc welding covers half
not have high frequency you will have to touch the of the previous bead. (See Figure 68-5.) Cool your
tungsten to the work lightly, then lift the tungsten plate is a quench tank regularly so it does not over-
off to establish an arc. This is best accomplished by heat. Be careful to avoid steam burns.

Copyright American Welding Society

FIGURE 69-1
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FIGURE 69-2

NAME POSITION
Outside corner joint Flat
ELECTRODE DIAMETER FILLER WIRE
2% thoriated tungsten %ln '/I<"
(pointed) or diameter E-70s-3
%ln

MATERIAL
2 pcs. Ve" X 1 %" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single String

Copyright American Welding Society

Procedure 69
Outside4orner Jolnt, IC Position

OBJECTIVE adding filler wire to the leading edge of the puddle.

Since the GTAW arc does not transfer metal, it is not
Upon completion of this lesson you should be able to too difficult to form the keyhole. if you use the cor-
weld an outside-corner joint. rect amperage and add the filler metal properly, you
will find you have a good deal of control over the
weld puddle.
Text Section I", 4A; page 309. 4, As you add the filler metal it will begin to shorten
and your fingers holding the wire will begin to get
close to the arc. When it becomes necessary to get
PROCEDURE another hold on your filler wire, break the arc keeping
the torch with its postpurge gas flow over the cooling
1. Adjust the welding current direct current electrode weld puddle, while keeping the end of the wire also
negative, 50 to 100 amperes. High frequency start, in the gas purge. This protects the end of the wire
1O to 15 CFH argon, % in. gas cup. from oxidation.
2. Grind or sand the surfaces to be welded. Tack the 5. Extend the wire again 10 to 12 in., strike an arc,
pieces together and position them as shown in Fig- establish a puddle, and begin adding the wire to the
ure 69-1. lead edge of the puddle.
3. Beginning at the right side of the joint use the torch 6. Remember to dab the wire into the puddle. Do not
angles shown in Figure 69-2 and strike an arc. Es- continuously feed it. Doing so can lead to porosity,
tablish a keyhole for complete penetration and begin lack of fusion, and slag entrapment.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

FIGURE 70-1
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FIGURE 70-2

FIGURE 70-3 FIGURE 70-4

NAME POSITION
Fillet weid Flat
~ ~~

ELECTRODE DIAMETER FILLER WIRE

2% thoriated tungsten %Zu 1/16.
(pointed) or diameter E-70s-3
~~~~~ ~

MATERIAL
1 pc. 1%" X l/a" X 8"carbon steel
1 pc. 3" X */au X 8" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 70

T=Joint Fillet, 1F Position

OBJECTIVE 4. Strike an arc and establish a puddle. Make sure the

side walls melt down to the root of the T. Because
Upon completion of this lesson you should be able to the side walls are nearer to the electrode than the
weld flat fillets. root of the joint, the arc will go to the side walls and
cause them to melt before the root of the joint does.
Text Reference: Section IV, Lesson 4A; page 31O. If you begin to add filler metal before the root of the
joint is molten the weld will bridge the joint and not
penetrate to the root. (See Figure 70-3.)
PROCEDURE 5. Add the filler wire in a dabbing motion, advancing
the torch when you withdraw the filler metal. When
1. Adjust the welding current direct current electrode you do this, you advance the puddle and prepare it
negative, 50 to 100 amperes. High frequency start, for the addition of more filler metal.
1O to 15 CFH argon, % in. gas cup.
2. Grind or sand the pieces to be welded. Tack them Remember: When withdrawing the wire keep the
together and position them as shown in Figure 70-1. end in the protective gas shield.
Position the T-base at a 45-degree angle so the weld
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will be applied flat. 6. Complete the bead, cool the assembly and add two
3. Hold the torch perpendicular to the joint pointing more passes as shown in Figure 70-4.
toward the direction of travel about 30 degrees. (See 7. Reposition the T and weld the other side as you did
Figure 70-2.) the first using three beads.

Copyright American Welding Society

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
FIGURE 71 1 -

1 5"

FIGURE 7 1-2

FIGURE 7 1 - 3

VAME
Butt weid
I POSITION
Flat
~

ELECTRODE DIAMETER FILLER WIRE

2% thoriated tungsten YlZ" %6"
(pointed) or diameter E-70s-3
3/.P

MATERIAL
2 pcs. 1 %" X 3" X 6" carbon sted
_ _ _ _ ~~ _ _ _ _ _ _

PASSES BEAD TIME (SEE INSTRUCTOR)

Multiple String

Copyright American Welding Society

Procedure 71
V-Groove Joint, 1 G Position

OBJECTIVE 4. Strike an arc and concentrate it on the root of the

joint. Form a keyhole to ensure penetration and begin
Upon completion of this lesson you should be able to adding filler metal, by dabbing it to the leading edge of
weld butt joints in the flat position. the puddle. Alternate the motion of adding the wire to
the edge of the puddle, then work the puddle forward
with the arc. Hold the torch perpendicular to the joint
Text Reference: Section IV, Lesson 4 4 page 31 1. pointing toward the direction of travel approximately
20 degrees.

PROCEDURE Remember: Every time you break the arc, hold the
arc, hold the torch over the weld to provide shielding while
1. Prepare the Yi in. steel plates by burning, machining, the bead is cooling down.
or grinding a 30-degree bevel on one 6 in. side of
each plate. Grind a 1/16 in. root face on each piece. 5. Thoroughly clean the weld after each bead by wire
2. Adjust the welding current direct current electrode brushing. Continue to weld the joint using the bead
negative, 90 to 150 amperes. High frequency start, sequence shown in Figure 71-3.
15 to 20 CFH Argon, YZ in. gas cup.
Remember: The bead sequence shown is typical.
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3. Tack the pieces together as shown in Figure 71 -1 and

position the plate so it is flat. After tacking, prebow Depending on the actual root spacing, groove angle, and
the plates as shown in Figure 71-2 so the plate will rate of filler wire addition the number of passes may vary
be flat after welding. from those specified.

Copyright American Welding Society

FIGURE 72-2

NAME POSITION
Corner ioint Horizontal
~ ~ ~

ELECTRODE DIAMETER FILLER WIRE

2% thoriated tungsten %2" %6"
(pointed) or diameter E-70s-3
3/32"

MATERIAL
2 DCS. l/8" X 1%" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single String

Copyright American Welding Society

Procedure 72
O u t s i d e 4 o r n e r Joint, 26 Position

OBJECTIVE 4. Keep the torch perpendicular and point toward the

direction of travel approximately 20 degrees. (See
Upon completion of this lesson you should be able to Figure 72-2.)
weld corner joints in the horizontal position. 5. Complete the joint in one pass controlling the height
of the bead by the rate at which you add the filler
Text Referenoe: Section IV, Lesson 4B; page 312. wire, and controlling the penetration by the force of
the arc.
PROCEDURE
Note: The arc has some force and can be used to
1. Adjust the welding current direct current electrode manipulate the weld puddle, increasing the arc length
negative, 50 to 100 amperes. High frequency start, will result in a softening of the arc, reducing the effect on
1 O to 15 CFH argon, % in. gas cup. the puddle.
2. Grind or sand the pieces to be welded. Tack them
together and position them as shown in Figure 72-1.
3. Begin at the right side of the joint and strike an arc. 6. Clean the joint thoroughly and inspect the bead for
When an arc is established form a keyhole in the root smoothness, and evenness of width. Check the root
of the joint. When the keyhole forms begin adding for penetration. If properly done, the root will show
filler metal to the leading edge of the puddle. some weld along its entire length.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

FIGURE 73-1 FIGURE 73-2

FIGURE 73-3 FIGURE 73-4 FIGURE 73-5

FIGURE 73-6

NAME POSITION
Fillet joint Horizontal
ELECTRODE DIAMETER FILLER WIRE
2% thoriated tungsten %ln %b"
(pointed) or diameter E-70s-3
%la

MATERIAL
1 pc. 1 %" X 1 l/a" X 6" carbon steel
1 pc. Va' X 3" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 73
T=Joint Fillet, 2F Position

OBJECTIVE arc to keep the metal up. Point the torch toward the
direction of welding approximately 20 degrees.
Upon completion of this lesson you should be able to
weld fillets in the horizontal position. 4. Add the filler metal from the left side of the puddle at
approximately a 20-degree angle from the flat. (See
Text, Referenoe: Section IV, Lesson 4B; page 313. Figure 73-3.) Be careful as in the flat position to make
sure you penetrate to the root of the joint. If you do
not, you will get lack of penetration. (See Figure 73-4.)
PROCEDURE 5. When the first bead is completed, thoroughly clean it
and deposit two more beads as shown in Figure 73-5.
1. Adjust the welding current direct current electrode When welding bead 2 you will have to favor the
negative, 50 to 100 amperes. High frequency start, bottom plate. Bead 3 will require you to adjust the
10 to 15 CFH argon, % in. gas cup. torch angle to favor the vertical leg of the fillet. (See
2. Grind or sand the pieces to be welded. Tack them Figure 73-6.) Half of bead 2 should cover half of the
together and position as shown in Figure 73-1. first bead with the balance being deposited on the
3. Hold the torch as shown in Figure 73-2. flat portion of the T. Half of bead 3 should cover the
rest of bead 1 with the remainder being deposited on
Note: The angle is changed to favor the vertical plate the vertical leg of the T.
more than the flat plate. This will help to keep the vertical 6. When the first side is completed, cool the T and weld
leg the same size as the flat leg by using the force of the the second side.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
32 -
1

FIGURE 74-1 FIGURE 74-2

W
FIGURE 74-3 FIGURE 74-4

\IAME POSITION
Groove joint Horizontal
!LECTRODE DIAMETER FILLER WIRE
2% thoriated tungsten %I" '/16'
(pointed) or diameter E-70s-3
3/32"

V(ATERIAL
2 pa. %" X 3" X 6" carbon steel
'ASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 74
V-Groove Butt Joint, 26 Position

OBJECTIVE and establish a weld puddle. Watch the puddle until

the root becomes molten. When this occurs begin
Upon completion of this lesson you should be able to adding the filler wire as shown in Figure 74-3 to the
weld horizontal open-root V-groove butt joints. leading edge of the puddle. Use the torch angle and
force of the arc to keep the puddle favoring the upper
plate. Gravity will cause the puddle to flow to the
Text Reference: Section IV, Lesson 4B; page 314. lower plate.
5. Continue to weld the plate using the bead sequence
shown in Figure 74-4.
PROCEDURE
Note: In the horizontal position the weld beads begin
1. Prepare one 6 in. side of each plate with a 30-degree on the bottom plate and serve as a shelf for succeeding
bevel by burning, grinding, or machining. Grind a 1/16 beads. Pay particular attention to interbead cleaning. On
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

in. root face on each piece. occasion, you will observe a smooth glass like deposit on
2. Adjust the welding current direct current electrode the bead. This is silicon and should be removed before
negative, 90 to 150 amperes. High frequency start, depositing another bead. If you do not you can trap this
1O to 15 CFH argon, '/z in. gas cup. in the weld. If that occurs you have a discontinuity called
3. Fit and tack the pieces, and prebow them for weld slag entrapment.
shrinkage as shown in Figure 74-1. Position the plate
as shown in Figure 74-2. 6. Complete the joint, thoroughly clean it, cool it, and
4. Hold the torch so that it points toward the upper plate carefully examine it for complete and even root pen-
at about a 20-degree angle. Point the torch toward the etration. Check the face surface for contour, face re-
direction of welding. (See Figure 74-3.) Strike an arc inforcement, and evenness of beads.

Copyright American Welding Society

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
FIGURE 75-1 FIGURE 75-2

%?"

MATERIAL
2 pcs. Va' X 1 VZ"X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Single String

Copyright American Welding Society

Procedure 75
Outside-Corner Joint, 36 Position

OBJECTIVE 3. Begin at the bottom of the joint and strike an arc.

Hold the torch as shown in Figure 75-2, straight into
Upon completion of this lesson you should be able to the joint and pointing upward slightly in the direction
weld vertical corner joints. of travel. Feed the wire from above into the leading
edge of the puddle. (See Figure 75-2.)
Text Reference: Section IV, Lesson 4C; page 31 5. 4. Use a slight side-to-side weave and progress vertically
up. Make sure you penetrate into the root of the joint.
Build a shelf of weld at the bottom and use it to build
PROCEDURE on. Dab the filler wire into the leading edge of the
puddle.
1. Adjust the welding current direct current electrode 5. Complete the weld, cool it, clean it, and examine
negative, 50 to 100 amperes. High frequency start, it for even root penetration and for evenness and
1O to 15 CFH argon, Ye in. gas cup. smoothriess of the face contour. The contour should
2. Grind or sand the pieces to be welded. Tack them be slightly convex.
together and position them as shown in Figure 75-1.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Top view

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
FIGURE 76-1 FIGURE 76-2

Top view

FIGURE 76-3 FIGURE 76-4

NAME POSITION
Fillet joint Vertical
ELECTRODE DIAMETER FILLER WIRE
2% thoriated tungsten %?" %2" diameter E-70s-3
(pointed)
MATERIAL
1 pc. l h " X 3" X 6" carbon steel
1 pc. lin" X 1 Y?" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 76
T=Joint Fillet, 3F Position

OBJECTIVE the joint causing lack of penetration as we saw in

previous lessons.
Upon completion of this lesson you should be able to 4. Establish a shelf to build your weld on. Use a slight
weld vertical fillets. side-to-side weave and add the filler wire from the
top. (See Figure 76-2.)
5. After the first pass clean it thoroughly and apply a
Text Reference: Section IV, Lesson 4C; page 31 5. second layer consisting of two beads as shown in
Figure 76-3.
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

6. After you have finished the three stringer bead side,

PROCEDURE cool the T and weld the second side using the
weave-bead technique. Weld the first pass as a nor-
1. Adjust the welding current direct current electrode mal stringer bead. Put the second layer in using a
negative, 50 to 1O0 amperes. High frequency start, weave bead, pausing at the sides to ensure the side
1O to 15 CFH Argon, YE in. gas cup. walls are properly fused. Use the weave technique
2. Grind or sand the pieces to be welded. Tack them and bead sequence shown in Figure 76-4. When
together and position them as shown in Figure 76-1. weavimg a bead, the width of the weave should not
3. Using the torch angles shown in Figure 76-2, strike an exceed the size of the cup, in this case Ya in. The
arc at the bottom of the joint. Make sure the puddle weld when finished should be slightly convex. The
extends into the root of the joint before you add filler face should merge smoothly with the base metal at
wire. Failure to do so could result in your bridging the toe of the weld.

Copyright American Welding Society

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
-
32 - 1 '
16

FIGURE 77-1

FIGURE 77-2

A+-J
15"i 15"\
Top view

FIGURE 77-4

FIGURE 77-3

NAME POSITION
Groove joint Vertical
ELECTRODE DIA METER FILLER WIRE
2% thoriated tungsten 3/3zn %6"
(pointed) or diameter E-70s-3
- ~~

3/31"
MATERIAL I
2 pcs. l/4" X 3" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 77

V-Groove Butt Joint, 36 Position

OBJECTIVE 3. Fit and tack the pieces and prebow them for weld
shrinkage, as shown in Figure 77-1. Put a Yz in. tack at
Upon completion of this lesson you should be able to each end. Position the plate as shown in Figure 77-2.
weld vertical grooves. 4. Strike an arc at the bottom of the joint. Melt the tack
and make sure your puddle melts through the plate
Text Reference: Section IV, Lesson 4C; page 31 6. so a small keyhole appears. Use a slight side-to-side
weave on the root to ensure root penetration and
blending of the toe of the weld into the side walls
PROCEDURE of the groove. Use the torch angles shown in Figure
77-3.
1. Prepare one 6 in. side of each plate with a 30-degree 5. Use a stringer-bead technique adding the filler metal
bevel by burning, grinding, or machining. Grind a 1/16 as shown in Figure 77-3. Make sure you fill the crater
in. root face on each piece. completely at the top of the joint. Thoroughly clean
2. Adjust the welding current, direct current electrode the joint between beads being careful to remove any
negative, 90 to 150 amperes. High frequency start, silicon deposit. Complete the joint using the stringer
1O to 15 CFH argon, !h in. gas cup. bead sequence shown in Figure 77-4.
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

FIGURE 78-1
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

FIGURE 78-2

rlAME POSITION
Corner joint Overhead
iLECTRODE DIAMETER FILLER WIRE
2% thoriated tungsten 3/11" %6"
(pointed) or diameter E-70s-3
Y311

VIATERIAL
2 pa. Va" X 1 %" X 6" carbon steel
'ASSES BEAD TIME (SEE INSTRUCTOR)
Single String

Copyright American Welding Society

Procedure 78
Outside-Corner Joint, 4 6 Position

OBJECTIVE 3. Hold the torch in the center of the joint pointing

toward the direction of travel about 20 degrees. (See
Upon completion of this lesson you should be able to Figure 78-2.)
weld overhead-corner joints. 4. Strike an arc and establish a puddle making sure
the puddle penetrates to the root of the joint. Begin
Text Reference: Section IV, Lesson 4D; page 31 8. adding filler metal as shown in Figure 78-2, to the
leading edge of the puddle. Keep the travel speed
and filler wire addition even to produce a bead with
PROCEDURE even width and build up.
5. Continue to the end of the joint. Cool the joint, clean
1. Adjust the welding current direct current electrode it, and examine it for evenness of the width. Examine
negative, 50 to 100 amperes. High frequency start, the face for smoothness and contour. The surface
10 to 15 CFH argon, Ye in. gas cup. should be slightly convex.
2. Grind or sand the pieces to be welded. Tack them
together and position them as shown in Figure 78-1.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

+<GTAW

FIGURE 79-1
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

10-15"
I

- Direction of travei

FIGURE 79-2 FIGURE 79-3

NAME POSITION
Fillet joint Overhead
ELECTRODE DIAMETER FILLER WIRE
2% thoriated tungsten Ha" %6"
(pointed) or diameter E-70s-3
%ln

MATERIAL
1 pc. %" X 1 %" X 6" carbon steel
1 pc. %" X 3" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 79
T-Joint Fillet, 4 W Position

OBJECTIVE pointing toward the direction of travel approximately

20 degrees. (See Figure 79-2.)
Upon completion of this lesson you should be able to 4. Strike an arc and establish a puddle. Make sure the
weld overhead fillets. puddle reaches into the root of the joint When you
begin to add filler metal as shown in Figure 79-2, use
the force of the arc to keep the metal on the overhead
Text Reference: Section IV, Lesson 4D; page 3 18. plate. Gravity will cause some metal to flow down on
the vertical part of the T. By varying the angle of the
torch you can control the leg length of the fillet.
PROCEDURE 5. Complete the first pass, cool the T assembly and thor-
oughly clean it. Add another layer consisting of two
1. Adjust the welding current, direct current electrode beads. You will have to change the torch angle for
negative, 50 to 100 amperes. High frequency start, each bead. For bead two the torch will be concen-
10 to 15 CHF argon, Ya in. gas cup. trated on the overhead plate. For bead three the torch
2. Grind or sand the pieces to be welded. Tack them must be concentrated on the vertical plate. (See Fig-
together and position them as shown in Figure 79-1. ure 79-3.)
3. Find a comfortable position, supporting the torch and 6. When you have completed the three beads, cool the
point it into the joint favoring the upper plate. Hold T assembly, clean it, and weld the other side with a
the torch at about 60 degrees from the plate and three bead fillet.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Y"Y
16

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
&
, <GTAW

FIGURE 80-2 FIGURE 80-3

FIGURE 80-4

NAME POSITION
Groove joint Overhead
ELECTRODE DIAMETER FILLER WIRE
2% thoriated tungsten Y3ZD 1/16"
(pointed) or diameter E-70s-3
I KI"
MATERIAL-
2 pa. Ve" X 3" X 6"carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

, Proeedure 80
V=Groove Butt Joint, 4 6 Position

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OBJECTIVE 4. For the root pass, position the torch perpendicular to
the joint, pointing toward the direction of travel. (See
Upon completion of this lesson you should be able to Figure 80-3.) As in the previous lessons, some support
weld overhead grooves. should be provided for the torch holding hand. This
can consist of nothing more than extending a few
fingers on that hand and having them rest on the
Text Reference: Section IV, Lesson 40; page 31 9. plate you are about to weld on. Another method
of providing support for the torch is to adjust the
tungsten stick out, so that you can rest the cup on
PROCEDURE the plate. This will work when you are down in a
groove but does not work when you are reinforcing
1. Prepare one 6 in. side of each plate with a 30-degree the joint. Another drawback is that it makes it more
bevel by burning, grinding, or machining. Grind a 1/16 difficult to see the weld puddle.
in. root face on each piece. 5. Strike an arc and establish a keyhole: add filler metal
2. Adjust the welding current, direct current electrode as shown in Figure 80-3. It may be necessary to weave
negative, 90 to 150 amperes. High frequency start, the torch slightly to ensure good fusion between the
15 to 20 CFH argon, 'h in. gas cup. toe of the weld and the side wall of the groove.
3. Fit and tack the pieces and prebow them for weld 6. Add a second and third layer consisting of stringer
I shrinkage, as shown in Figure 80-1. Put a 'h in. tack beads as shown in Figure 8-4.
on each end. Position the plate as shown in Figure
80-2. Note: The torch angle changes with each bead.

Copyright American Welding Society

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G a s Tungsten Arc
W e l d i n g of Aluminurn
In the following procedures you will apply to aluminum what you have learned
about gas tungsten arc welding of carbon steel.
We will use the movements and motions we have learned and add some new
skills to weld aluminum.
One of the major differences will be the type of current we will use. In the previous
procedures, direct current electrode negative with a high frequency start was used
to weld carbon steel. Aluminum i s welded using alternating current with continuous
high frequency. The continuous high frequency serves the purpose of creating a more
stable arc as the current flow reverses direction.

GENERAL INSTRUCTIONS
These procedureswill specify argon as the shieldinggas. Helium may be used; however,
higher gas flows are required, and the arc is not as stable as when using argon. Follow
these general instructions for the procedures in this section:

1. Aluminum, to be properly welded, must be cleaned immediately prior to weld-

ing. The oxide formed on the surface of aluminum makes it extremely difficult to
achieve a satisfactory weld. The surface can be cleaned chemically, or mechani-
cally, by sanding, grinding, or wire brushing. If wire brushes are used, they should
be made of stainless steel to prevent iron contamination.
2. When welding aluminum with the gas tungsten arc welding process use a pure
tungsten electrode with a balled end. The end can be balled by inserting into the
GTAW torch a blunt tungsten electrode.
3. With the power supply set on direct current electrode positive, turn on the current
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

and gradually increase the amperage. A ball will begin to form on the end of the
electrode.
4. When the ball is correctly formed, turn off the current and change over the power
supply to alternating current for welding aluminum.

MATERIALS AND EQUIPMENT

Personal equipment called for i n this section consists of:

1. Welding shield with appropriate filter lens

2.
3.
4.
Safety glasses
Short cuff leather gloves
Appropriate welding clothing
5. Stainless steel wire brush
6. Pliers 9
181
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182 GAS TUNGSTEN ARC WELDING PROCESS

fEEEE?I
FIGURE 8 1 1 -

.(AME POSITION
Pad of stringers Flat
:LEORODE DIAMETER FILLER WIRE
Pure tungsten (balled) 1/88 %
6
'
or diameter ER-4043
V,P

AATERIAL
1 DC. V4" X 6" X 6" aluminum
~

'ASSES BEAD TIME (SEE INSTRUCTOR)

Multiple String

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 8 1
Running a Flat Pad of Stringers

OBJECTIVE 3. Aluminum will not show a lot of color as it melts

because of its low melting point. When a puddle i s
Upon completion of this lesson you should be able to developed it will appear very shiny.
weld in the flat position. 4. When you have established the puddle, begin adding
the filler metal to the leading edge of the puddle. After
you have added filler metal withdraw it from the arc
Text Reference: Section IV, Lesson 5A; page 322. but keep it within the protective gas envelope. The
hot filler wire will oxidize very rapidly if exposed to
the atmosphere. Be careful not to hold the filler metal
PROCEDURE too close to the arc. Because of its low melting point,
a large globule will form very quickly on the end of
1. Adjust the welding current, alternating (AC) continu- the wire if it is allowed to remain near the arc.
ous high frequency 175 to 210 amperes, 20 to 25 5. Run stringer beads the length of the plate overlapping
CFH argon, %? in. gas cup. them with the last weld covering one-half of the first.
2. Begin at the right side of the plate and strike an arc. (See Figure 81-1 .)
The arc will have a buzzing sound, unlike the silence 6. Be sure to fill the crater every time you break an
of a direct current arc. arc. Hold the torch over the weld end for 15 to 20
seconds after you extinguish the arc to protect the
Note: The area on the aluminum where the arc con- hot weld from being exposed to the atmosphere.
tacts the plate changes in appearance. This change i s a 7. Cool the plate frequently during welding to retain
result of the arc cleaning action. Regardless of how well more control over the puddle. Examine every bead
you have cleaned the metal the arc will further clean the for even bead width, good bead contour, and smooth
surface. surface.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

*GTAW A

FIGURE 82- 1

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
FIGURE 82-2

~ ~~

NAME POSITION
Fillet Flat
ELECTRODE DIAMETER FILLER WIRE
Pure tungsten (balled) %Zu 1/16"
or diameter ER-4043
%2"

MATERIAL
1 pc. lh" X 1'h" X 6" aluminum
1 pc. l h a X 3" X 6" aluminum
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 82
T=Joint Fillet, 1F Position

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
OBJECTIVE the arc exactly where you want it. Alternating current
will radiate from the surface of the ball on the end of
Upon completion of this lesson you should be able to the.tungsten and will arc to the closest siirface. (See
weld flat fillets. Figure 82-2.)

Text Reference: Section IV, Lesson 5A; page 322.

Note: Distance A i s closer to the electrode than dis-
tance B, therefore the arc will be drawn across the short-
est distance and will establish a puddle on the side wall
PROCEDURE at point A before the root (point B) melts.
1. Adjust the welding current, alternating (AC) continu-
ous high frequency, 125 to 160 amperes, 20 to 25 4. Begin adding the filler wire to the leading edge of
CFH argon, Ya in. gas cup. the puddle. Be careful not to get the wire too close to
2. Clean the pieces, tack them together, and position the electrode or it will melt onto the tungsten. This
them as shown in Figure 82-1. It may be necessary contaminates the tungsten and will require it to be
to add filler metal to make the tack. dressed before further use.
3. Strike an arc on the right side of the T assembly 5. Continue to the end of the joint applying a single pass
and establish a puddle. Make sure the joint becomes fillet, cool the plate, and put a single pass fillet weld
molten to the root of the joint. This will not be as easy * on the other side.
as it was when using direct current. The concentrated 6. Cool the plate and examine it for bead appearance,
arc of direct current allows you to direct the heat of leg length, and undercut at the toe of the weld.

Copyright American Welding Society

GTAW

FIGURE 83-1
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

- Direction of travel

FIGURE 83-2

1 NAME
Groove
POSITION
Flat
.
- ~~

ELECTRODE DIAMETER FILLER WIRE

Pure tungsten (balled) '/a" 'h6"
or diameter ER-4043
./JI"
1 MATERIAL
2 DCS. 1 h R X 3" X 6" aluminum
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 83
Square=GrooveButt Joint, 1 6 Position

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
OBJECTIVE 2. Clean the pieces, tack them together, and position
them as shown in Figure 83-1.
Upon completion of this lesson you should be able to 3. Strike an arc and establish a keyhole. When the key-
weld flat butts. hole is formed begin adding filler wire to the leading
edge of the puddle. (See Figure 83-2.) Pay attention
to the penetration and bead width.
Text Reference: Section IV, Lesson 5 4 page 323.
4. Progress from the right to the left. As you progress the
plate will heat up causing the puddle to get larger. You
can control this by either decreasing the amperage or
PROCEDURE increasing your travel speed.
5. Complete the joint, cool it and examine it for face ap-
1. Adjust the welding current, alternating (AC) continu- pearance and toe undercut. The penetration through
ous high frequency 175 to 210 Amperes, 20 to 25 the joint should be complete with even width and
CFH argon, ?h in. gas cup. root reinforcement.

Copyright American Welding Society

FIGURE 84-1

<
Direction of travel

FIGURE 84-2

4AME POSITION
Fillet Horizontal
[LECTRODE DIAMETER FILLER WIRE
Pure tungsten (balled) '/31" '/isn
or diameter ER-4043
Kl"
IIATERIAL
1 pc. Va" X llh"X 6" aluminum
1 pc. lh" X 3" X 6" aluminum
'ASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 84
T=Joint Fillet, 2F Position
~

OBJECTIVE Remember: It may be necessary to use filler wire to

make the tack.
Upon completion of this lesson you should be able to
weld horizontal fillets. 3. Strike an arc on the right side of the T assembly and
establish a puddle. Use a torch angle of 45 degrees to
Text Reference: Section IV, Lesson 5B; page 324. the joint, with the torch pointing toward the direction
of travel approximately 20 degrees. (See Figure 84-2.)
4. Concentrate the arc evenly on both the vertical and
PROCEDURE horizontal legs so you apply an equal leg fillet weld.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
5. Complete the weld, cool the joint, and weld the
1. Adjust the welding current, alternating (AC) continu- other side, cool the assembly ancl examine the weld
ous high frequency, 125 to 160 amperes, 20 to 25 for even face contour, equal leg length, and lack of
CFH argon, Ya in. gas cup. undercut at the toe of the weld.
2. Clean the pieces, tack them together and position
them as shown in Figure 84-1.

Copyright American Welding Society

FIGURE 85-1

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
Direction of travel

FIGURE 85-2

FIGURE 85-3

NAME POSITION
Groove Horizontal
ELECTRODE DIAMETER FILLER WIRE
Pure tungsten (balled) vem %6"
or diameter ER-4043

MATERIAL
2 pa. Ve" X 3" X 6" aluminum
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 85
S q u a r e - G r o o v e Butt Joint, 26 Position

OBJECTIVE 3. Strike an arc and establish a puddle. Use the torch

angle shown in Figure 85-2, positioning the torch so
Upon completion of this lesson you should be able to you favor the upper plate. Point toward the direction
weld horizontal grooves. of travel approximately 20 degrees.
4. Establish a keyhole and add filler metal to the leading
edge of the puddle at an angle of 15 to 20 degrees.
Text Reference: Section IV, Lesson 5B; page 324. (See Figure 85-2.)

Remember: Keep the end of the wire within the

PROCEDURE protective gas envelope. Pay attention to the keyhole and
watch for even root penetration.You may find it necessary
1. Adjust the welding current, alternating (AC) continu- to use a slight back and forth motion of the torch to keep
ous high frequency, 175 to 210 amperes, 20 to 25 root penetration consistent. (See Figure 85-3.)
CFH argon, "2 in. gas cup.
2. Clean the pieces, tack them together and position 5. Cool the plate, clean it, and examine it for even root
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

them as shown in Figure 85-1. penetration, bead width, and face reinforcement.

Copyright American Welding Society

FIGURE 86-1

FIGURE 86-2
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

~ ~~~ ~

\IAME POSITION
Fillet Vertical
~~

iLECTRODE DIAMETER FILLER WIRE

Pure tungsten (balled) %2" '/16 "
or diameter ER-4043
%2"

vlATERIAL
1 pc. '/a" X 1 %" X 6" aluminum
1 DC. l/aW X 3" X 6" aluminum
~~ ~

'ASSES BEAD TIME (SEE INSTRUCTOR)

Multiple String

Copyright American Welding Society

l Procedure 86
T-Joint Fillet, 3F Position

OBJECTIVE 3. Strike an arc and establish a puddle. The sides will

melt before the root. Make sure the side walls are
Upon completion of this lesson you should be able to melted to the root before you add filler metal or
weld vertical fillets. you will bridge the joint and get incomplete joint
penetration. Use a torch angle of 45 degrees to the
Text Reference: Section IV, Lesson 5C; page 325. joint with the torch pointing upward approximately
20 degrees. (See Figure 86-2.)
PROCEDURE 4. Add the filler wire from above at a 15 to 20 degree
angle from vertical. (See Figure 86-2.) Keep the torch
1. Adjust the welding current, alternating (AC) continu- steady without a weave and progress evenly vertically
ous high frequency, 125 to 160 amperes, 20 to 25 up. Dab the filler metal into the leading edge of the
CFH argon, Ys in. gas cup. puddle. By dabbing the wire regularly and keeping
2. Clean the pieces, tack them together and position your travel speed even you will produce beads with
them as shown in Figure 86-1. even size and good contour.
5. When you have finished the first side, cool the T bar,
Remember: It may be necessary to use filler wire to clean it, examine the weld, then weld the second side.
make the tack.

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Copyright American Welding Society

FIGURE 87-1

.
FIGURE 87-2

~~ ~~

VAME POSITION
Groove Vertical
ELECTRODE DIAMETER FILLER WIRE
Pure tungsten (balled) l/aw %6"
or diameter ER-4043
3A."

MATERIAL
2 pa. 1/a" X 3" X 6" aluminum
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 87
Square-Groove Butt Joint, 36 Position

OBJECTIVE 3. Strike an arc and establish a puddle. Use the torch

angle as shown in Figure 87-2. Point toward the
Upon completion of this lesson you should be able to direction of travel approximately 20 degrees.
weld vertical groove joints. 4. Look for the keyhole before adding wire. When the
keyhole forms add the filler wire from the top at a 15-
Text Reference: Section IV, Lesson 5C; page 326. to 20-degree angle. Dab it in the leading edge of the

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puddle evenly. This along with an even travel speed
will produce an even bead with good penetration.
PROCEDURE 5. Add enough filler wire to reinforce the face of the
weld to a maximum of 1/16 in. Root reinforcement
1. Adjust the welding current, alternating (AC) continu- should also not exceed 1/16 in.
ous high frequency 175 to 210 amperes, 20 to 25 6. Complete the joint, cool it, clean it, and examine the
CFH argon, ‘h in. gas cup. face and root surfaces for appearance and size.
2. Clean the pieces, tack them together and position
them as shown in Figure 87-1.

Copyright American Welding Society

FIGURE 88-1

- Direction of travel
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FIGURE 88-2

FIGURE 88-3

NAME POSITION
Fillet Overhead
ELECTRODE DIAMETER FILLER WIRE
Pure tungsten (balled) %2" %S"
or diameter ER-4043
H."

MATERIAL
1 pc. %" X 1 %" X 6" aluminum
1 DC. '/a" X 3" X 6" aluminum
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 88
T-Joint Fillet, 4 F Position

OBJECTIVE a puddle, making sure the joint is molten to the root

before adding filler metal. Position the torch to favor
Upon completion of this lesson you should be able to the top plate. (See Figure 88-2.) Gravity will help the
weld overhead fillets. puddle to flow down on the vertical plate to form an
equal leg fillet.
4. Add filler metal to the front edge of the puddle as
Text Reference: Section IV, Lesson 5D; page 327. shown in Figure 88-2.

Remember: Dab the metal into the puddle. Con-

PROCEDURE tinuous addition of the filler metal could lead to lack of
fusion at the root of the joint. (See Figure88-3.) This results
1. Adjust the welding current, alternating (AC) continu- because the filler metal bridges the joint and does not
ous high frequency, 125 to 160 amperes, 10 to 25 allow the arc to,penetrate to the root.
CFH argon, Ya in. gas cup.
2. Clean the pieces, tack them together and position 5. Continue to the end of the joint, applying a single
them as shown in Figure 88-1. pass fillet. Cool the plate and put a single pass fillet
3. Strike an arc on the right side of the joint. Establish weld on the other side.

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Copyright American Welding Society

, ~ G T A W

FIGURE 89-1

-61
/i.
10-15"

FIGURE 89-2

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Copyright American Welding Society

Procedure 89
Square-Root Butt Joint, 4 6 Position

OBJECTIVE 2. Clean the pieces, tack them together and position

them as shown in Figure 89-1.
Upon completion of this lesson you should be able to 3. Strike an arc and establish a keyhole. Hold the torch
weld overhead grooves. perpendicular to the joint and pointing toward the
direction of travel 1O to 15 degrees. (See Figure 89-2.)

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4. When the keyhole is established and you have pen-
Text Reference: Section IV, Lesson 5D; page 328.
etration through the root of the joint begin adding
filler wire to the leading edge of the puddle. (See Fig-
ure 89-2.) Add it using the dab method, regularly to
PROCEDURE the leading edge of the puddle. This will result in a
bead of even width and reinforcement.
1. Adjust the welding current, alternating (AC) continu- 5. Complete the joint, cool it and examine it for even-
ous high frequency, 175 to 21O amperes, 20 to 25 ness of bead width and height of reinforcement. Re-
CFH argon, '/z in. gas cup. inforcement should not exceed 1/16 in.

Copyright American Welding Society

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ShortlCircuiting Are
Welding of Steel
In the following lessons you will be welding carbon steel with the gas metal arc
welding (GMAW) process, using the short circuiting method of transfer.

GENERAL INSTRUCTIONS
Review the following instructions before beginning the Procedures in this section.

1. Before you start to weld you must check out and set up your equipment. Inspect
the equipment. if there is any equipment that needs repair notify your instructor.
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2. Go to the power supply and check the cable connections. The correct current for
GMAW short-circuiting transfer is DCEP.
3. Check the work cable and turn on the power supply.
4. Proceed to the wire feeder and check for the proper size filler wire and wire feed
rolls. For the lessons in this section, you will be told to use .O35 in. diameter
E-70s-3 filler wire. If the wire is not threaded through the gun and cable assembly
use the wire feeder switch or gun trigger to feed wire through the conduit assembly
and through the gun.

Caution: If you use the gun trigger to feed the wire make sure the gun is not
touching or near objects on which an arc might be struck. Remove the tip when the
wire is being fed through the gun. When the wire is fed through release the wire feed
button and install the contact tip. For short-circuiting transfer, the tip should protrude
beyond the gas nozzle '/s in.

5. Set the gas flow to 25 to 35 CFH of 75% argon 25% carbon dioxide. Apply
antispatter compound to the gas cup and contact tip to prevent spatter buildup.

MATERIALS AND EQUIPMENT

For this section the materials and equipment will be as follows:
Gas nozzle
1. Welding shield with appropriate lens
2. Safety glasses
3. Gauntlet type leather gloves
4. Appropriate welding clothing
5. Wire brush
6. Diagonal side cutters P
Wire extension

203
Copyright American Welding Society
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204 GAS METAL ARC WELDING PROCESS

Direction of welding

Forehand Torch Backhand

technique perpendicular technique

FIGURE 80-1 WIGURE 90-2

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FIGURE BO-3 FIGURE 90-4

.IAME POSITION
Pad of stringer beads Flat
LECTRODE DIAMETER AMPERAGE VOLTAGE
E-70s-3 .035" 140-150 18-19
75%Ar 25%CO2 @ 25-35 CFH
AATERIAL
1 pc. %" X 6" X 10" carbon steel
'ASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

Copyright American Welding Society

Procedure 90

Running a Flat Pad of Stringer Beads

OBJECTIVE Use one of the weaves shown in Figure 90-3 to

spread the weld bead. This will prevent excessive
Upon completion of this lesson you should be able to reinforcement and help make sure the toe of the weld
weld a pad of stringer beads in the flat position. merges smoothly with the base metal.
3. Before stopping the weld be sure you fill the crater by
Text Reference: Section V, Lesson 4A; page 369. using a circular motion of the gun over the puddle to
fill the crater and reinforce it. When you extinguish
the arc hold the gun over the crater to allow the post
PROCEDURE flow of gas to protect the hot weld bead from the
atmosphere.
1. Adjust the power supply and wire feeder to obtain 18 4. Continue to deposit overlapping beads on the plate,
to 19 volts and 140 to 150 amperes, gas flow 25 to as shown in Figure 90-4. Cool the plate as necessary.
35 CFh. 5. When finished the beads should be straight, of even
2. Using the forehand technique (see Figure 90-1 begin width and height, and have a smooth contour.
at the right side of the plate and deposit a weld 6. Weld another plate, using the same welding condi-
bead approximately 'h in. from the edge of the plate. tions and bead sequence, with the backhand tech-
(See Figure 90-2.) Travel at an even speed. This will nique. Note the difference in bead appearance and
produce a bead with even width and reinforcement. buildup.

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Copyright American Welding Society

-
FIGURE 91 1

FIGURE 91-2

IAME POSITION
Fillets Flat
LECTRODE DIAMETER AMPERAGE VOLTAGE
E-70s-3 .035" 140-1 50 18-19
75% Ar 25% COZ@ 25-35 CFH
IATERIAL
1 pc. %" X 1 %" X 8" carbon steel
1 pc. %" X 3" X 8" carbon steel
ASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

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Copyright American Welding Society

Procedure 91

T-Joint Fillet, 1F Position

OBJECTIVE the weaves, weld a bead from right to left. Use an

even travel speed and watch for even reinforcement
Upon completion of this lesson you should be able to and good tie in of the toe of the weld to the base
weld fillets in the flat position. metal.

Remember: When stopping, fill and cool the crater

Text Referenee: Section V, Lesson 4 4 page 369. properly.

4. Complete the first weld bead and apply two more

PROCEDURE beads as shown in Figure 91-2. Cool the plate be-
tween beads.
'1. Adjust the power supply and wire feeder to obtain 18 5. When you have completed the three bead fillet, cool
to 19 volts and 140 to 150 amperes, gas flow 25 to the T assembly and inspect it. The legs should be
35 CFH. of equal length. The toe of the weld should merge
2. Clean the pieces to be joined. The areas to be welded smoothly with the base material. The face of the weld
should be thoroughly cleaned of any mill scale or should be nearly flat with no excessive concavity or
rust. The CMAW process does not have the ability convexity.
to remove many impurities because it does not have 6. Weld the second side of the T assembly using the
a flux. Clean weld joints will result in higher quality backhand technique. Note the difference in bead ap-
welds. pearance and buildup. Use the same weave tech-
3. Tack the pieces together and position them as shown niques and bead placement you used on the first side.
in Figure 91-1. Hold the gun perpendicular to the When you have completed it, inspect it as you did the
joint and using the forehand technique and one of first side.

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Copyright American Welding Society

FIGURE 92-1

@:O

FIGURE 92-2

NAME POSITION
Grooves Flat
ELECTRODE DIAMETER A M PERACE VOLTAGE
E-70s-3 .035" 125-150 18-1 9
75% Ar 25% CO2 @ 25-35 CFH
MATERIAL
2 pcs. Yam X 3" X 6" carbon steel with a 30 degree bevel on one side
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 92

V=Groove Butt Joint, 1 6 Position

OBJECTIVE dicular to the joint and strike the arc at the tack.
Weave the gun from side to side. As you weave watch
Upon completion of this lesson you should be able to closely when you are in the center of the joint. By
weld flat grooves. concentrating the arc on the leading edge of the pud-
dle you can cause the bead to penetrate through the
joint and fuse both root faces. You must be very care-
Text Reference: Section V, Lesson 4A; page 370. ful. If you bring the arc too far down the puddle, the
wire will go through the joint and the arc will be-
come very erratic. If you allow the arc to go too far
PROCEDURE up on the puddle your penetration will decrease and
you will not penetrate the joint. Practice will help you
1. Adjust the power supply and wire feeder to obtain 18 use the arc to control the flow of the weld puddle.
to 19 volts and 125 to 150 amperes, gas flow 25 to 5. Complete the joint using the bead sequence shown
35 CFH. in Figure 92-2. Use a slight weave to help the weld
2. Thoroughly clean the pieces to be joined. Pay partic- flow and to fuse to the side walls of the groove and
ular attention to the top of the plate, the side walls the previous beads.
of the groove, and the underside of the joint. Grind 6. When you have completed the plate, cool and ex-
or file a y32 in. root face on each beveled piece. (See amine it. The root should show fill penetration along
Figure 92-1 .I the entire length. The root face should protrude be-
3. Tack the pieces together and position as shown in yond the joint from O to 1/16 in. The face of the weld
Figure 92-1. Put spacers under the plate so you do should merge smoothly with the base metal. The face
not weld the plate to your table. should be at least flush with the base metal and not
4. Using the backhand technique hold the gun perpen- exceed H2 in. reinforcement.

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Copyright American Welding Society

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FIGURE 93-2

NAME POSITION
Fillets Horizontal
ELECTRODE DIAMETER A M PERAGE VOLTAGE
E-70s-3 .035" 140-1 50 18-19
75% Ar 25% CO2 @ 25-35 CFH
MATERIAL
1 pc. %" X 1 %" X 8" carbon steel
1 pc. %" X 3" X 8" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

Copyright American Welding Society

Prooedure 93

T-Joint Fillets, 2F Position

OBJECTIVE 2. Clean the pieces to be joined, tack them together and

position them as shown in Figure 93-1.
Upon completion of this lesson you should be able to 3. Use the forehand technique, beginning at the right
weld horizontal fillets. side of the joint and progress to the left. Use a slight
weave, hesitating on the vertical part of the T joint.
Use the gun angles shown in Figure 93-2.
Text Referenee: Section V I Lesson 48; page 371. 4. Deposit two more beads using the bead sequence
and gun angles shown in Figure 93-2.
5. Cool the T-bar assembly and examine the weld. The
PROCEDURE toe of the weld should merge smoothly with the base
metal.The legs should be equal and the face of the weld
1. Adjust the power supply and wire feeder to obtain 18 should be nearly flat.
to 19 volts, 140 to 150 amperes, gas flow 25 to 35 6. Weld the second side of the T-bar assembly using the
CFH. backhand technique.

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Copyright American Welding Society

FIGURE 94-2

FIGURE 94-1
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FIGURE 94-3

NAME POSITION
Grooves Horizontal
ELECTRODE DIAMETER AMPERAGE VOLTAGE
E-70s-3 .035" 125-150 18-19
75% Ar 25% CO2 @ 25-35 CFH
MATERIAL
2 pcs. W" X 3" X 6" carbon steel with a 30-degree bevel on
one 6" side
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

Copyright American Welding Society

Procedure 84

V=GrooveButt Joint, 26 Position

OBJECTIVE 2. Thoroughly clean the pieces to be joined, tack them

together and position them as shown in Figure 94-1.
Upon completion of this lesson you should be able to 3. Use the backhand technique beginning at the left side
weld horizontal grooves. of the plate. Use the arc on the puddle to push the
weld through the joint to penetrate the root. Use a
Text Reference: Section V, Lesson 4B; page 372. slight weaving motion, hesitatingon the top plate. Use
a gun angle as shown in Figure 94-2.
4. Complete the plate using the bead sequence shown
PROCEDURE in Figure 94-3. Cool the plate and examine it for
penetration, reinforcement, and bead appearance.
1. Adjust the power supply and wire feeder to obtain 18 5. Weld another joint using the backhand technique for
to 19 volts and 125 to 150 amperes, gas flow 25 to the root pass (first pass) and the forehand technique
35 CFH. for the rest of the beads.

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Copyright American Welding Society

GMA

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iI
Top view

FIGURE 99-1

FIGURE 95-2

FIGURE 95-3

VUSITIUN
Fillets Vertical up
ELECTRODE - ~ DIAMETER AMPERAGE
~ __
E-70s-3 .035" 125-1 50 18-19
75% Ar 25% CO2 Q 25-35 CFH
MATERIAL
I 1 pc. %" X 1 %" X 8" carbon steel I
1- pc. %" X 3" X 8" carbon steel
PASSES .. ._. BEAD I TIME (SEE INSTRUCTORI -..,
I Multiple Weave

Copyright American Welding Society

Procedure!95

T=Joint Fillet, 3 F Position, Upward Welding

OBJECTIVE angles shown in Figure 95-2 and begin to weld using a

weaving motion similar to that shown in Figure 95-3.
Upon completion of this lesson you should be able to 4. The weld will build a shelf at the bottom of the joint

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weld vertical up fillets. which you can build on. Make sure when you weave
the torch that the arc reaches the root of the joint.
Text Reference: Section V, Lesson 4C; page 373. This ensures good root penetration. Hesitate on the
sides to fill in the weld and prevent undercut. Increase
your travel speed when going from side to side to
PROCEDURE prevent excessive buildup, which would result in a
very convex bead.
1. Adjust the power supply and wire feeder to obtain 18 5. Complete the first pass, keeping the fillet size to as
to 19 volts and 125 to 150 amperes, gas flow 25 to close to Y4 in. as possible.
35 CFH. Stay on the low side of the range for vertical 6. Cool the plate thoroughly and deposit a second pass.
welding. Keep the second pass fillet size to Ya in. (See Fig-
2. Thoroughly clean the pieces to be joined, tack them ure 95-4.)
together and position them as shown in Figure 95-1. 7. Weld the second side of the T-bar assembly using the
3. Beginning at the bottom of the joint, use the gun same technique as the first side.

Copyright American Welding Society

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45"
Top 'view

FIGURE 96-1

FIGURE 96-2

Top view

FIGURE 96-3 FIGURE 96-4

NAME POSITION
Fillets Vertical down
ELECTRODE DIAMETER AMPERAGE VOLTAGE
E-70s-3 .035" 125-150 18-19
75% Ar 25% CO2 @ 25-35 CFH
MATERIAL
1 pc. %" X 1 Vza X 8" carbon steel
1 pc. 114" X 3" X 8" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

Copyright American Welding Society

Procedure 96

T=Joint Fillet, 3 F Position,

Downward Welding

OBJECTIVE to get a condition known as cold lap* in vertical down

welding. if you do not weave the gun to make sure
Upon completion of this lesson you should be able to weld the arc melts the side walls and fuses the weld and
vertical down fillets. base metal, the arc will dwell on the puddle which
will cushion the force of the arc and cause lack of
fusion.
Text Reference: Section V, Lesson 4C; page 374.
4. Continue down the joint. Your speed of travel must
be fast enough to stay ahead of the weld puddle so
the arc can melt the base metal. if you do not travel
PROCEDURE fast enough you will lose penetration and eventually
the puddle will sag and fall out of the joint.
1. Adjust the power supply and wire feeder to obtain 18 5. Apply two more beads, as shown in Figure 96-4.
to 19 volts and 125 to 150 amperes, gas flow 25 to Make sure you use a slight weave to ensure side wall
. 3 5 CFH. penetration and fusion.
2. Clean the pieces to be cleaned, tack them together 6. Weld the second side using the same techniques you
and position them as shown in Figure 96-1. learned on the first side. Inspect both sides for leg
3. Begin at the top of the joint. Use the gun angles shown length, bead appearance, and fusion at the toe of the
in Figure 96-2. Use a slight weave pattern like the one weld.
shown in Figure 96-3. Some weave is necessary to *Cold lap is a condition where the metal lies against another surface,
ensure fusing along the toe of the weld. it is possible without melting and fusing to it.

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Copyright American Welding Society

FIGURE 97-1

&" max.

FIGURE 87-2 FIGURE 87-3

NAME POSITION
Grooves Vertical up
ELECTRODE DIAMETER AMPERAGE VOLTAGE
E-70s-3 .035" 120-140 18-19
75%Ar 25%CO2 Q 25-35 CFH
MATERIAL
2 pa. 3h" X 3"X 8"carbon steel with a 30-degree bevel on
one 6" side
1 pc. %" X I" X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

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Copyright American Welding Society

Procedure 97

V=Groove Butt Joint, 36 Position with

Backup Bar, Upward Welding

OBJECTIVE 3. Begin at the bottom of the groove using the gun

positions shown in Figure 97-2. Build a shelf for
Upon completion of this lesson you should be able to the weld and using a slight weave motion continue
weld vertical up grooves. the weld up the joint. Make sure the weave is wide
enough to cause the arc to melt the root of the joint
Text Reference: Section V, Lesson 4C; page 374. ensuring good penetration and fusion.
4. After completing the root pass, deposit two more
layers using a single bead weave to produce each
PROCEDURE layer. (See Figure 97-3.) Increase the width of the
weave for each layer. The second layer should be
1. Adjust the power supply and wire feeder to obtain 18 just under flush. This will allow you to reinforce the
to 19 volts and 120 to 140 amperes, gas flow 25 to joint properly. Hesitate on each side when weaving to
35 CFH. Stay on the low side of the range. fill in the weld and prevent undercut. Cool the plate
2. Clean the pieces to be joined, tack them together and between each layer.
position them as shown in Figure 97-1. Thoroughly
tack the backing bar to the plates.

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Copyright American Welding Society

\ /

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
i
Top view

FIGURE 98-1 FIGURE 98-2

FIGURE 98-3 FIGURE 98-4

JAME POSITION
Grooves Vertical down
LECTRODE DIAMETER AMP ERAGE VOLTAGE
E-70s-3 .035" 120-1 4 0 18-1 9
75% Ar 25% CO2 @ 25-35 CFH
IATERIAL
2 pcs. %" X 3" X 6" carbon steel with a 30-degree bevel on
one 6" side
'ASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave

Copyright American Welding Society

Procedure 98

V-Groove Butt Joint, 36 Position,

Downward Welding

OBJECTIVE Keep the tip of the wire on the very leading edge of
the puddle and deep into the joint. (See Figure 98-3.)
Upon cornpietion of this lesson you should be able to This will cause the root of the weld to penetrate be-
weld vertical down grooves. yond the root of the joint and give a convex root re-
inforcement. Gauge your travel speed to keep ahead
of the puddle.
Text Reference: Section V, Lesson 4C; page 375. 4. Continue with the root pass to the end of the joint.
Cool the plate and add more passes to complete the
joint using the sequence shown in Figure 98-4. Use
PROCEDURE a slight weave on each bead.
5. Note: It takes more passes to fill the joint. To prevent
1. Adjust the power supply and wire feeder to obtain 18 weld puddle sag it is necessary to keep the wire
to 19 volts and 120 to 140 amperes, gas flow 25 to on the leading edge of the puddle. This results in

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
35 CFH. fast travel speeds which keeps deposition rates low.
2. Clean the pieces to be welded. Grind or file a K2 in. Whenever welding vertical down, it is very important
root face on each plate bevel. Tack and position the to keep the wire on the lead edge of the puddle
pieces as shown in Figure 98-1. and to weave the puddle enough to point the arc
3. Start at the top using the gun positions shown in Fig- to those points you want to weld. Vertical down,
ure 98-2. Use a side-to-side weaving technique. A short-circuiting GMAW does not have a ?hot? arc.
weld will form across the root opening. Carefully ma- Gun manipulation is extremely important to prevent
nipulate the gun side to side to get side wall fusion. lack of fusion defects.

Copyright American Welding Society

FIGURE 99-1

FIGURE BB-2

NAME POSITION
Fillets Overhead
ELECTRODE DIAMETER AMPERAGE VOLTAGE
E-70s-3 .035" 125-1 50 18-1 9
75% Ar 25% COZ @ 25-35 CFH
MATERIAL
1 pc. %" X i%" X 8" carbon steel
1 DC. %" X 3" X 8" carbon steel
~ ~~

PASSES BEAD TIME (SEE INSTRUCTOR)

Multiple Weave

Copyright American Welding Society

Procedure 99

T=Joint Fillet, 4 F Position

OBJECTIVE 2. Clean the pieces to be welded, tack them together,

and position them as shown in Figure 99-1.
Upon completion of this lesson you should be able to 3. Use the gun angles shown in Figure 99-2 and the
weld overhead fillets. forehand technique to put in the first pass. Slightly
weave the gun to prevent lack of fusion along the toe
Text Reference: Section V, Lesson 4D, page 376. of the weld.
4. Cool the plate, clean it, and put in two more passes
using the gun angles shown in 99-2.
PROCEDURE 5. Cool the plate and weld the second side of the T
assembly using the backhand technique and the gun
1. Adjust the power supply and wire feeder to obtain 18 angles shown in Figure 99-2.
to 1 9 volts and 125 to 150 amperes, gas flow 25 to
35 CFH.
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Copyright American Welding Society

FIGURE 100-1

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FIGURE 100-2 FIGURE 100-3

NAME POSITION
Grooves Overhead
ELECTRODE DIAMETER AMPERAGE VOLTAGE
E-70s-3 .035" 125-1 50 18-1 9
75% Ar 25% CO2 @ 25-35 CFH
MATERIAL
2 pss. Ya" X 3" X 6" carbon steel with a 30-degree bevel on one side
~~

PASSES BEAD TIME (SEE INSTRUCTOR)

Multiple Weave

Copyright American Welding Society

Procedure 100

V=GrooveButt Joint, 46 Position

OBJECTIVE 3. Keep the gun perpendicular to the joint using a slight

backhand technique and a weave. Begin at the end
Upon completion of this lesson you should be able to of the joint and keep the wire at the leading edge of
weld overhead grooves. the puddle. The position of the wire will determine
the amount of penetration and shape of the root pass.
Text Reference: Section V, Lesson 4D; page 376. Keep the wire on the leading edge of the puddle and
deep into the joint as you did in the previous lesson.
(See Figure 100-2.) This will push the weld puddle
PROCEDURE through the joint to produce convex root face with
reinforcement beyond the root of the joint.
1. Adjust the power supply and wire feeder to obtain 18 6. Complete the joint using the bead sequence shown
to 19 volts and 125 to 150 amperes, gas flow 25 to in Figure 100-3. Change the gun angle for each bead
35 CFH. to point in the direction of the bead. Weave each
2. Clean the pieces to be welded. File or grind a Y32 in. bead to ensure good penetration with the side walls
root face on the bevel. Tack the pieces together and of the groove, and other weld beads.
position them as shown in Figure 100-1.

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Copyright American Welding Society

Provided by IHS under license with AWS Licensee=IHS Subs and Mgrs /IHSINTL003, User=GCN, serPemex
No reproduction or networking permitted without license from IHS Not for Resale, 09/13/2005 16:49:30 MDT
Spray Transfer
W e l d i n g of Steel
In this section you will practice welding carbon steel with the gas metal arc process
using the spray transfer. As you have learned there are several gases or gas mixes that
can be used for shielding. For the lessons in this section we will be using 98% argon
2% oxygen. The arc in GMAW spray transfer is considerably hotter, producing more
infrared and ultraviolet radiation than the short-circuiting GMAW process. Precaution
must be taken to protect yourself and others in the area from this high intensity arc.
Painful burns can result from short exposure to these rays.

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GENERAL INSTRUCTIONS
Set up your equipment as you did for short arc welding, however, recess your tip YB
in. below the lip of the cup. If you do not you will stand a good chance of burning the
wire back to the tip and melting it off. The wire size we will use for the procedures
in this section is .O45 in.

MATERIALS AND EQUIPMENT

For this section the material and equipment will be as follows:

I . Welding shield with appropriate lens

2. Safety glasses
3. Gauntlet type leather gloves
4. Appropriate welding clothing
5. Wire brush
6. Diagonal side cutters t”

227

Copyright American Welding Society

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FIGURE 101-1

FIGURE 101-2

NAME POSITION
Fillet Flat
ELECTRODE DIA M ETER AMP ERAGE VOLTAGE
E-70s-3 .035" 190-21 O 24-25
100% Ar @ 25-35 CFH
MATERIAL
1 pc. %" X 1 %" X 8" carbon steel
1 pc. %" X 3" X 8"carbon steel
_ _ _ _ ~

PASSES BEAD TIME (SEE INSTRUCTOR)

Multiple String

Copyright American Welding Society

Procedure 101

T=Joint Fillet, 1F Position

OBJECTIVE 3. Using the forehand technique begin at the right side

of the T assembly and weld toward the left. Note that
Upon completion of this lesson you should be able to the wire does not contact the plate and the puddle
weld flat fillets. i s very fluid and flows well thus making weaving
unnecessary.
Text Reference: Section V, Lesson SA; page 379. 4. Watch the root of the joint to make sure the arc melts
the metal completely. Regulate your travel accord-
PROCEDURE ingly. Move the gun only when melting is complete.

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Keep the gun perpendicular to the joint.
1. Adjust the power supply and wire feeder to obtain 24 5. Apply a three-pass weld using the bead sequence
to 25 volts and 190 to 210 amperes, gas flow 25 to shown in Figure 101-2. When you are through with
35 CFH. the first side cool the plate and weld the second side
2. Clean the pieces to be welded, tack them together, using the backhand technique. Use the same bead
and position them as shown in Figure 1O1- I . sequence you did on the first side.

Copyright American Welding Society

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FIGURE 102-1

FIGURE 102-2

Copyright American Welding Society

Procedure 102

VIGroove Butt Joint, I G Position with

Backup Bar

OBJECTIVE 2. Clean the pieces to be welded, tack them together,

and position them as shown in Figure 102-1.
Upon completion of this lesson you should be able to 3. Use the forehand technique to weld the root pass,
weld flat grooves. welding from right to left. Weld the root in one pass.
Keep the gun perpendicular to the joint.
4. Complete the joint using the bead sequence shown in
Text Reference: Section V, Lesson SA; page 379. Figure 102-2. When reinforcing the weld pay atten-
tion to the toe of the weld. It is possible, when using
spray transfer, to undercut the base metal at the toe
PROCEDURE of the weld. To prevent this, either slow down your
travel speed or use a slight weave.
1. Adjust the power supply and wire feeder to obtain 24 5. Prepare and weld another joint using the backhand
to 25 volts and 190 to 21O amperes, gas flow 25 to technique. Use the bead sequence shown in Fig-
35 CFH. ure 102-2.

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Copyright American Welding Society

FIGURE 103-1

FIGURE 103-2

NAME POSITION
Fillet Horizontal
ELECTRODE DIAMETER AMPERAGE VOLTAGE
E-70s-3 .035" 190-210 24-25
100% Ar @ 25-35 CFH
MATERIAL
1 pc. %" X 1 Vz" X 8" carbon steel
1 pc. '14" X 3" X 8" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
MuìtiDìe Sirine

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Copyright American Welding Society

Procedure 103

T=Joint Fillet, 2F Position

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OBJECTIVE 2. Clean the pieces to be welded, tack them together,

and position them as shown in figure 103-1.
Upon completion of this lesson you should be able to 3. Using the torch angles shown in Figure 103-2, weld
weld horizontal fillets. a three-pass fillet weld using the forehand technique.
Pay close attention to the third bead. Since the weld
Text Reference: Section V, Lesson 56; page 380. puddle is large and very fluid you must tilt the gun
to deposit the metal on the vertical part of the T
PROCEDURE assembly. Watch the toe of the weld closely and use
the gun angle and travel speed to prevent undercut
1. Adjust the power supply and wire feeder to obtain 24 in this area.
to 25 volts and 190 to 210 amperes, gas flow 25 to 4. Cool the T assembly and weld the second side of the
35 CFH. joint using the backhand technique.

Copyright American Welding Society

FIGURE 104-1 FIGURE 104-2

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- - ~~ ~~ ~

VAME POSITION
Groove Horizontal
ELECTRODE DIAMETER AMPERAGE VOLTAGE
E-70s-3 .035" 190-21 O 24-25
100% Ar @ 25-35 CFH
MATERIAL
3h" X 3" X 6" carbon steel
%" X 1 " X 6" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 104

V=GrooveButt Joint, 26 Position with

Backup Bar

OBJECTIVE 2. Clean the pieces to be welded, tack them together,

and position them as shown in Figure 104-1.
Upon completion of this lesson you should be able to 3. Use the gun angle shown in Figure 104-2 and the
weld horizontal fillets. forehand technique to weld the root pass in one bead.
4. Alter the gun angle from O to 10 degrees to deposit
Text Referenee: Section V, Lesson 5B; page 380. the remaining beads in the joint. The last bead is
where you must pay particular attention to prevent
PROCEDURE undercut. Use a gun angle of 10 degrees below hor-
izontal, and watch your travel speed. Keep the arc
1. Adjust the power supply and wire feeder to obtain 24 length short.
to 25 vdts and 190 to 21O amperes, gas flow 25 to 5. Weld another assembly using the backhand tech-
35 CFH. nique. Use the same gun angles and bead sequence.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Provided by IHS under license with AWS Licensee=IHS Subs and Mgrs /IHSINTL003, User=GCN, serPemex
No reproduction or networking permitted without license from IHS Not for Resale, 09/13/2005 16:49:30 MDT
Flux-Cored Are
Welding of Steel
in this section you will be welding carbon steel with the Flux-Cored Arc Welding
(FCAW) process.

GENERAL INSTRUCTIONS
Before you start to weld you must check out and set up your equipment.

1. Inspect the equipment. If there i s any equipment that needs repair notify your
instructor.
2. Go to the power supply, and check the cable connections. Check the correct
voltage for the wire you are using and set the power supply accordingly.
3. Check the work cable and turn on the power supply.
4. Proceed to the wire feeder and check for the proper size filler wire and wire
feed rolls. For the lessons in this chapter you will be told to use .O45 in. diameter
E-71T-1 filler wire. if the wire is not threaded through the gun and cable assembly
use the wire feeder switch or gun trigger to feed wire through the conduit assembly
and through the gun.

Caution: if you use the gun trigger to feed the wire make sure the gun i s not
touching or near objects on which an arc might be struck. Remove the tip when the
wire is being fed through the gun. When the wire is fed through release the wire
feed button and install the contact tip. For Flux-Cored Arc Welding the tip should be
even with the gas nozzle.

5. Set the gas flow rate to 30 to 40 CFH of carbon dioxide. Apply antispatter
compound to the gas cup and contact tip to prevent spatter buildup.

MATERIALS AND EQUIPMENT

For this section the material and equipment will be as follows: Gas nozzle

1. Welding shield with appropriate lens

2. Safety glasses
3. Gauntlet type leather gloves
4. Appropriate welding clothing !Contact tip

239
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Copyright American Welding Society

Direction of welding
*
FIGURE 105-1 FIGURE 105-2

FIGURE 105-3 FIGURE 105-4

VAME POSITION
Pad of stringer beads Flat
ELECTRODE DIAMETER AMPERAGE VOLTAGE
E-71T-1 .045" 170-1 90 21-23
Gas flow 30 to 40 CFH carbon dioxide
UATERIAL
1 pc. líaa X 6" X 10"carbon steel
'ASSES BEAD TIME (SEE INSTRUCTOR)
Muitide Weave

Copyright American Welding Society

Procedure 105

Running Flat Pad of Stringers

OBJECTIVE bead approximately Yi in. from the edge of the plate.

(See Figure 105-2.) Travel at an even speed. This will
Upon completion of this lesson you should be able to produce a bead with even width and reinforcement.
weld a flat pad of stringer beads. Use one of the weaves shown in Figure 105-3 to
spread the weld bead. This will prevent excessive
Text Reference: Section VI, Lesson 4A; page 41 9. reinforcement and help make sure the toe of the weld
merges smoothly with the base metal.
3. Before stopping the weld be sure you fill the crater
PROCEDURE by using a circular motion of the gun over the puddle
to fill the crater and reinforce it. Allow the bead to
1. Adjust the power supply and wire feeder to obtain 21 cool and clean the slag from the weld.
to 23 volts and 170 to 190 amperes, gas flow 30 to 4. Continue to deposit overlapping beads on the plate,
40 CFH. as shown in Figure 105-4. Cool the plate as necessary.
2. Using the backhand technique (see Figure 105-1) 5. When finished the beads should be straight, of even
begin at the right side of the plate and deposit a weld width and height, and have a smooth contour.
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

FIGURE 106-2

NAME POSITION
Fillets Flat
ELECTRODE DIAMETER AMPERAGE VOLTAGE
E-71T-1 .045" 170-1 90 21-23
Gas flow 30 to 40 CFH carbon dioxide
MATERIAL
1 pc. %" X 1 %" X 8" carbon steel
1 pc. V4" X 3' X 8"carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 106

T=Joint Fillet, I F Position

OBJECTIVE in Figure 106-1. Hold the gun perpendicular to the

joint and using the backhand technique and one of
Upon completion of this lesson you should be able to the weaves, weld a bead from left to right. Use an
weld flat fillets. even travel speed and watch for even reinforcement
and good tie at the toe of the weld. Remember when
stopping to fill the crater properly.
Text Reference: Section Vi, Lesson 4A; page 419. 4. Complete the first weld bead, clean it and apply two
more beads as shown in Figure 106-2. Cool the plate
between beads.
PROCEDURE 5. When you have completed the three-bead fillet, cool
the T assembly and inspect it. The legs should be
1. Adjust the power supply and wire feeder to obtain 21 of equal length. The toe of the weld should merge
to 23 volts and 170 to 190 amperes, gas flow 30 to smoothly with the base material. The face of the weld
40 CFH. should be nearly flat with no excessive concavity or
2. Clean the pieces to be joined. The areas to be welded convexity.
should be thoroughly cleaned of any mill scale or rust. 6. Weld the second side of the T assembly using the
Clean weld joints will result in higher quality welds. same technique and bead placement you used on
3. Tack the pieces together and position them as shown the first side.

Copyright American Welding Society

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srt< FCAW

FIGURE 107-1

FIGURE 107-2

YAME POSITION
Grooves Flat
ELECTRODE

MATERIAL
E-71T-1
DIA M ETER
.045"
Gas flow 30 to 40 CFH carbon dioxide
~~~~~~

1 pc. %" X 1" X 6" carbon steel

I 170-190
VOLTAGE
21-23

2 pa. Yo" X 3" X 6" carbon steel with a 30-degree bevel on

one 6"cide

PASSES
MUlt¡Dk!
BEAD
Weave
I TIME (SEE INSTRUCTOR)

Copyright American Welding Society

Procedure 107

V-Groove Butt Joint, 16 Position with

Backup Bar

OBJECTIVE dicular to the joint and strike the arc at the tack.
Weave the gun from side to side. As you weave
Upon completion of this lesson you should be able to watch closely when you are in the center of the joint.
weld flat grooves. By concentrating the arc on the leading edge of the
puddle you can cause the bead to penetrate into the
Text\ReferencetSection VI, Lesson 4 4 page 420. backing strip and fuse both root faces. You must be
very careful. If you allow the arc to go too far up on
the puddle your penetration will decrease and you
PROCEDURE will not penetrate the joint. Practice will help you
use the arc to control the flow of the weld puddle.
1. Adjust the power supply and wire feeder to obtain 21 5. Complete the joint using the bead sequence shown
to 23 volts and 170 to 190 amperes, gas flow 30 to in Figure 107-2. Use a slight weave to help the weld
40 CFH. flow and to fuse to the side walls of the groove and
2. Thoroughly clean the pieces to be joined. Pay partic- the previous beads.
ular attention to the top of the plate, the side walls of 6. When you have completed the plate, cool it and
the groove and the underside of the joint. (See Fig- examine it. The root should show fill penetration
ure 107-1.) along the entire length. The root face should protrude
3. Tack the pieces together and position as shown in beyond the joint from O to 1/16in. The face of the weld
Figure 107-1. Tack the backing strip firmly to the should merge smoothly with the base metal. The face
plates. should be at least flush with the base metal and not
4. Using the backhand technique hold the gun perpen- exceed 732 in. reinforcement.
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

FCAW>+,

FIGURE 108-1

FIGURE 108-2

NAME POSITION
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Fillets Horizontal
ELECTRODE DIAMETER AMPERAGE VOLTAGE
E-71T-1 .045" 170-1 90 21-23
Cas flow 30 to 40 CFH carbon dioxide
MATERIAL
1 pc. 'h"X 1 VZ' X 8"carbon steel
1 pc. '14" X 3" X 8" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 108

T=Joint Fillet, 2F Position

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OBJECTIVE 2. Clean the pieces to be joined, tack them together,
and position them as shown in Figure 108-1.
Upon completion of this lesson you should be able to 3. Use the backhand technique, beginning at the left
weld horizontal fillets. side of the joint and progress to the right. Use a slight
weave, hesitating on the vertical part of the T joint.
Use the gun angles shown in Figure 108-2.
Text Reference: Section VI, Lesson 4B; page 421.
4. Deposit two more beads using the bead sequence
and gun angles shown in Figure 108-2.
5. Cool the T-bar assembly and examine the weld. The
PROCEDURE toe of the weld merge smoothly with the base metal.
The legs should be equal and the face of the weld
1. Adjust the power supply and wire feeder to obtain 21 should be nearly flat.
to 23 volts and 170 to 190 amperes, gas flow 30 to 6. Weld the second side of the T-bar assembly using the
40 CFH. backhand technique.

Copyright American Welding Society

FIGURE 109-2 FIGURE 109-3

IAME
Grooves
I POSITION Horizontal
LECTRODE DIAMETER AMPERAGE VOLTAGE
E-71T-1 .045" 170-1 90 21-23
Cas flow 30 to 40 CFH carbon dioxide
IATERIAL
1 pc. 114" X 1" X 6" carbon steel
2 pcs. Ya" X 3" X 6" carbon steel with a 30-degree bevel on
one 6" side
ASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Procedure 108

VmGroove Butt Joint, 26 Position with

Backup Bar

OBJECTIVE 2. Thoroughly clean the pieces to be joined, tack them

together, and position them as shown in Figure 109-1.
Upon completion of this lesson you should be able to 3. Use the backhand technique beginningat the left side
weld horizontal grooves. of the plate. Use a slight weaving motion, hesitating
on the top plate. Use a gun angle as shown in Fig-
ure 109-2.
Text Referenee: Section Vi, Lesson 4B; page 422. 4. Complete the plate using the bead sequence shown
in Figure 109-3. Cool the plate and examine it for
penetration, reinforcement, and bead appearance.
PROCEDURE
1. Adjust the power supply and wire feeder to obtain 21
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

to 23 volts and 170 to 190 amperes, gas flow 30 to

40 CFH.

Copyright American Welding Society

FCAW
! Top view
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FIGURE 1 1O- 1 FIGURE 110-3

FIGURE 110-3 FIGURE 110-4

NAME POSITION
Fillets Veriical
ELECTRODE DIAMETER AMPERAGE VOLTAGE
E-71T-1 .045" 170-1 90 21 -23
Cas flow 30 to 40 CFH carbon dioxide
MATERIAL - 1
1 pc. 114' X 1 %" X 8" carbon steel
1 pc. %" X 3" X 8' carbon steel
PASSES
Multiple
BEAD
Weave
I TIME (SEE INSTRUCTOR)

Copyright American Welding Society

Procedure 110

T-Joint Fillet, 3 F Position

OBJECTIVE angles shown in 110-2 and begin to weld using a

weaving motion similar to that shown in Figure 110-3.
Upon completion of this lesson you should be able to 4. The weld will build a shelf at the bottom of the joint
weld vertical up fillets. which you can build on. Make sure when you weave
the torch that you make sure the arc reaches the root
Text Reference: Section VI, Lesson 4C; page 422. of the joint to ensure good root penetration. Hesitate
on the sides to fill in the weld and prevent undercut.
Increase your travel speed when going from side to
PROCEDURE

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
side to prevent excessive buildup, which would result
in a very convex bead.
1. Adjust the power supply and wire feeder to obtain 21 5. Complete the first pass, keeping the fillet size to as
to 23 volts and 170 to 190 amperes, gas flow 30 to close to VI in. as possible.
40 CFH. Stay on the low side of the range for vertical 6. Cool the plate thoroughly and deposit a second pass.
welding. Keep the second pass fillet size to )/s in. (See Fig-
2. Thoroughly clean the pieces to be joined, tack them ure 110-4.)
together, and position them as shown in Figure 1 10-1. 7. Weld the second side of the T-bar assembly using the
3. Beginning at the bottom of the joint, use the gun same technique as the first side.

Copyright American Welding Society

FIGURE 1 1 1 1-

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y
Top view

h" max.

FIGURE 11 1-2 FIGURE 111-3

NAME POSITION
Grooves Vertical
ELECTRODE DIAMETER AMPERAGE VOLTAGE
E-71T-1 .045" 170-1 90 21-23
Gas flow 30 to 40 CFH carbon dioxide
MATERIAL
1 pc. %" X 1 X 6" carbon steel
2 pn. 3 h " X 3" X 6" carbon steel with a 30-degree bevel on
one 6" side
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple Weave -

Copyright American Welding Society

Procedure 11 1

V=GrooveButt Joint, 36 Position with

Backup Bar

OBJECTIVE 3. Begin at the bottom of the groove using the gun

positions shown in Figure 111-2. Build a shelf for
Upon completion of this lesson you should be able to the weld and using a slight weave motion continue
weld vertical up grooves. the weld up the joint. Make sure the weave is wide
enough to cause the arc to melt the root of the joint
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Text Reference: Section Vi, Lesson 4C; page 423. ensuring good penetration and fusion.
4. After completing the root pass, deposit two more
layers using a single-bead weave to produce each
PROCEDURE layer. (See Figure 111-3.) Increase the width of the
weave for each layer. The second layer should be
1. Adjust the power supply and wire feeder to obtain 21 just under flush. This will allow you to reinforce the
to 23 volts and 170 to 190 amperes, gas flow 30 to joint properly. Hesitate on each side when weaving to
40 CFH. Stay on the low side of the range. fill in the weld and prevent undercut. Cool the plate
2. Clean the pieces to be joined tack them together and between each layer.
position them as shown in Figure 111-1. Thoroughly
tack the backing bar to the plates.

Copyright American Welding Society

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---
FIGURE 112-1

FIGURE 112-2

NAME POSITION
Fillets Overhead
ELECTRODE DIAMETER A M PERACE VOLTAGE
E-71T-1 .045" 170-1 90 21-23
Gas flow 30 to 40 CFH carbon dioxide
MATERIAL
1 pc. %" X 1 %" X 8" carbon steel
1 pc. %" X 3" X 8" carbon steel
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure I 1 2

T=Joint Fillet, 4F Position

OBJECTIVE 2. Clean the pieces to be welded, tack them together,

and position them as shown in Figure 112-1.
Upon completion of this lesson you should be able to 3. Use the gun angles shown in Figure 112-2 and the
weld overhead fillets. backhand technique to put in the first pass. Slightly
weave the gun to prevent lack of fusion along the toe
Text Reference: Section VI, Lesson 4D; page 424. of the weid.
4. Cool the plate, clean it and put in two more passes
using the gun angles shown in Figure 112-2.
PROCEDURE 5. Cool the plate and weld the second side of the T
assembly using the backhand technique and the gun
1. Adjust the power supply and wire feeder to obtain 21 angles shown in Figure 112-2.
to 23 volts and 170 to 190 amperes, gas flow 30 to
40 CFH.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

I i

FIGURE 1 13-1
--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

FIGURE 113-2

NAME POSITION
Grooves Overhead
ELECTRODE DIAMETER AMPERAGE VOLTAGE
E-71T-1 .045" 170-1 90 21-23
Cas flow 30 to 40 CFH carbon dioxide
MATERIAL
1 pc. l h a X 1" X 6" carbon steel
2 pcs. K" X 3" X 6" carbon steel with a 30-degree bevel on
one 6" side
PASSES BEAD TIME (SEE INSTRUCTOR)
Multiple String

Copyright American Welding Society

Procedure 1 1 3

V=Groove Butt Joint, 46 Position with

Backup Bar

OBJECTIVE 2. Clean the pieces to be welded. Tack the pieces to-

gether and position them as shown in Figure l l 3-1.
Upon completion of this lesson you should be able to 3. Keep the gun perpendicular to the joint using a slight
weld grooves in the overhead position. backhand technique and a weave. Begin at the end
of the joint and keep the wire at the leading edge of
the puddle. The position of the wire will determine
Text Referenoe: Section VI, lesson 4D; page 425. the amount of penetration into the backing strip and
shape of the root pass. Keep the wire on the leading
edge of the puddle and deep into the puddle.
PROCEDURE 4. Complete the joint using the bead sequence shown
in Figure 113-2. Change the gun angle for each bead
1. Adjust the power supply and wire feeder to obtain 21 to point in the direction of the bead. Weave each
to 23 volts and 170 to 190 amperes, gas flow 30 to bead to ensure good penetration with the side walls
40 CFH. of the groove, and other weld beads.

--`,``,,,`,``,,````,,,,`````,`-`-`,,`,,`,`,,`---

Copyright American Welding Society

Introduction To Welding: Master Chart of Welding and Allled Processes
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