SMAW (Stick Welding) SECTION OVERVIEW: Section Overviews are provided on the introductory slides at the front of each topical area to explain the intended use for the slides included in the section. Slide numbers are included on the Section Overview slides for easy reference when preparing for delivery of the slide content. TEACHER NOTES: Teacher Notes are included on the Section Overview slides as a reference tool when making class preparations. Suggested Activities are included as ideas for teachers to use to help students gain practical experience with the welding content. However, these are designed to be supplemented by each teacher based on local program needs. Slides have been developed to incorporate content information regarding performance standards from the American Welding Society (AWS) and the National Academic Standards for English, Science, and Math. INDIVIDUAL WELDING LESSON NOTES ARE AVAILABLE IN LESSON PLAN FACILITATOR’S GUIDE

SMAW Unit Topics During this overview, we will discuss the following topics: Safety SMAW Basics Equipment Set-Up Welding Variables Process Advantages and Limitations AWS Connection National Academic Standards Connection SECTION OVERVIEW: This slide is meant to start generating conversation and thoughts about content to be covered in this lesson. TEACHER NOTES: Bulleted information on topical areas is provided to lead class discussion on areas which are to be covered in the training. The SMAW process is great for maintenance and repair work!

SMAW Safety SECTION OVERVIEW: The next few slides are meant to point out safety requirements when doing SMAW welding. TEACHER NOTES: Slides 4-6: Bulleted information on topical areas is provided to lead class discussion on important areas of safety to be practiced in the SMAW welding environment. To download your own copy of ‘Safety in Welding, Cutting and Allied Processes’ (ANSI Z49.1) go to: www.aws.org/technical/facts/Z49.1-2005-all.pdf To download your own copy of Lincoln Electric’s Arc Welding Safety (E205) document go to: http://content.lincolnelectric.com/pdfs/products/literature/e205.pdf To order copies of Lincoln Electric’s Arc Welding Safety (E205) document and poster (E201) go to: www.lincolnelectric.com (Quick Link: Literature Request) MSDS can be obtained from Lincoln Consumable packaging, online at www.lincolnelectric.com (Quick Link: MSDS) or by calling 1-216-481-8100 For a free DVD on Welding Safely, submit order form in the back of the Lesson Plan Facilitator’s Guide (shipping and handling charges apply). See Facilitator’s Guide for more information on welding hazards such as Fumes and Gases and Electrical Shock.

SMAW Safety Fumes and Gases can be dangerous Keep your head out of the fumes Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area The SMAW process can withstand wind and exhaust near the arc from ventilation equipment Electric Shock can kill – to receive a shock your body must touch the electrode and work or ground at the same time Do not touch the electrode or metal parts of the electrode holder with skin or wet clothing Keep dry insulation between your body and the metal being welded or ground Arc Rays can injure eyes and skin - Choose correct filter shade (See chart below) ** Information taken from ANSI Z49.1:2005**

SMAW Principles SECTION OVERVIEW: These slides are meant to lead into the discussion of the SMAW process TEACHER NOTES: Slides 7-16: For more information on the American Welding Society, see ‘Arc Welding Basics’ and www.aws.org Discussion could be given on stick electrodes commonly being between 9-18” long, and come in diameters ranging from 1/16” to 1/4”. An activity could be to show 3 electrodes all the same diameter: E6010 or E6011, E7018, and E7024. Ask students to compare flux coatings (color, thickness, feel) The size of the electrode is determined by the diameter of its metal core. PLEASE NOTE: The overall diameter of the electrode changes due to flux coating even though metal diameter remains the same. An arc digs into the base metal much like water from a nozzle on a garden hose digs into the earth. (The flow of the water is like welding current and water pressure is similar to voltage)

SMAW Principles The American Welding Society defines SMAW as Shielded Metal Arc Welding SMAW: Is commonly known as ‘Stick’ welding or manual arc welding Is the most widely used arc welding process in the world Can be used to weld most common metals and alloys

SMAW Welding Circuit Current flows through the electrode cable, to the electrode holder, through the electrode, and across the arc On the work side of the arc, the current flows through the base material to the work clamp and back to the welding machine

SMAW Process Let’s take a little closer look at the SMAW process… 1 2 Travel direction Electrode Arc 2 Weld Puddle 3 Shielding Gas 4 Solidified Weld Metal 5 Slag 6 Electrode 1 Travel direction Shielding Gas 4 Slag 6 3 Weld Puddle 2 Arc 5 Solidified Weld Metal

Is a consumable - it gets melted during the welding process 1- The Electrode Is a consumable - it gets melted during the welding process Is composed of two parts Core Rod (Metal Filler) Carries welding current Becomes part of the weld Flux Coating Produces a shielding gas Can provide additional filler Forms a slag

2- The Arc An arc occurs when the electrode comes in contact with the work-piece and completes the circuit … like turning on a light! The electric arc is established in the space between the end of the electrode and the work The arc reaches temperatures of 10,000°F which melts the electrode and base material Can you identify the weld joint and position being used?

3- Weld Puddle As the core rod, flux coating, and work pieces heat up and melt, they form a pool of molten material called a weld puddle The weld puddle is what a welder watches and manipulates while welding 1/8” E6013 at 125 Amps AC

A shielding gas is formed when the flux coating melts. 2 3 Shielding Gas 4 A shielding gas is formed when the flux coating melts. This protects the weld puddle from the atmosphere preventing contamination during the molten state The shielding gas protects the molten puddle from the atmosphere while stabilizing the arc

5- Solidified Weld Metal As the molten weld puddle solidifies, it forms a joint or connection between two pieces of base material When done properly on steel, it results in a weld stronger than the surrounding base metal

6- Slag Slag is a combination of the flux coating and impurities from the base metal that float to the surface of the weld. Slag quickly solidifies to form a solid coating The slag also slows the cooling rate of the weld The slag can be chipped away and cleaned with a wire brush when hard This welder chips the slag off of a weld during the repair of railroad tracks

Equipment Set Up SECTION OVERVIEW: These slides explain how to set up the equipment for SMAW and the process variables used. TEACHER NOTES: Slides 19-21: These slides explain SMAW equipment set up and operator controlled variables The exposed metal end of the electrode should fit securely within the jaws of the electrode holder Discuss how the correct amperage setting for any given electrode is important to ensure proper shape of bead, proper penetration, and minimal spatter. Explain when the amperage is set too high the bead may be flat, have excessive spatter, have some porosity and the electrode will overheat. If the amperage setting is too low, difficulty is experienced in striking the arc and maintaining the correct arc length. The weld bead becomes convex with excessive overlap and poor penetration. Discuss polarity – All stick electrodes run on DC. Not all will weld on AC. All electrodes have a preferred polarity and most are designated by the AWS.

SMAW Equipment Set Up Turn power supply on Connect work clamp Select electrode a. Type b. Diameter 4. Adjust output a. Polarity b. Amperage 6. Insert electrode into electrode holder

SMAW Process Variables Settings on the machine Polarity : AC, DC+, DC- Amperage Output Operator Controlled Variables Work Angle Travel Angle Arc Length Travel Speed A straight AC machine will not have a polarity switch like this AC/DC machine

Type of Coating and Current Electrode E 60 1 10 Electrode Tensile Strength Position Type of Coating and Current Type of electrode   position uses E6013 All Used for welding clean, new sheet metal. E7024 Flat ,Horizontal commonly used for plate that is ½" and up E6010 For pipeline

Welding positions