14

Shielded Metal Arc

Welding Practice:
Jobs 14-J26J42* (Plate)

Introduction Chapter Objectives

This second section of the course in shielded metal arc After completing this chapter, you will be able to:
welding (SMAW) provides practice in a number of weld
14-1 Demonstrate ability to make overhead position welds
joints that are more difficult to weld and require greater with cellulose electrodes.
skill than those experiences that you have had up to this
14-2 Demonstrate ability to make groove welds with and
point. You will also have the opportunity to practice with
without backing in the flat, horizontal, and vertical
a series of new electrodes of the low hydrogen and low (travel up and down) positions.
hydrogen with iron powder types.
14-3 Demonstrate ability to make fillet welds with stringer
This chapter will also provide considerable prac-
and weave bead techniques in the horizontal and
tice in welding various types of basic joints in the flat, vertical positions with cellulose and low hydrogen
horizontal, and vertical positions. You will have your electrodes.
first experience welding in the overhead position. See
14-4 Demonstrate ability to make outside corner welds in
Table 14-1 on page 427 for a list of all jobs outlined in the vertical position with cellulose electrodes.
this chapter. For economic and quality reasons in the
shop every effort is made to position the work so that
welding can be in the flat or horizontal positions, but it
is not always possible to position all of the welding in
this way. A portion of the work will always need to be
welded in the vertical and overhead positions, Fig.141.
A greater amount of out-of-position welding is encoun-
tered in field work. It is not possible to position a build-
ing or all of the joints on a pipeline. When you have
achieved a high degree of skill in welding in the vertical

*The jobs in Chapters 13 to 15 are numbered consecutively because these

units constitute a course in shielded metal arc welding.

388
 Direction of Travel

Plate
Plate 90 Bead
Bead Oscillate
Electrode
Electrode
Hold close arc.
515
Electrode
Side View Front View Drag
(Work Angle) (Travel Angle)
A B

Fig. 14-2 Electrode position when making stringer beads in the

overhead (4) position.

Fig. 14-1 Making a weld in the vertical (3) position. Note the pro-
tective clothing. Location: Northeast Wisconsin Technical College
McGraw-Hill Education/Mark A. Dierker, photographer

and overhead positions, you are well on your way to

becoming a skilled welder able to perform the tasks
required by industry.

Practice Jobs
Job 14-J26 Stringer Beading
Objective
To deposit stringer beads on flat steel plate in the over-
head position with DCEP and/or a.c. shielded metal arc
electrodes (AWS E6010E6011).

General Job Information
Although the tendency today in shops is to eliminate as
much overhead welding as possible by positioning the work,
you must be able to weld in this position. Much of the work
in the piping, shipbuilding, and structural fields is overhead.
Overhead welding will seem quite difficult at first, mainly
because of the position that you must assume. In order to
minimize fatigue, you should be as comfortable as possible.
If you are standing, drape the heavy welding cable over your
shoulders to reduce the weight on the arm you are welding
with. Never wrap the weld cables around your body.
Welding Technique
Current adjustment should be about the same as for verti-
cal welding. Hold the electrode at a 90 work angle to the
plate, Fig.14-2A, and at a drag travel angle of 5 to 15,
Fig.14-2B. Move the electrode back and forth in an oscil-
lating manner. Figure14-3 shows the actual position for
Fig. 14-3 Position of the electrode and electrode holder when
welding in the overhead (4) position. This weld will be made from
left to right with the proper drag angle. Location: Northeast Wisconsin
Technical College McGraw-Hill Education/Mark A. Dierker, photographer
welding. You should be in such a position that you can see
the metal being deposited behind the arc if the direction
of travel is away from you. It is often necessary, however,
that the direction of travel be toward the welder. This is
usually true of pipe welding.
Hold a close arc gap, and do not let the pool become
too molten. A slight oscillating motion back and forth
along the line of weld preheats the base metal ahead of
the weld and keeps the slag washed back on the weld.
If the weld pool gets too hot, move forward faster. If it
becomes too cold, slow down your rate of travel. The
molten weld metal is held up by molecular attraction and
surface tension until each drop solidifies. Study the basic
motions shown in Fig.14-4, page 390.

Shielded Metal Arc Welding Practice: Jobs 14-J26J42 (Plate) Chapter 14389
 Overhead Basic Motions 3. Lay out parallel lines as shown on the job drawing.
Position Similar to Vertical
4. Mark the lines with a center punch.
Box
Direction of Travel
Steady
Weave 5. Obtain electrodes of each quantity, type, and size
specified in the job drawing.
Whip
Z 6. Fasten the plate in the overhead position. Use an
Weave
overhead welding jig, Fig.14-6.
Proper Proper
J J
7. Set the power source at 110 to 170 amperes. Set a
d.c. power source for electrode positive.
Inverted
Circle
8. Make stringer beads on 58-inch center lines
T
asshown on the job drawing. Manipulate
the electrode as instructed in Figs.14-2
through 14-4.
Fig. 14-4 Basic motions when welding in the overhead
(4)position. 9. Chip the slag from the beads, brush, and inspect.
Refer to Inspection.
Practice starts and stops. Travel should be in all 10. Make additional stringer beads between the beads
directions. Weld on both sides of the plate. already deposited as shown on the job drawing.
11. Chip the slag from the beads, brush, and inspect.
Operations Refer to Inspection.
1. Obtain plate; check the job drawing, Fig.14-5, 12. Practice these beads until you can produce good
for size. beads consistently with both types of electrodes and
2. Obtain a square head and scale, dividers, scribe, and with 532-inch diameter electrodes.
center punch from the toolroom.

Fig. 14-5 Job drawing J26.

390Chapter 14 Shielded Metal Arc Welding Practice: Jobs 14-J26J42 (Plate)

 Fig. 14-7 Typical ap-
pearance of stringer beads
welded in the overhead
(4)position with DCEP or a.c.
shielded metal arc coated
electrodes.

Inspection beads and has to be practiced diligently. The technique is

Compare the beads with Fig.14-7 commonly used in pipe welding.
and check them for the following
weld characteristics: Welding Technique
Current adjustment must not be too high. Hold the elec-
Width and height: Uniform
trode at a 90 work angle to the plate, Fig.14-8A, and at
Appearance: Smooth with
a travel angle no more than 10 in the direction of travel,
close ripples; free of voids
Fig. 14-8B. Weave the electrode from side to side and
and high spots. Restarts
hesitate at the sides to prevent undercut.
should be difficult to locate.
It is essential that the arc gap be close and that the
Size: Refer to the job drawing.
gap be uniform for the entire width of the bead. You may
Face of beads: Slightly convex
advance the weld by keeping the electrode in the pool,
Edges of beads: Good fusion,
but you must prevent the molten metal from becoming so
no overlap, no undercut
fluid that it sags. If sagging occurs, advance the electrode
Starts and stops: Free of de-
along either side of the weld in the box weave shown in
pressions and high spots
Fig.14-4, page 390. Lengthen the arc but do not break
Beginnings and endings:
it when you correct the sag. Lengthening the arc with a
Full size, craters filled
conventional power source will reduce amperage. This
Penetration and fusion: To
in turn reduces the melt rate of the electrode. However,
plate surface and adjacent
with solid-state and inverter-type power sources this may
beads
not be the case. They are equipped with a closed loop
Surrounding plate surfaces:
feedback electronic circuitry to maintain the amperage
Free of spatter
that has been set. With these type of power sources do
Slag formation: Full coverage,
not lengthen the arc, as this will increase voltage with
easily removable
no drop off in amperage so the total heat increases and
Disposal will cause the possibility for more sag. The technique
to use with these type of power sources is to maintain
Discard completed plates in the the shorter arc length and simply move out of the weld
waste bin. Plates must be filled pool to allow it to cool down and control the sag in this
on both sides. manner. Figure14-9, page 392 shows this relationship on

Job 14-J27 Weave Plate Direction of Travel

Beads
Objective Bead Plate
90 Bead
To deposit weave beads on flat Weave
Side to Electrode
Fig. 14-6 Overhead
steel plate in the overhead po- Side
welding jig. sition with DCEP and/or a.c. Hesitate at sides
Electrode to prevent undercut. 010
shielded metal arc electrodes
Side View Front View
(AWS E6010E6011). (Work Angle) (Drag Travel Angle)
A B
General Job Information
On many jobs it is necessary to make weave beads in the Fig. 14-8 Electrode position when making weave beads in the
overhead position. This is more difficult than stringer overhead (4) position.

Shielded Metal Arc Welding Practice: Jobs 14-J26J42 (Plate) Chapter 14391
 E Conventional very usable on cellulose-type electrodes (E6010E6011);
Solid-State Inverter however, it should never be used with the low hydrogen-
Enhanced Inverter
type electrodes (E7016E7018). Do not keep the arc out
of the crater any longer than necessary. Keeping it out too
long will cause excess spatter ahead of the weld. Move
Long Arc Voltage the electrode across the face of the weld rapidly so that
you do not overheat the metal deposited in the middle of
the weld and cause it to sag. Making beads wider than 34
Short Arc Voltage inch is not good welding practice.
Practice starts and stops. Travel in all directions. Fill
both sides of the plate.
I
Note
Current Variation Operations
1. Obtain plate; check the job drawing, Fig.14-10,
Fig. 14-9 Conventional, solid-state inverter, and enhanced for size.
inverter power source volt-amp curves.
2. Obtain a square head and scale, dividers, scribe, and
center punch from the toolroom.
various power source volt-amp curves. Compare this to 3. Lay out parallel lines as shown on the job drawing.
the volt-amp curve of the power source you are using; 4. Mark the lines with a center punch.
this will help you understand what type of manipulative 5. Obtain electrodes of each quantity, type, and size
technique to use. This long arc or whipping technique is specified in the drawing.

Fig. 14-10 Job drawing J27.

392Chapter 14 Shielded Metal Arc Welding Practice: Jobs 14-J26J42 (Plate)

 6. Fasten the plate in the overhead position. Use an
overhead welding jig.
7. Set the power source at 75 to 125 amperes. Set a d.c.
power source for electrode positive.
8. Make weave beads between the 34-inch parallel
lines. Manipulate the electrode as instructed in
Fig.14-8, page 391.
9. Chip the slag from the beads, brush, and inspect.
Refer to Inspection.
10. Make stringer beads between the weave beads
already deposited. Current should be set a little
higher (110- to 170-ampere range). Manipu-
late the electrode as in Figs.14-2 through 14-4,
pages389390.
11. Chip the slag from the beads, brush, and inspect.
Refer to Inspection.
12. Practice these beads until you can produce good
beads consistently with both types of electrodes and
with 532-inch diameter electrodes.
Inspection
Compare the beads with Fig.14-11 and check them for the
following weld characteristics:
Width and height: Uniform
Appearance: Smooth with close ripples; free of voids
and high spots. Restarts should be difficult to locate.
Size: Refer to the job drawing, Fig.14-10.
Face of beads: Slightly convex
Edges of beads: Good fusion, no overlap, no undercut
Starts and stops: Free of depressions and high spots
Beginnings and endings: Full size, craters filled
Penetration and fusion: To plate surfaces and
adjacent beads
Surrounding plate surfaces: Free of spatter
Slag formation: Full coverage, easily removable
Disposal
Discard completed plates in the waste bin. Plates must be
filled on both sides.
Fig. 14-11 Typical appearance of weave beads welded in the overhead
(4)position with DCEP or a.c. shielded metal arc coated electrodes.
Shielded Metal Arc Welding Practice: Jobs 14-J26J42 (Plate) Chapter 14393
Job 14-J28 Welding a
Single-V Butt Joint (Backing
Bar Construction)
Objective
To weld a single-V butt joint assembled with a backing
bar in the flat position by means of multipass groove
welds with stringer and weave bead technique with
DCEP and/or a.c. shielded metal arc electrodes (AWS
E6010E6011).
General Job Information
This form of joint construction is used quite frequently
in piping, pressure vessel, and shipyard construc-
tion. The backing material creates the effect of weld-
ing a joint with a chill ring. The single-V butt joint
with backing bar is identical to the test specified by
code authorities such as the Bureau of Shipping, De-
partment of the Navy, and by the American Welding
Society. The root opening varies with different weld-
ing shops. If it is as large as 38 inch, two or three root
passes are needed to weld the joint. For economic rea-
sons, it should be kept as narrow as possible but yet
attain proper weld quality.
Welding Technique
First PassCurrent adjustment can be high. Hold the
electrode at a 90 work angle to the joint, Fig.1412A,
page 394, and at a 10 to 20 drag travel angle, Fig.14-12B.
Use the familiar technique for running stringer beads
with a very slight weave. Secure good fusion with the
backing bar and the root and groove faces of the bevel
plates. Keep the face of the weld as flat as possible.
Second and Third Passes Current adjustment can be
high. Electrode position should be approximately that
shown in Fig.14-12. Weave wider beads than for the
first pass. Do not advance the electrode rapidly. This
will cause coarse ripples and even voids. Keep
the side-to-side motion within the limits of
the finished bead width to avoid undercutting.
Close arc gap control is important. Remove
the slag thoroughly so that good fusion may
be obtained with preceding passes and with
the groove faces of the beveled plate. Use the
edges of the plate as a guide for determining
the width of the last pass.
Practice starts and stops. Travel in all
directions.
 Electrode 1020 4. Set up the plates and tack weld them as shown on the
Weave side to job drawing and Fig.14-14. Make sure the backing
side, second
& third passes.
bar is tight against the back side of the plate.
Electrode
Groove 5. Place the joint in the flat position on the welding
90
Welds
Joint
table. Make sure it is connected to the work
connection.
6. Make the first pass with a 532-inch electrode.
Backup Strip Direction of Travel Manipulate the electrode as instructed in Fig.14-12.
Side View (Work Angle) Front View (Drag Travel Angle)
A B

Fig. 14-12 Electrode position when welding a single

V-groove butt joint in the flat (1G) position.
J OB T IP

Operations
1. Obtain plates; check the job drawing, Fig.14-13, for
quantity and size.
2. Obtain electrodes of each quantity, type, and size
specified in the job drawing.
3. Set a d.c. power source for electrode positive at 110
to 170 amperes or an a.c. power source at 115 to
190 amperes.
Centerline
Success in business is all about innova-
tion. Take, for example, Centerline, a designer and maker
of equipment for resistance welding. It began in Ontario
in 1957, founded by Don Beneteau and Fred Wigle. No
longer a two-person shop, it now has four manufacturing
facilities and employs 350 people worldwide. Its success
is due to foreseeing what industry will be needing.

Fig. 14-13 Job drawing J28.

394Chapter 14 Shielded Metal Arc Welding Practice: Jobs 14-J26J42 (Plate)