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How do
Shielded Metal Arc Welding on piping

I G position
Pipe rotated, Electrode is always at the top
Either a split bead or weave technique
may be used

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2G Position
Pipe Axis Vertical, Weld is
Horizontal, Pipe is
considered in a fixed
position.
Always use a split bead
technique
Always work from the
bottom up.

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5G Position
Axis of the Pipe is Horizontal, The weld in
vertical.
Progression may be up or down.
A weave bead is best used.

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6G Position
Pipe axis is fixed
in position at a 45
degree incline.
Thhe position
includes flat,
horizontal,
vertical, and
overhead welds.
A split bead
tecvhnique is best
used.
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Electrode
The SMAW process uses a consumable electrode.

Electrode must be compatible with base metal.

Electrodes are available for different metals.

Carbon steels
Low alloy steels
Corrosion resisting steels
Cast irons
Aluminum and alloys
Copper and alloys
Nickel and alloys

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Electrode
The AWS system
distinguishes the
tensile strength, weld
position and, coating
and current.
Manufactures may
and do use there own
numbering system
and produce
electrodes that do not
fit in the AWS system.

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Welding Currents
Not all electrodes are designed to work with all
currents.
Common SMAW currents.

Alternating Current (AC)

Direct Current straight polarity (DCSP) or (DCEN)
Direct Current Reverse polarity (DCRP) or (DCEP)

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Electrode Grouping
Electrodes are also grouped according to there
performance characteristics.
Fast-freeze
Mild steel
Quick solidification of weld pool
Deep penetrating
Recommended for out of position welds
Deep penetrating arc
Fast-fill
Highest deposition rate
Stable arc
Thick flux
Flat position and horizontal laps only
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Electrode Grouping
Fill-freeze
General purpose electrodes
Characteristics of fast-freeze and fast-fill
Low hydrogen
Welding characteristics of fill-freeze
Designed for medium carbon and alloy steels

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Electrode Storage
Electrodes are damaged by rough treatment, temperature
extremes and moisture.
The should be kept in their original container until used.
They should be stored in a heated cabinet that maintains
them at a constant temperature.
The storage of low hydrogen electrodes is very critical.

Designed to reduce underbead cracking in alloy and

medium carbon steels by reducing the the amount of
hydrogen in the weld pool.
The flux is hydroscopic--attracts moisture (H2O).
Moisture in the flux also causes excessive gasses to
develop in the weld pool and causes a defect in the weld
caused worm holes.
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Selecting Electrode Size

The optimum electrode diameter is determined by
the thickness of the base metal, the welding position
and the capacity of the welding power supply.
A smaller diameter is usually recommended for out of
position welding.
When completing root passes in V-joints, a smaller
diameter maybe used and then a larger diameter is
used for the filler passes.
A diameter of 3/32 or 1/8 inch can be used on
metals up to 1/4 inches thick without joint
preparation.
ROT: the diameter of the electrode should not exceed
the thickness of the metal.

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SMAW Welding Process

Electrode

Flux
Slag

Gas
shield

Electrode
metal

Penetration
Base metal

Bead

Molten
puddle
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Equipment
Power Supply

Polarity Switch

Power
Cord
Electrode Holder

Power Switch

Electrode
Amperage
Adjustment
Amperage
Scale
Ground Cable

Electrode Cable

Base Metal
(work Piece)
Ground Clamp

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Direct Current straight polarity

(DCSP) or (DCEN)
A rectifier allows current to flow in one direction only.
The direction of the current flow determines the DC
polarity.
DC- or direct current electrode negative is the
arrangement of direct current arc welding
cables/leads in which the electrode is the negative
pole and the workpiece is the positive pole of the
welding arc.
When using DC- polarity, the majority of the heat is
directed at the electrode.
The electrodes designed for DC- polarity produce
weld deposits with shallow penetration. Primary
applications are fast travel speeds on sheet metal.

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Direct Current straight polarity

(DCSP) or (DCEN)

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Direct Current Reverse polarity

(DCRP) or (DCEP)
DC+ or direct current electrode positive is the
opposite of DC- or direct current electrode negative.
In this case, the electrode is the positive pole and the
workpiece is the negative pole.
When using DC+ polarity, the majority of the heat is
directed at the work piece.
The electrodes designed for DC+ polarity produce
weld deposits with deep penetration.
Primary applications are for pipe welding, general
purpose and maintenance welding, deep penetration
applications, and on base material with surface
contaminants.

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Direct Current Reverse polarity

(DCRP) or (DCEP)

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STARTING THE ARC

Before you start to weld, ensure that you have all the required
equipment and accessories. Listed below are some additional
welding rules that should be followed.
Clear the welding area of all debris and clutter.
Do not use gloves or clothing that contains oil or grease.
Check that all wiring and cables are installed properly.
Ensure that the machine is grounded and dry.
Follow all manufacturers directions on operating the welding
machine.
Have on hand a protective screen to protect others in the
welding area from FLASH bums.
Always keep fire-fighting equipment on hand.
Clean rust, scale, paint, or dirt from the joints that are to be
welded.
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Striking The Arc

Select the best electrode

Set the welder (Fig 26-8)
Turn on welder
Warn bystanders
Lower helmet
Start arc (two methods)
Brushing
Tapping

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Brushing Method

Hold end of electrode about 1/4 - 1/2 inch above the surface.
Lower helmet
Gently brush surface of the metal with the end of the electrode.
When arc starts, lift electrode 1/8 inch.
If electrode sticks, twist it back and forth. If it does
not break loose, release electrode from electrode
holder.
Do not shut off the welder with the electrode stuck to the
metal.

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Tapping Method
Set up welder
Hold the electrode at the travel angle and 1/4 - 1/2
inch above the metal.
Quickly lower the electrode until it touches the metal
and then lift it 1/8 inch.

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Electrode Angle
The electrode angle influences the
placement of the heat.
Two angles are important:
Travel
Work
The travel angle is the angle of the
electrode parallel to the joint.
The correct travel angle must be
used for each joint.
Beads = 15o from vertical or 75o from the
work.
Butt joint = 15o from vertical or 75o from
the work.
Lap joint = 45o.
T joint = 45o.
Corner = 15o from vertical or 75o from
the work.
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Electrode Angle-cont.
The work angle is the angle of the electrode
perpendicular to the joint.

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Electrode Angle-cont.
The appropriate angle must be
used for each joint.
Beads = 90o
Butt joint = 90o
Lap joint = 45o
T joint = 45o
Corner = 90o
The work angle may need to be
modified for some situations.
For example, a butt joint with two
different thickness of metal.

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Arc Length
When an arc is too long, the
metal melts off the electrode in
large globules and the arc may
break frequently. This produces a
wide, spattered, and irregular
deposit with insufficient fusion
between the base metal and the
weld. When an arc is too short, it
fails to generate enough heat to
melt the base metal properly,
causes the electrode to stick
frequently to the base metal, and
produces uneven deposits with
irregular ripples. The
recommended length of the arc is
equal to the diameter of the bare
end of the electrode
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Arc Length
The arc length is the distance from the metal part of
the electrode to the weld puddle.
The best arc length is not a fixed distance, but should
be approximately equal to the diameter of the
electrode.
Arc length can be adjusted slightly to change the
welding process.
Excessive length
Excessive spatter
Reduced penetration
Poor quality weld
Insufficient length
Electrode sticks
Narrow weld
Poor quality weld
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Speed of Travel
The speed of travel (inches per minute) is an
important factor when arc welding.
The best speed of travel (welding speed) is
determined by several factors:
The size of the joint,
The type of electrode
The size of the electrode
The amperage setting on the machine
Deposition rate of the electrode (cubic inches per minute)
The deposition rate of an electrode will change with
the welding amperage.

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Speed-cont.
The ideal speed can be
calculated using the volume of
the joint and the deposition
rate of the electrode.
Step one: determine the area
of the weld. (Assuming 1/16
inch penetration.)

Area =

1
0.25 in x 0.25 in
bh =
= 0.0625 in2
2
2

Step Two: knowing the

deposition rate of the
electrode, determine the
welding speed. (Deposition
rate = 2.5 in3/min.)

in
2.5 in3
=
min
min

1
2

0.0625 in

= 40

in
min

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Speed-cont.
The correct welding speed is indicated by the
shape of the ripples.
Too slow = excessive width,
excessive penetration
Too fast = narrower width,
elongated ripple pattern,
shallow penetration.
Recommended = width 2-3
times diameter of electrode,
uniform ripple pattern, full
penetration.

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Current and Speed

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Examples of SMAW Welds

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Flat Position Butt Joints piping

Earlier reexplained that welding can be done in any position, but it
is much simpler when done in the flat position. In this position,
the work is less tiring, welding speed is faster, the molten puddle
is not as likely to run, and better penetration can be achieved.
Whenever possible, try to position the work so you can weld in
the flat position. In the flat position, the face of the weld is
approximately horizontal.

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Flat Position Butt Joints piping

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Flat Position Butt Joints piping

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Flat Position Butt Joints Multipass

piping

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Weaving Motions
You may use one
of the weaving
motions shown,
depending upon
the type of joint
and size of
electrode.

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Horizontal Position
You will discover that it is impossible to weld all
pieces in the flat position. Often the work must be
done in the horizontal position. The horizontal
position has two basic forms, depending upon
whether it is used with a groove weld or a fillet
weld. In a groove weld, the axis of the weld lies in a
relative horizontal plane and the face of the weld is
in a vertical plane. In a fillet weld, the welding is
performed on the upper side of a relatively
horizontal surface and against an approximately
vertical plane

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Vertical Position
A vertical weld is defined as a weld that is applied to a vertical
surface or one that is inclined 45 degrees or less. Erecting
structures, such as buildings, pontoons, tanks, and pipelines,
require welding in this position. Welding on a vertical surface is
much more difficult than welding in the flat or horizontal position
due to the force of gravity. Gravity pulls the molten metal down.
To counteract this force, you should use fast-freeze or fill-freeze
electrodes. Vertical welding is done in either an upward or
downward position. The terms used for the direction of welding
are vertical up or vertical down.
Vertical down welding is suited for welding light gauge metal
because the penetration is shallow and diminishes the possibility
of burning through the metal. Furthermore, vertical down welding
is faster which is very important in production work.
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Overhead Position
Overhead welding is the most difficult position in welding. Not only do
you have to contend with the force of gravity but the majority of the time
you also have to assume an awkward stance. Nevertheless, with practice
it is possible to make welds equal to those made in the other positions.

Current Settings and Electrode Movement

To retain complete control of the molten puddle, use a very short arc and
reduce the amperage as recommended. As in the vertical position of
welding, gravity causes the molten metal to drop or sag from the plate.
When too long an arc is held, the transfer of metal from the electrode to
the base metal becomes increasingly difficult, and the chances of large
globules of molten metal dropping from the electrode increase.
When you routinely shorten and lengthen the arc, the dropping of molten
metal can be prevented; however, you will defeat your purpose should
you carry too large a pool of molten metal in the weld.

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Show SMAW piping

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Knowledge is the key to success

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