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Miller Shielded Metal Arc Welding, Manuallines

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Processes

Stick (SMAW) Welding

155 095 A

July 2005

Visit our website at

www.MillerWelds.com

Guidelines For

Shielded Metal Arc

Welding (SMAW)

WARNING

This document contains general information about the topics discussed herein.

This document is not an application manual and does not contain a complete

statement of all factors pertaining to those topics.
This installation, operation, and maintenance of arc welding equipment and the

employment of procedures described in this document should be conducted

only by qualified persons in accordance with applicable codes, safe practices,

and manufacturer’s instructions.
Always be certain that work areas are clean and safe and that proper ventilation

is used. Misuse of equipment, and failure to observe applicable codes and safe

practices, can result in serious personal injury and property damage.

ARC WELDING can be hazardous.

Summary of Contents for Shielded Metal Arc Welding

Page 1: ...pertaining to those topics This installation operation and maintenance of arc welding equipment and the employmentof procedures described in this document should be conducted only by qualified persons...

Page 2: ...Technique 8 3 5 Positioning Electrode Holder 9 3 6 Electrode Movement During Welding 10 3 7 Conditions That Affect Weld Bead Shape 11 3 8 Poor Weld Bead Characteristics 12 3 9 Good Weld Bead Character...

Page 3: ...CFR 1910 147 see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure th...

Page 4: ...any combustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and exti...

Page 5: ...services computers and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician p...

Page 6: ...g OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super int...

Page 7: ...n the electrode and the workpiece and is influenced by electrode diameter Current is a more practical measure of the power in a weld circuit and is measured in amperes Amps The amperage needed to weld...

Page 8: ...acturer when setting weld amperage see Section 3 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the elec trode to the workpiece A short arc wit...

Page 9: ...13 7014 7018 7024 Ni Cl 308L 50 100 150 200 250 300 350 400 450 ELECTRODE DC AC POSITION PENETRATION USAGE MIN PREP ROUGH HIGH SPATTER GENERAL SMOOTH EASY FAST LOW HYDROGEN STRONG SMOOTH EASY FASTER C...

Page 10: ...ift electrode slightly after touching work If arc goes out electrode was lifted too high If electrode sticks to workpiece use a quick twist to free it S 0049 1 2 3 3 4 Striking An Arc Tapping Techniqu...

Page 11: ...elds After learning to start and hold an arc practice running beads of weld metal on flat plates using a full elec trode Hold the electrode nearly perpen dicular to the work although tilting it ahead...

Page 12: ...eave bead or multiple stringer beads work better 1 Stringer Bead Steady Move ment Along Seam 2 Weave Bead Side To Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in o...

Page 13: ...e IMPORTANT Weld bead shape is affected by electrode angle arc length travel speed and thickness of base metal S 0661 Too Slow Normal 10 30 Drag Too Short Normal Too Long Spatter Angle Too Small Angle...

Page 14: ...Crater During Welding 4 Bad Overlap 5 Poor Penetration S 0053 A 5 4 2 3 1 3 9 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer fo...

Page 15: ...cal Weld Joints 804 248 Vertical Position Welds Overhead Position Welds Flat Position Welds Horizontal Position Welds Tee Joint Butt Joint Lap Joint Tee Joint Butt Joint Lap Joint Tee Joint Butt Joint...

Page 16: ...rom material after cutting A grind er can also be used to prepare bevels Create a 30 degree angle of bevel on ma terials in V groove welding Butt Joint Training Procedure Practice welding butt joints...

Page 17: ...heavi er fillet is needed Use any of the weaving patterns shown in Section 3 6 Remove slag before making another weld pass 45 Or Less S 0060 S 0058 A S 0061 1 2 1 3 2 3 13 Welding Lap Joints 1 Electr...

Page 18: ...strip to the plates to make the first weld pass root pass easier 804 260 30 Direction Of Welding 45 90 2 Direction Of Welding Tilt Electrode 15 In Direction Of Travel Make First Weld Pass Root Pass M...

Page 19: ...ee Section 3 11 Tack weld a backing strip to the plates to make the first weld pass root pass easier 804 260 Single Pass Bead Weld Single Pass Vertical Butt Joint Weld Or First Pass Of Multi Layer Dep...

Page 20: ...able for all electrodes For maximum strength weld both sides of joint 804 260 OR Direction Of Welding Direction Of Welding Direction Of Welding Arrows Show Lifting Up Of Electrode And Return To Crater...

Page 21: ...ow weld puddle to so lidify When weaving is necessary use the pattern shown Bevel edges if warranted by ma terial thickness see Section 3 11 Tack weld a backing strip to the plates to make the first w...

Page 22: ...en on a V groove joint made in several layers and calls for addi tional cleaning between layers If the original beveled surface is vis ible the material was not fully melted which is often caused by i...

Page 23: ...ce stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique K...

Page 24: ...ectrode Increase and or maintain steady travel speed 4 7 Waviness Of Bead Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal Possible Causes Corrective Acti...

Page 25: ...tes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL THICKNES...

Page 26: ...www manaraa com Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual...

Page 27: ...www manaraa com Notes Over 80 000 trained since 1930 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now...

Page 28: ...is Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA Canada FAX 920 735 4134 International FAX 920 735 4125 Euro...

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