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Shielded Metal Arc Welding is a process by which electric current from a welding machine
produces an arc between the electrode and the metals to be joined. As the arc is struck
between the metal rod (electrode) and the work-piece, both the rod and work-piece surface
melt to form a weld pool. Simultaneous melting of the flux coating on the rod will form gas
and slag which protects the weld pool from the surrounding atmosphere. The gases
surrounding the arc are superheated causing the base metal to melt while the filler metal
deposits into the molten puddle.
Welding leads are insulated copper wire and they come in number 4, 2, 1 and 1/0
(single odd). The larger the number the smaller the diameter.
The size of the leads depends on how many Amps that will be used and how long the
leads are.
Welding Rods Classification
Welding rods are tagged with a letter followed by several digits giving the user some
sort of specification such as Tensile Strength, Position and Type of Coating and Current.
Some of the more common rods for carbon steel are E6010, E6011, E6013 and E7018. These
numbers are written on the rods.
For example E6010:
The E indicates an arc welding electrode.
The first two numbers 60, indicates that the filler metal has a tensile strength of
60,000 psi (pounds per square inch). Tensile strength is the force it takes to pull it apart.
The third number indicates the position the rod can be used in. 1 indicates that the
weld puddle solidifies quickly and this rod can be used in any position; flat, vertical or over
head. 2 indicated that the molten puddle remains so fluid, this rod can be used only in a flat
position.
The last two numbers together indicated the composition of the flux coating.
There are two group of welding rods; fast freeze and filler.
The fast freeze rods (E6010 and E6011) have a strong arc force that provides deep
penetrations. After welding the puddles solidifies relatively quick.
Filler rods (E6013, E7018, E7024) dont penetrate as deep. They fill up. This gives a
smoother finish.
The fast freeze is better for modification or repairs. They are often used as first pass to leave
an open and then filled with a filler rod.
E6013 uses either AC or DC+ current for general purpose welding. this is the easiest of all the
rods to use. It produces a smooth finish.
E7018 is a low hydrogen iron with iron powder in the flux this uses AC and DC+ these
produce the highest quality weld. designed for cast steels and this prevent the weld from
cracking. This creates a smooth finish.
E7024 uses AC or DC+ could only be used in the flat position.
If the electrode grounds to the metal and becomes stuck, jerk the stinger to break the rod free
either from the stinger clamp or the weld metal. If the arc is lost because you move the
electrode too far from the metal's surface, stop the process and clean the slag from the spot
you are welding so when you restrike the arc to continue, there will be no slag in the weld
area to contaminate the new weld you are beginning from the place the arc was lost or
broken. Never lay a new bead over existing slag, as this material will melt in the arc plasma
and bubble through the new layer of metal you are placing, resulting in a weak and dirty
weld.
The angle of the rod not only affects how the filler metal is affected but how the
molten slag will behave. When the rod is held between 45 and 90 degrees, the slag is forced
back where it belongs.
When welding in the flat position; relax, get comfortable and use to hands on the
stinger. Maintain the arc gap and constant travel speed. Watch the outside edges of the puddle
and make sure it is staying even.
If the weld bead sags change the weld speed, slow enough to allow fusion but fast
enough to keep the base metal from overheating.
Clean the slag
Slag is a residue left from the welding process. During the weld, the slag protects the hot
metal from contaminants. The slag covering does not cool at the same rate as the weld bead,
which can cause the slag to pop off the weld. Use the chipping hammer to break the slag off
the weld or bump the slag off
Safety glasses should be worn while welding so that when the shield is raised the eyes are
protected.
Tap the slag only hard enough to loosen the slag and avoid putting hammer marks in the new
weld.
Use the wire brush to clean the weld. Remove as many excess particles as possible, especially
if you are going to do another pass.
Allow the metal to cool.
If this is only practice, dipping the metal in water will cool it faster. Cooling in water will
make the weld brittle, so allow any structural welds to cool by air instead.
Safety in Arc Welding
Welding operators should wear dry gloves in good condition.
Inspect the work area for any flammable materials and remove them from the area.
Never touch the electrode or metal parts of the electrode holder with skin or wet clothing.
Be sure to insulate themselves from the work and ground, keeping dry insulation between
their body and the metal being welded or ground.
Inspect the electrode holder for damage before beginning to weld and keep the welding cable
and electrode holder insulation in good condition.
Wear face shields with radiation protection which protects your eyes and face but still allows
the user to see molten weld puddle.
Wear Flame resistant clothing.
Safety Equipment
A critical part of welding safely is having, and knowing how to use, the correct safety
equipment for the job. Here are some typical items that are required for welding safely.
Welding shield (hood). This is the mask which is worn to protect the person welding from the
bright flash of the arc, and from sparks being thrown during welding. Standard arc welding
lenses are tinted very darkly, since exposure to the arc flash can cause flash burns to the retina
of the eye. A level 10 darkness is the minimum for arc welding. Welding hoods with a flip up
lens was once preferred, as the dark lens can be lifted up, and a separate clear glass lens will
protect the welder from bits of slag while the weld is chipped. The newer self darkening
welding shields are the most desirable welding shield now sold. These welding shield lens are
very light colored for grinding and torch cutting. When an arc is struck the automatic self
darkening lens will change to a preset #10 shade. Even newer on the market are the variable
shade automatic self darkening lens.
Welding gloves. These are special, insulated leather gloves that reach about 6 inches (15.2
cm) above the wrists, and protect the hands and lower arms of the welder (the person
welding). They also provide limited protection from accidental shock if the person welding
comes into contact with the electrode accidentally.
Welding leathers. This is an apron like leather jacket that covers the shoulders and chest of
the welder, used for overhead work where sparks might ignite the welder's clothing, or cause
burns.
Work boots. The person welding should wear at least a 6 inch (15.2 cm) lace-up type boot to
prevent sparks and hot slag from burning his feet. These boots should have insulating soles
made from a material which does not melt or burn easily.
References
I. (2012). Arc Welding Lessons. Retrieved June 10, 2016, from
https://www.youtube.com/watch?v=2537L5H7NiY
http://www2.mae.ufl.edu/designlab/Lab%20Assignments/EML2322L-Welding.pdf