7
General
This line of welding machines utilizes a
process known as Shielded Metal-Arc
Welding (SMAW). This process is used to
bond metals by heating them with an
electric arc created between the
electrode and the work piece.
Electrodes used for shielded metal arc
welding have two parts. The inner core is
a metal rod or wire that should be similar
in composition to the base metal. The
outer coating is called flux. Various types
of flux exist. Each coating is used for a
particular welding situation.
While the metal is molten, it can be
contaminated by elements in the air. This
contamination could weaken the weld.
The flux coating creates a protective
barrier called slag that protects the
molten metal from contaminants.
When current (amperage) flows through
the circuit to the electrode, an arc is
formed between the end of the electrode
and the work piece. The arc melts the
electrode and the work piece. The melted
metal of the electrode flows into the
molten crater and forms a bond with the
work piece as shown in Figure 4.
NOTE:
Discontinue using and discard
electrodes that burn down to 1 to 2
inches from the electrode holder.
STRIKING AN ARC
Place the bare end of the electrode in the
holder. Grip the holder lightly to reduce
tiring of the hand and arm.
NOTE:
Always keep the jaws of the
holder clean to insure good electrical
contact with the electrode.
Be careful not to
touch the work
piece or welding bench with the
electrode as this causes arc flashes.
The best method of striking an arc is the
scratching method. Drag the electrode at
an angle along the surface much like
striking a match. Upon contact with the
plate, lift the electrode approximately
1/16” off the surface or it will stick (See
Figure 5).
NOTE:
Should the electrode stick to the
work piece, break it loose by quickly
twisting or bending at the holder while
pulling upward. If the electrode does not
break loose, disengage the electrode by
releasing it from the holder.
!
WARNING
ELECTRODE TYPE AND SIZE
Four types of electrodes are
recommended for this welder. The
electrodes are commonly known by the
AWS (American Welding Society)
designation as follows:
1. E-6011 DEEP PENETRATING
•
Flat bead with deep penetrating arc.
•
For rusted or dirty mild steel general
repair work.
2. E-6013 GENERAL PURPOSE
•
All position, smooth deposit rod with
low spatter.
•
For all mild steel and general purpose
work.
3. E-7014 FAST FILL
•
Smooth bead and fast deposition
•
Ideal for joints with poor fitup and
general repair work.
4. E-7018-AC HIGH STRENGTH
•
Ideal for pipes and structural
applications.
•
Low hydrogen reduces porosity for a
strong weld.
NOTE:
Only the E-7018-AC electrode is
recommended for use with these
welders. Other E-7018 electrodes are
designed for use with higher open
circuit voltages than these welders are
capable of producing. Recommended
electrode diameter is 3/32” or 1/8”.
Arc Welding Basics
Four basic techniques affect weld
quality. These are: amperage setting,
weld angle, arc length, and travel
speed. Proper use of these techniques is
necessary for good weld quality.
Slag
Weld
Wire
Flux
Work
Piece
Crater
Figure 4 - Weld Components
1/16"
Same as Electrode Diameter
Figure 5 - Scratching Method
Welding Guidelines
Welder/Generator
Maintenance
(Continued)
valve is in the closed position.
Refer to the engine manual that
accompanies this unit for instructions
regarding maintenance of engine
components.
Never tamper with
engine speed
settings or welder/generator frequency
settings. Any governor adjustments
should be made by qualified personnel
only.
WELD CABLES
1. Check condition of weld cables and
immediately repair or replace any
cables with damaged insulation.
!
WARNING
2. Check condition of electrode holder
insulating pieces and immediately
replace cracked or missing parts.
Every 3 months:
Replace any unreadable labels on the
welder. Use compressed air to blow all
dust and lint from the ventilation
openings.
www.chpower.com
