Professional Documents
Culture Documents
THE MANAGERS
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THE MANAGERS
GUIDE FOR WELDING
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S M A C N A TITLE*MGW 73 = 8187350 0004995 507
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SMACNA TITLErMGW 9 3 = L89350 0004996 4 4 3
FOREWORD
Over the years, sheet metal contractors have known that joining metal is a very labor-intense part of the
business. Many hours have been spent in welding the various parts together that make up the total sheet
metal system. Managing the welding operation of the contractors business is a vital part of the total
operation.
The purpose of the new edition as in the past was to provide the sheet metal manager with the tools to
manage the welding operation of the business. In the last decade there have been changes that have
effected the welding operations in many respects. The Welding Committee of SMACNA developed this
new edition after reviewing the needs of the Contractor and revised the guide to reflect the latest
technology and methods. It was hoped that the revised guide will help Contractors managing their welding
operation more profitably. This edition includes updated coverage for welding processes such as
submerged arc; flux cored wire guidelines; power supplies and spool guns. An expanded safety chapter
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cover such item as health effects, hazards, controls, and OSHA. The latest methods of joint design are
included with updated figures and drawings. New guidelines for developing a welding procedure are
provided in the chapter on standards, codes and specifications. Weld quality is updated and includes
coverage for burn table applications. Estimating is expanded and provides both a short and long method
of estimating welding cost and examples are given. Welder training is updated and covers the Nation
Training Fund (NTF) program and welder qualification. Integration of the metric standards are incorporated
into the text using a "soft" conversion.
Welding in the sheet metal business is a joining process that is part of the contractors' operation and it is
a significant pari of the business. SMACNA through its welding committee working with members,
chapters, and the welding industry is committed to providing sheetmetal contractors with guide-lines for
managing their welding.
SMACNA sincerely appreciates the contributions of the welding industry and the input of concerned and
interested individuals.
WELDING COMMITTEE
OTHERCONTRIBUTORSAND
FORMER COMMITTEE MEMBERS
Gerard L. lacouzze
GLI ASSOCIATES
Bowie, Maryland
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4. AWS A5.1-81, "Specification for Carbon
Steel Covered Arc Welding Electrodes," Note: Later editions of these publications may
American Welding Society, Miami, Florida be available.
-
Chapter 4 Safety
I . Method for Marketing Portable Compressed 12. Electric Welding, Safe Practices Pamphlet
Gas Containers to Identify the Material No.105, National Safety Council
Contained, ANSI Standard 248.1-1954 (IS0 13. Use Arc Welding Equipment Safely,
R443 and R448), American National Industrial Safety Chart No. 2, U.S.
Standards Institute Department of Labor (Available from U.S.
2. Compressed Gas Cylinder Valve Outlet and Superintendent of Documents)
Inlet Connections, ANSI Standard B57.1- 14. Occupational and Educational Eye and Face
1965, OGA V-1-1965 ( I S 0 R40), Protection, Practice for (Partial Revision of
Compressed Gas Association 22.1-1959), ANSI Standard 287.1-1968,
3. Regulator Connection Standards, American National Standards Institute
Compressed Gas Association 15. Practices for Respiratory Protection, ANSI
4. Safe Handling of Compressed Gas Standard 288.2-1 969, American National
Cylinders, Pamphlet P-1, Compressed Gas Standards Institute
Association 16. Industrial Head Protection, Safety
5. Gas Welding and Flame Cutting, Safe Requirements, ANSI Standard 289.1-1969,
Practices Pamphlet No. 23, National Safety American National Standards Institute
Council 17. Allowable Concentrations of Toxic Dust and
6. Use Gas Welding and Cutting Equipment Gases, ANSI Standard 237, American
Safely, Industrial Safety Chart No. 2, Series National Standards Institute
M, U.S. Department of Labor (Available from 18. Threshold Limit Values of Airborne
U.S. Superintendent of Documents) Contaminants, American Conference of
7. Requirements for Electric Arc Welding Governmental Industrial Hygienists
Apparatus, ANSI Standard C87-1971, 19. Safety Code for Building Construction, ANSI
National Electrical ManufacturersAssociation Standard A I 0.2, American National
8. Safety Standard for Transformer Type Arc Standards Institute
Welding Machines, ANSI Standard C33.2- 20. Safe Practices in Gas and Electric Cutting
1956, Underwriters' Laboratories and Welding RP2009, Third Edition,
9. National Electrical Code, ANSI Standard C I , American Petroleum Institute, 1967
NFPA No. 70, National Fire Protection 21. Health Protection in Welding, Metropolitan
Association Life Insurance Company
1O. Recommended Installation and Test 22. Manual of Accident Prevention in
Procedures for High Frequency Stabilized Construction, ANSI Standard A10.1,
Arc Welders, National Electrical American National Standards Institute.
Manufacturers Association
11. National Electrical Safety Code, National
Bureau of Standards and American National
Standards Institute
AWS D.l Structural Welding Code 1. Cary, Howard B., "Modern Welding
AISC Specification for Design, Fabrication and Technology," Prentice-Hall, Inc., Englewood
Erection of Structural Steel for Buildings Cliffs, NJ
AISI Cold Formed Structural Steel (Light 2. AWS A2.4-93, "Standard Symbols for
Gage) Welding, Brazers and Non-destructive
Aluminum Association Specification for Examination," American Welding Society,
Aluminum Structures Miami, FL
AISI Stainless Steel Cold Formed Structural 3. ANSVAWS A3.0-80 Welding Terms and
Design Manual Definitions
ASME Boiler and Pressure Vessel and Piping
Codes
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1. Hobart School of Welding Technology, 600 3. Linde Division, Union Carbide Corporation,
West Main Street, Troy, Ohio 270 Park Avenue, New York, NY 10017
2. James F. Lincoln Arc Welding Foundation, 4. Airco Welding Products Company, 575 -
The Lincoln Electric Company, 22081 St. Mountain Avenue, Murray Hill, New Jersey
Clair Avenue, Cleveland, Ohio 441 17 07974
-
~
SMACNA TITLE*NGW 93 NOTICE TO USERS W 8189350 0005000 572
OF THIS PUBLICATION
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with the document or publication is obtainable 6. Reprint Permission
only on the basis of written petition, addressed to
Nonexclusive, royalty-free permission is granted
the committee and sent to the Associations
to government and private sector specifying
national office in Chantilly, Virginia, and subse-
authorities to reproduce only any construction
quent receipt of a written response signifying the
details found herein in their specifications and
approval of the chairman of the committee. In
contact drawings prepared for receipt of bids on
the event that the petitioner has a substantive
new construction and renovation work within the
disagreement with the interpretation, an appeal
United States and its territories, provided that the
may be filed with the Technical Resources Com-
material copied is unaltered in substance and
mittee which has technical oversight responsibili-
that the reproducer assumes all liability for the
ty. The request must pertain to a specifically specific application, including errors in reproduc-
identified portion of the document that does not
tion.
involve published text which provides the request-
ed information. In considering such requests, the 7. The SMACNA Logo
Association will not review or judge products or
components as being in compliance with the The SMACNA logo is registered as a member-
document or publication. Oral and written inter- ship identification mark. The Association pre-
pretations otherwise obtained from anyone scribes acceptable use of the logo and expressly
affiliated with the Association are unofficial. This forbids the use of it to represent anything other
procedure does not prevent any committee chair- than possession of membership. Possession of
man, member of the committee, or staff liaison membership and use of the logo in no way
from expressing an opinion on a provision within constitutes or reflects SMACNA approval of any
the document, provided that such person clearly product, method, or component. Furthermore,
compliance of any such item with standards
states that the opinion is personal and does not
published or recognized by SMACNA is not
indicated by presence of the logo.
FORWARD iii
COMMITTEE ROSTER iv -
REFERENCES V
NOTICE TO USERS OF THIS PUBLICATION vii
TABLE OF CONTENTS viii
Chapter 1
INTRODUCTION
Joining metal by welding is one of the most welding jobs. It covers weld productivity
most labor-intense operations in the sheet metal and weld quality and provides guidelines for
industry. Predicting and controlling costs and recognizing acceptable performance in these
quality of welding is absolutely essential if areas. This text deals with estimating and
contractors are to manage the work effectively. qualifying welding procedures and welders. It
The present revision was undertaken to refine also provides a checklist for hiring and training
and clarify several areas and to upgrade the competent welders.
manual to promote its use as an effective
contractors guide. A certified welding program of the
National Training Fund (NTF) is available to a
There has been a mystique in the past contractors welders. This certification is
about welding and too often sheet metal administered by NTF to welders seeking
contractors have been totally reliant upon the American Welding Society National Certification
welder for guidance in such matters as the and the program is a way for the contractor to
correct welding procedure, the achievable secure work.
productivity, welding costs and in many instanc-
es, the type of equipment to be purchased. SMACNAs Welding Committee is hopeful
that as contractors use this manual they will
This guide is intended to provide the become more proficient in managing the work
contractors, mangers and supervisory employees and controlling quality to the end that welding
sufficient information to predict welding costs, costs will become more predictable and more
audit welding productivity and recognize weld controllable. Contractors must be able to
quality even though they may not have extensive recognize that in many instances, there are
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experience in laying down a weld. distinct advantages in using welding over other
joining processes.
This text is not intended for welder
training nor does it purport to provide all of As new applications are developed and
the information necessary for weld design. It more experience is gathered, it is anticipated that
will, however, provide the non-expert with the changes in this manual will be required.
information needed to select the type of Constructive responses from users of this manual
equipment and welding process required for are encouraged.
Chapter 2
ELECTRIC ARC WELDING PROCESSES
2.1 Processes
2.2 Carbon Arc Welding (CAW)
2.3 Shielded Metal Arc Welding (SMAW)
2.4 Gas Tungsten Arc Welding (GTAW)
2.5 Gas Metal Arc Welding (GMAW)
2.6 Flux-Cored Arc Welding (FCAW)
2.7 Plasma Arc Welding (PAW)
2.8 Submerged Arc Welding (SAW)
2.9 Summary of Practices and Procedures
2.1 PROCESSES
-
It has been said that any welding process is to by such names as "stick welding," "MIG welding,"
the best welding process . . . for some application. "TIG welding," "Heliarc welding," etc. Although in
-
This section will attempt to describe the basic common usage, these names do not always accu-
characteristics and equipment requirements of rately describe the actual process used. Therefore,
several different arc welding processes that are either in describing welding processes in this manual, the
in common use in the sheet metal industry at the terminology will be that used by the American
present time, or show potential for greater use in the Welding Society (AWS).
near future. Hopefully, an understanding of these Basically, welding processes differ from one
various processes will assist the sheet metal another in the type of electrode used, and whether a
contractors in selecting the best welding process for shielding gas is required or not. Shown below are
each particular application. the more common processes along with their
Over the years, the various welding distinguishing type of electrode and shielding gas
processes used in the sheet metal industry have requirements, if any.
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been referred
EXTERNAL
PROCESS ELECTRODE SHIELDING GAS
Shielded Metal Arc Welding (SMAW) Coated Metal Rod Not Required
Fiux-cored Arc Welding (FCAW) Flux and Metallic Powders Sometimes Required
encased in a metallic
sheath
The power source is usually the constant current to 24 gage [.7Omm]) galvanized carbon steel. In this
(CC) type and must supply direct current (DC). l h e application, the carbon steel sheets are not melted,
carbon electrode must be negative and this is but rather a lower melting point filler metal such as
referred to as straight polarity or Direct Current silicon bronze is melted by the heat of the arc and
Electrode Negative (DCEN). Reverse polarity is flows into the joint. This particular application of the
referred to Direct Current Electrode Positive (DCEP). Carbon Arc Welding process is sometimes referred to
Because the carbon electrode is capable of as "braze welding or "everdur." By concentrating the
carrying high electrical currents, the heat is concen- arc onto the filler metal, it is possible to avoid
trated in a small area. For this reason, Carbon Arc damaging the adjacent galvanized coating, thus
Welding has found application in welding copper. leaving the corrosion resistance of the coated carbon
However, the most common application of this sheet steel relatively intact.
process in the sheet metal industry involves the
joining of light gage (18 [I .3mm]
CARBON
ELECTRODE
4J \\ CARBON
4u TLLERROD
Figure 2-1
CARBON
MANUALLY HELD
TORCH
p 5
ELECTRODE
POWER SOURCE
WORK
Figure 2-2
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SMACNA T I T L E * M G W 93 W 8389350 0005007 9 2 7
METAL
WORK
Figure 2-4
2.4 GAS TUNGSTEN ARC WELDING in certain special applications where minimum
(GTAW) penetration is desired.
Actually, when using DC, the polarity of the elec-
In this process (Figure 2-5), the heat required for trode has a significant effect on the resulting weld.
welding is produced by an electric arc established With the electrode negative (straight polarity) most of
between a tungsten wire electrode and the work. As the energy created by the arc is concentrated in the
in the Carbon Arc Welding process, the electrode is base metal and this results in deeper weld
not consumed. A shielding gas, usually argon, penetration and a relatively narrow melted area.
helium or a mixture of the two, is fed through a However, if the electrode is positive (reverse polarity),
special electrode holder, or torch. This shielding gas the effect is opposite and most of the heat is
exists from the torch around the tungsten electrode concentrated in the electrode. This results in less
and shields both the arc and the weld pool from weld penetration and a wider melted area. Because
atmospheric gases. The effect of the shielding gas is of the concentration of heat in the electrode, a large
such that the resulting weld is smooth, free of spatter diameter electrode must be used. Electrode heating
and slag and is easy to clean or polish. The use of is one of the reasons why DC reverse polarity
the inert gases argon and helium in this process has (electrode positive) is much less popular than DC
resulted in it sometimes being referred to as "TIG" straight polarity (electrode positive).
welding, for "Tungsten Inert Gas" or "Heliarc" welding. DC straight polarity (electrode negative) is used
For specific requirements of internal cleanliness a in the GTAW process to weld a wide variety of metals
backing gas or flux may be necessary. including carbon steel, stainless steel, titanium,
The power source for Gas Tungsten Arc Welding copper and copper alloys. The application of the
should be a constant current (CC) machine. Both GTAW process to the welding of stainless steel is
alternating current (AC) and direct current (DC) are especially important in the food processing, kitchen
used in this process. When using DC, the most com- equipment and other specialty segments of the sheet
mon arrangement is straight polarity (electrode nega- metal industry where welds must be ground smooth
tive). Reverse polarity (electrode positive) is used and blended perfectly into the finish of the base
only metal.
Alternating current (AC) is used in GTAW to weld
aluminum, magnesium and their alloys. Dense oxide
Gas Tunqsten Arc Welding Process layers form very rapidly on aluminum and magnesium
surfaces when they are exposed to the atmosphere
and these oxide layers inhibit the welding process.
However, the periodic reversing flow of atom-sized
WELDING particles that take place when using alternating
-
$
I TORCH
current actually tends to break up these oxide layers,
SHIELDING GAS
\ \L II
and therefore, the base metal is automatically
MOLTEN WELD \ \i, III)/)
1 /
TUNGSTEN
ELECTRODE "cleaned". Usually when using alternating current, a
high frequency current is superimposed on the basic
AC current and this high frequency component further
increases the cleaning action on the weld. Also, the
high frequency current makes it easier to initiate the
arc without contaminating the tungsten electrode.
The weld characteristics using AC are somewhere
between those obtained using DC electrode negative
Figure 2-5 and DC electrode positive.
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n INERT GAS
FOOT PEDAL
Figure 2-6
Gas Tungsten Arc Welding using a water-cooled provided there is good joint fit-up. When the material
torch and with optional foot pedal is shown in Figure is so thick that- required penetration cannot be
2-6. The foot pedal is used to give variable control of achieved without some form of joint preparation (such
the welding current and is especially useful in as edge beveling), or when there is poor joint fit-up, -
initiating and terminating the weld. Although not then a filler rod will be necessary. The filler rod
shown in Figure 2-6, the torch is also available with should be compatible with the base metal and it is -
an "on-off" switch. fed into the weld pool.
Regardless of whether AC or DC is used, the Tungsten is used as the electrode because it has
heat generated in the electrode requires that the low electrical resistance, good heat conductivity, can
electrode holder (or torch) be cooled. If the welding easily emit electrons and has the highest melting
current is less than 150 amps, an air-cooled torch will point of any metal (6,170'F [3410 CI). The current-
usually be adequate. Over 150 amps, a water-cooled carrying capacity of the electrode and its ability to
torch is usually required. emit electrons when hot are enhanced by allowing
When welding thinner metals using the Gas the tungsten with thorium or zirconium. The
Tungsten Arc Welding process, good fusion of the presence of these alloying elements in the tungsten
base metal can be achieved using just the arc without electrode also results in a more stable arc and better
filler rod arc starting. The AWS has standardized
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Tungsten Electrodes
AWS
CLASSIFICATIONS TYPE TIP COLOR
Wrong - crosswise
GRINDING WHEEL POINTERS
grind m a r k s restrict
welding current, cause
- arc wander, chance in- Silicon carbide wheels cut faster than other kinds, but
clusions in weld
cost more, and do not last as long; they need frequent
dressings and tend to be brittle.
Right-lengthwise grind
marks don't restrict cur- Alumina oxide wheels cut slower then carbide
rent Finish pointing on
wheels, but outlast them. Premium alumina oxide
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120-grit wheel
wheels are worth the extra cost, because they lessen
the chance of contaminating welds through pickup on
the wheel.
Figure 2-7
The Gas Metal Arc Weldina Drocess is similar in GMAW are listed in Tables 2-8 throuah 2-13.
concept to the Gas Tungsten ;c Welding process. The GMAW process is often referied to as "MIG"
The main difference between the two is that the welding for "Metal Inert Gas" or "Wire Welding." This
tungsten electrode used in GTAW is replaced with a is not completely accurate, however, since shielding
continuously fed wire which acts as both electrode gases which are not inert (such as CO,) are
and filler wire. A wire feeder is required to commonly used.
mechanically feed the wire at a controlled rate The power source used for GMAW differs signifi-
through the torch (or gun as it is sometimes called). cantly from that used in GTAW. For GMAW a con-
Shielding gases are also fed through the torch and stant voltage (CV) machine must be used instead of
exit around the exposed wire electrode. As in the the constant current (CC) machine used in GTAW.
~
case of GTAW, the choice of shielding gases will The power is almost always supplied as direct current
depend on the particular application. Shielding gas (DC) with the electrode positive.
- selections, suggested flow rates and filler metals for
. 8 1 ~ 3 5 0O O O ~ O I , I , 358
Figure 2-8
m
Figure 2-9
I BUT WELD
A leadingangle
to thegun
gives a lagging
gas shield
2 to 15' angle
dependingon speed
Travel
. _
-'Y
Figure 2-1 1
Reprinted from Welding and Fabricating Data Book 1992/93, pg A21
ELECTRODE
WIRE REEL
WIRE FEED CONTROL
GUN CONTROL
GAS SOURCE& I
(OPTIONAL) I I
WITHOUT GAS
VOLTAGECONTROL !
I
I
I 1
I I
I I
I
I
I
I I
I I
I
-_.-'
I
-\
WORK POWER SOURCE
Figure 2-12
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SMACNA TITLEmMGW 9 3 m 8 3 8 9 3 5 0 00050l14 Ob7 m
The power source and welding circuit used in In the PAW process, the plasma is created
FCAW are the same as used in GMAW, that is, the within a specially constructed welding torch which
power source is a constant voltage (CV) machine directs the flow of plasma gas (usually Argon) past
supplying direct current (DC) and the wire electrode a tungsten electrode and then through a very small
can be positive (reverse polarity) or negative (straight orifice (see Figure 2-13). An electric current is
polarity) depending on the application. Refer to established between the tungsten electrode and
Figures 2-11 and 2-12 for pictures of this arrange- either the work piece or the metal nozzle of the
ment. Tables 2-15 through 2-17 should be consulted torch. This electric current flowing through the
for American Welding Society (AWS) classifications restricted gas stream results in very high current
and electrode equivalents; carbon and low alloy steel densities within the gas, and these high current
electrodes, and stainless steel flux cored electrodes. densities heat the gas to such an extent that
One problem with FCAW is that it produces a thermal ionization takes place and a plasma is
considerable amount of smoke and fumes; even more generated.
than the SMAW process. The control of this smoke Since the plasma gas is usually an inert gas, a
must be considered for reasons of safety and health. certain amount of shielding of the weld area will
An efficient means of collecting the smoke and fumes take place. However, additional shielding is usually
generated by this process is to use a smoke-exhaust necessary and for this reason, the Plasma Arc
welding gun. This gun is equipped with an annular Welding torch has a concentric nozzle which sur-
suction nozzle which completely surrounds the rounds the plasma orifice and through which a
conventional nozzle, and since nearly all smoke and shielding gas (usually argon, helium or a mixture of
fume is trapped at the arc it becomes safer than the two) is introduced.
other common welding processes.
Figure 2-14
Figure 2-14 depicts the two modes of concentrated in a very narrow area. This results
Plasma Arc Welding which are referred to as the in high travel speeds, narrow weld areas, deep
"transferred" mode and the "non-transferred'' penetration and minimal distortion. These high
mode. In the transferred mode, the electric temperatures require that all Plasma Arc Welding
current flows between the tungsten electrode and torches be water cooled. The equipment
the work piece while in the non-transferredmode, required for the PAW process is shown in Figure
the current flow is between the electrode and the 2-15.
torch nozzle. The transferred mode is the most The usual applications of PAW are in the
commonly used mode in PAW because it current range of 1O0 amperes or less, however,
concentrates both the heat of the plasma stream it has been used with currents as high as 500
and the electric arc in the weld area. The non- amperes. One of the more exotic applications of -
transferred mode is usually used for such this process is in the welding of foil thickness
processes as metal spraying or the concentrated materials using currents ranging as low as .10
-
heating of non-metallic materials. amperes. Various welding conditions used when
The high temperature oi the plasmaoarc applying the PAW process to several different
(30,OOO'F [16,649 Cl to 50,000 F [27,760 Cl) metals are listed in Table 2-15.
and its restricted cross sectional area allow large
quantities of heat to be
CONTROL CONSOLE ( O 0o
FILLER
Dnn TORCH l o
WORK 1
SOURCE GAS SUPPLIES
Figure 2-15
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SMACNA T I T L E x M G W 9 3 8389350 0005016 93T
2.8 SUBMERGED ARC WELDING (SAW)
The Submerged Arc Welding (SAW low need for manipulation skills. Some of the
process (see Figure 2-16) is very different from disadvantages: generally limited to plate or pipe
the other processes previously described. in horizontal or flat position; not very portable
Generally limited to flat or horizontal position (automatic operation); flux kept dry and requires
welds, it is usually used in automatic welding slag removal between passes.
applications. It is not easily portable, that is, the
work must usually be brought to the equipment. SAW can use contact voltage (cv) or
In this process the arc melts a continuous filler constant current (cc) power sources 200 to 1,500
metal wire electrode under a blanket of granular amps, 28 to 44 volts at 60 to 100 percent duty
flux that shields the molten metal from cycle. Welding torches come in 3 basic types;
contamination. Similar to SMAW, the arc also side and concentric flux delivery or deep groove
melts some of the flux which produces gases, flux delivery. A gravity hopper delivers flux to the
shielding the arc and molten weld metal from the welding gun. The gun can be hand held (semi-
atmosphere. It also forms a slag coating which automatic) or machine mounted (automatic).
further protects the solidified weld as it cools. Forced air flux feed systems are sometimes
The remaining granular flux is then collected by used. Granular fluxes are described in AWS
vacuuming or brushing to be screened and A5.17 and A5.24. Filler metal electrodes are
reused. The slag is removed by conventional continuous wire (solid or flux cored) and are
chipping methods and is usually discarded, but described in AWS A5.17, A5.23, A5.9 or A5.14.
the slag may be reprocessed and reused if this
process is extensively used. Because flux covers and shields the arc,
SAW poses less radiation danger than other
SAW may be used on carbon and processes. It also emits less smoke and fumes,
stainless steels in plate thicknesses. Sheet metal so less ventilation is required. Equipment and
gage thicknesses are not usually welded using flux is sensitive and therefore requires greater
this process. Some of the many advantages of care. All other safety precautions used in other
SAW are: high quality weldments; very high processes apply to the SAW process.
deposit rates; smooth, uniform finish welds; no
-
spatter; little or no smoke, no arc flash; minimal
protective clothing or equipment; easily
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automated and
TO AUTOMATIC
WIRE FEED
TO WELDER TO FLUX
POWER HOPPER
CONTACT W I ' :
I
w ELDING BA~E
L i WIRE METAL
TABLE 2-1
Performance Characteristics of Covered Carbon Steel Electrodes for SMAW
Capable of producing
AWS satisfactory welds in
classification Type of covering positions showna Type of currentb
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E6013 High titania potassium F,V,OH,H ac, dcep or dcen
E6019 Iron oxide titania F,V,OH,H ac, dcep or dcen
potassium
E6020 High iron oxide ac or dcen
{ :-fillets ac, dcep or dcen
NOTES:
a. The abbreviations indicate the welding positions as follows:
F = Flat
H = Horizontal
H-fillets = Horizontal fillets
V-down = Vertical with downward progression
V = Vertical for electrodes 3/16 in. (4.8mm) and under, except 5/32 in. (4.00mm)
OH = Overhead I{
and under for classifications E7014, E7015, E7016, E7018, and E7018M.
b. The term "dcep" refers to direct current electrode positive (dc, reverse polarity). The term "dcen"
refers to direct current electrode negative (dc, straight polarity).
c. Electrodes of the E6022 classification are intended for single-pass welds only.
d. Electrodes with supplemental elongation, notch toughness, absorbed moisture, and diffusible
hydrogen requirements may be further identified as shown in Tables 2, 3, 10, and 11.
e. Low hydrogen electrodes are available with low moisture content.
Reprinted from AWS A51 - 91
Annealed E430 Annealingimproves ductility. Rod has 15-17 percent Cr for corrosion resistance
405 and ductility.
As-Welded E309 Austenitic welds are soft and ductile. However, base metal heat-affectedzone
E310 has limited ductility.
409 As-Welded E309 Has improved ductility in weld heat-affectedzone. Weld metal has limited
W409 touahness.
As-Welded Weld metal is soft and ductile, but base metal heat-affectedzones have limited
ductility. Heat-affectedzone is susceptibleto corrosion.
446 I
As-Welded
I E308
E309
E310
Type 308 weld metal will not display scaling resistanceequal to the base metal.
Consideration must be given to difference in coefficient of expansion of base and
weld metals.
Annealed or Hardened Annealing imparts difficulty to heat-affectedzones and weld. Weld responds to
and Stress-Relleved heat treatment in a manner similar to the base metal.
As-Welded Austenitic welds are soft and ductile in as-welded condttion. However, base metal
E310 heat-affectedzone will have limited ductility
201 304 As-Welded or E308 Actual weld analysis requirements are 0.08 percent max C. 19.0 percent min Cr
202 305 Fully Annealed and 9 O percent min Ni.
301 308
302
3026 As-Welded or E309 Type 310 weld may be used, but pickup of silicon from the base metal may result
Fully Annealed in weld hot cracking.
304L As Welded or
Stress-Relieved
E347
E308L
-
Stress-RelievingTreatments: 1,200-F (64903-1h or i,600 F (871C)-2hAC.
Avoid stress-relievingbetween 900. (482) and i, i OO. F (593)
303Sc
303
309 309s
I
I
I
As-Weldedor
Fully Annealed
As-Welded
I
I
I
E312
E309
Free-machiningbase metal will increasetendency for hot cracking in welds. Type
312 weld contains a large amount of delta territe to overcome this cracking
tendencv.
321 As-Welded or after stabilizing and E347 Type 321 electrodes are not regularly made because titanium is lost during
deposition.
I
stress-relievinqheat treatment
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TABLE 2-3
Shielding Gas Selections For GTAW
Welding
type Shielding gas Advantages
Manual Argon Better arc starting, cleaning action, and weld
Welding quality; lower gas consumption.
I Argon-helium I High welding speeds possible.
Machine Argon-helium Better weld quality, lower gas flow than required
Welding with straight helium.
Helium (DCSP) Deeper penetration and higher weld speeds than
can be obtained with argon-helium.
spot Argon Generally preferred for longer electrode life. Better
Welding weld nugget contour. Ease of starting, lower gas
flows than helium.
Manual Argon Better pool control, especially for position welding.
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
Welding
Machine Helium Higher speeds obtained than with argon.
Welding
Manual Argon Permits controlled penetration on thin gage material
Welding (up to 14 gage [1.994mm]).
Argon Excellent control of penetration on light gage mate-
rials.
Steel
Machine Argon-helium Higher heat input, higher welding speeds possible
Welding on heavier gages.
Argon-hydrogen Prevents undercutting, produces desirable weld
(UPto 35% H2) contour at low current levels, requires lower gas
flows.
Argon-hydrogen- An excellent selection for high speed tube mill
helium operation.
Helium Provides highest heat input and deepest
penetration.
Argon Ease of obtaining pool control, penetration, and
Nickel and bead contour on thin gage metal.
Cu-Ni-alloys
Argon-helium Higher heat input to offset high heat conductivity of
heavier gages.
Helium Highest heat input for welding speed on heavy
metal sections.
Argon Low gas flow rate minimizes turbulence and air con-
Titanium tamination of weld; improved heat affected zone.
Helium Better penetration for manual welding of thick sec-
tions (inert gas backing required to shield back of
weld against contamination).
Silicon- Argon Reduces cracking of this "hot short" metal.
bronze
Aluminum- Argon Less penetration of base metal.
Bronze
Alternating
Base Material Direct Current Current
DCSP DCRP
Aluminum up to 3/32" (2.4mm) P G E
Aluminum over 3/32" (2.4mm) P P E
Aluminum bronze P G E
Aluminum castings P P E
Beryllium copper
Brass alloys
Copper base alloys
Cast Iron
Deoxidized copper
Dissimilar metals
~~
Hard facing
High alloy steels P G
High carbon steels P G
Low alloy steels P G
Low carbon steels P G
Magnesium up to 1/8" (3.2mm) G E
Mg over 1/8" (3.2mm) P E
Magnesium castings G E
Nickel & Ni-alloys G
Stainless steel G
Silicon bronze P
Titanium G
E-Excellent G-Good P-Poor
TABLE 2-5
Typical Current Ranges for Tungsten Electrodes in GTAW
I DCSP
Amps
EWP EWP
Amps
DCRP I High frequency unbalanced
wave. ac. Amps
High frequency balanced wave,
ac, Amps
-
Reprinted from AWS C5.5-80
TABLE 2-7
Typical GTAW Procedure For Stainless Steel
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
Joint design Straight butt Single-V-groove
Current, Amps 50-90 70-120
Polarity DCSP DCSP
Arc voltage 12 12
Travel Speed As required As required
Electrode type EWTh-2 EWTh-2
Electrode size, in. (mm) 3/32 (2.4) 3/32 (2.4)
Filler metal type ER-308 ER-308
Filler metal size, in. (mm) 1/16 or 3/32 (1.6 or 2.4) 3/32 or 1/8 (2.4 or 3.2)
Carbon steel 75% argon Less than 1/8 in. (3.2mm) thick; high welding speeds without burn-thru, minimum
+25% Co, distortion and spatter.
75% argon More than 1/8 in. (3.2mm) thick: minimum spatter; clean weld appearance; good
+25% Co, puddle control in vertical and overhead positions.
Stainless steel 90% helium +7.5% No effect on corrosion resistance; small heat-affected zone; no undercutting;
argon +2.5% CO, minimum distortion.
Low-alloy steel 60-70% helium Minimum reactivity; excellent toughness; excellent arc stability, wetting charac-
+25-35% argon teristics, and bead contour; little spatter.
+4-5% Co,
75% argon Fair toughness; excellent arc stability; wetting characteristics, and bead contour;
+25% Co, little spatter.
Aluminum, copper Argon & argon Argon satisfactory on sheet metal; argon-helium preferred on thicker sheet
magnesium, nickel, + helium material (over 1/8 in. [3.2mm]).
and their alloys
Aluminum Argon O to 1 in. (O to 25 mm) thick; best metal transfer and arc stability; least spatter.
35% argon 1 to 3 in. (25 to 76 mm) thick; higher heat input than straight argon; improved fusion
+65% helium characteristics with 5XXX series Al-Mg alloys.
25% argon Over 3 in (76 mm) thick; highest heat input; minimizes porosity.
Magnesium Argon Excellent cleaning action.
Carbon steel Argon Improves arc stability; produces a more fluid and controllable weld puddle;
+3-5% oxygen good coalescence and beat contour; minimizes undercutting; permits higher speeds
than pure argon.
Argon +5-10% Less oxidation of weld than Argon-O, mixtures; better penetration pattern and bead
Carbon dioxide wetting comparable to Argon +3-5% O.,
Low-alloy steel Argon +2% Minimizes undercutting; provides good toughness.
oxygen
Argon +2-8% Less oxidation of weld than Argon-O, mixtures: better penetration pattern and bead
Carbon dioxide wetting comparable to Argon +3-5% O.,
Stainless steel Argon +1% Improves arc stability; produces a more fluid and controllable weld puddle, good
oxygen coalescence and bead contour; minimizes undercutting on heavier stainless steels.
Argon +2% Provides better arc stability, coalescence, and welding speed than 1 percent oxygen
oxygen mixture for thinner stainless steel materials.
Copper, nickel, and Argon Provides good wetting; decreases fluidity of weld metal for thickness up to and
their alloys their alloys 1/8 in. (3.2 mm).
Argon Higher inputs of 50 & 75 percent mixtures offset high heat dissipation of heavier
+helium gages.
Titanium Argon Good arc stability; minimum weld contamination; inert gas backing is required to
prevent air contamination on back of weld area.
TABLE 2-1OM
20-40 20130
20-40 20128
.O50 20-40 15/25
16 .O63 20-40 15123
14 ,078 20-40 15120
12 .IO5 20-40 12/16
pj-p
11 .I25 20-40 12115
20-40 12115
20-40 12116
.250 20-40 10115
NOTES (See Below)
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
TABLE 2-11M
Gas Metal Arc Weldinn- of Stainless Steel
I
Material Thickness
I
Electrode
Welding Current
Amperes DCRP ARC
1
Shielding Travel
Gage (mm)
Diameter
(mm.) Groove I Fillet
Voltage Gas Flow
UMIN
Speed
MMIS
I I I I 50165
+
22 0.777 0.8 45/60 16119 9.4-18.9 8.5-12.7
I 20 I 0.929 I 0.8 60185 I 65/90 16/19 9.4-18.9 8.5-11.6
I 18 I 1.270 I 0.9 65/85 70190 16119 9.4-18.9 6.4-10.6
I I I
+
16 1.600 0.9 761100 82/99 16119 9.4-18.9 6.4-9.7
14 1.981 0.9 871115 I 941108 16119 9.4-18.9 6.4-8.5
12 2.642 0.9 9811 30 106/117 17/20 9.4-18.9 5.1-6.8
I 11 I 3.175 I 0.9 104/138 1131121 17/20 9.4-18.9 5.1-6.4
10 3.429 0.9 110/145 I 1201135 17/20 9.4-18.9 6.1-6.4
311 6 4.750 1.I 1351150 I 145/160 18/22 9.4-18.9 5.1-6.8
I 114 I 6.350 I 1.1 1351155 I 1451165 18/22 9.4-18.9 4.2-6.4
NOTES 1 Shielding gas composition
Helium SO%, Arson 7 5%, Carbon Dioxide 2 5%
2 Elecirode Class ER3XX
TABLE 2-12
Gas Metal Arc Welding of Aluminum
Wire Shielding Travel
Feed Gas Flow Speed
IMP CFH IPM
25O-275 15 12-18
25O-275 15 12-20
275-290 15 12-24
275-290 15 12-24
295-320 15 14-24
330-370 30 24-36
30 30-33
175-190 35 20-25
215-225 35 20-25
114 .250 1/16 170-225 21-26 150-195 35 20-24
NOTE 1. For groove and fillet welds - material thickness also indicated fillet weld size. Use vee groove for 3/16" and
thicker.
2. Use Argon for thin and medium material; use 50% Helium for thick material increase gas flow rate 10% for
overhead position.
TABLE 2-12M
Gas Metal Arc Weldina of Aluminum
-
NOTE 1. For groove and fillet welds material thickness also indicated fillet weld size. Use vee groove for 4.750mm and
thicker.
2. Use Argon for thin and medium material; use 50% Helium for thick material. Increase gas flow rate 10% for
overhead position.
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SMACNA T I T L E + M G W 73 D 8389350 000502b 889 D
TABLE 2-13
Filler Metals (Electrodes) For GMAW
~ I Base
metal Material
Suggested Electrode
Electrode
Current range
Electrode
type classification n diameter
(use latest
edition) Amperes
Copper
and
Copper
alloys
Deoxidized copper
Cu-Ni alloys
Manganese bronze
Aluminum bronze
TW bronze
ERCuNi
ERCUAI-A2
ERCUAI-B
ERCuSn- A
A5.6 { 0.035
0.045
1/16
3.32
0.9
1.2
1.6
2.4
150-300
200-400
250-450
350-550
Austenitic
' Inconel** Alloy 600
Type 201
ERNiCrFe-5
ER308
A5.14
{ 0.035
0.045
1/16
0.020
0.9
1.2
1.6
0.5
100-160
150-260
100-400
__-
stainless Types 301, 302, 0.025 0.6 __-
steels 304 & 308 ER308 0.030 0.8 75-150
Type 304L ER308L 0.035 0.9 100-160
Type 310 ER310 0.045 1.2 140-310
Type 316 ER316 1/16 1.6 280-450
Type 321 ER321 5/64 2.0 ___
Type 347 ER347 3/32 2.4 ___
7/64 2.8 ---
___
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
118 3.2
I 0.052
1/16
5/64
3/32
i/a
1.3
1.6
2.0
2.4
3.2
160-450
275-475
___
---
___
Charpy
V-notch,
flb(f) Single/
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
TABLE 2-15
I ELECTRODE EQUIVALENTS 1
I SMAW FLUX-CORED I SMAW FLUX-CORED I
E7018 E70T-5 E8018-C1 E81Tl-Ni2
E70T-1 E91Tl-Ni2
E71T-1 E80T5-Ni2
E705-5 E90T1-n12
E7018-1 E705-5 E8018-C2 E80T5-Ni3
E7018-A1 E70T5-Al E8018-NM E80T5-Kl
E80T1-Al E8018-W E80T1-W
E81T1-Al E9018-M E90T1-K2
E8018-82 E80T1-82 E91Tl-K2
E81T1-82 E90T5-K2
E80T5-B2 E10018-M E l 00T1-K3
E9018-83 E90T1-83 E l 00T5-K3
E91T1-B3 E10018-D2 E l 00T5-D2
E8018-C3 E80T1-Nil E11018-M E l 1OT5-K3
E81T1-Nil E l 10t1-K3
E80T5-Ni1
I AWS
CLASS
I
TYPICAL MECHANICAL
KSI
PROPERTIES
75/25
(Nmm')
TYPICAL WELD
DEPOSIT Yo
75/25 (CO,)
APPLICATION
________~~
Tensile Strength C- 0.032 (0.034) For welding types 301, 302, 304, 304L. 308, and 308L. May be used for
86.0 (593) Mn- 1.20 (1.17) welding types 321 and 347 if sewice temperature does not exceed 500'F
308L Yield Strength SI- 0.79 (.067) (260C). Low carbon content minimizes carbide precipitation.
58.5 (403) P- 0.014 (.014)
A522 Elongation in 2" (50mm) S- 0.005 (0.005)
E306LT-1 45% Cr- 19.50 (19.20)
o Tensile Strength
NI- 9.98
C- 0.034
(9.85)
(0.034) Designed for welding type 309 wrought, or cast forms, but used extensively
309L 84.5 (589) Mn- 1.32 (1 25) for welding type 304 to mild or carbon steel. Also used for welding 304 clad
Yield Strength SI- 0.94 (.88) sheets and for applying stainless steel sheet linings to carbon steel.
A5.22 66.5 (450) P- 0.025 (.025)
E309LT-1 Elongation in 2" (50mm) S- 0.007 (0.007)
37% Cr- 22.63 (22.39)
NI- 12.60 (12.52)
Tensile Strength C- 0.038 (0.032) For welding type 316 stainless. Contains molybdenum which increases
31 6L 89.2 (615) Mn- 1.32 (1.25) creep resistance at high temperatures and resists pitting corrosion induced
Yield Strength SI- 0.86 (32) by sulfuric and sulphurous acids, chlorides and cellulose solutions. Used
A522 69.0 (476) P- 0.027 (.025) widely in the rayon, dye and paper making industries.
E316LT-1 Elongation in 2" (50mm) s- 0.011 (0.010)
36% Cr- 18.52 (18.28)
NI- 12.29 (12.30)
MO- 2.47 (2.47)
* Mechanical properiies shown were established using the recommended 75% Ar/25% CO, When using straight CO, properties will still be well within AWS A5 22 specifications for their respective
classifications.
WELDING DATA
~
AMPERES 130 165 190 220 AMPERES 170 210 250 300
~ VOLTS 25 26 28 30 VOLTS 25 27 26 29
'+ For 10 ga (3 429 mm) material and heavier For 3/16' (4 75 mm) plate, or heavier
0 4 5 (1 2 mmj 1 1 6 (1 6 mm)
VERTICAL-UP VERTICAL-UP
OVERHEAD OVERHEAD
For be51 results, set wire feed speed and adpst voltage for SmOolheSl operalion Electrode extension range is fmm 112'to 1" (12 5 rnm 10 25 mmj, with an optimum range of 5W 10 .Y4 (15 mm to 20 mm). Weid using reverse pclarity DC(+)
Ga. (mm) Class Dia. (in) (mm) TypeIPolarity IPM MMIS Groove Fillet
18 (1.311) ER70S-6 0.035 (0.9) DCEP 12/18 518 551100 901110 15/17
I l I I I I I I I
16 I (1.613) I ER70S-6 I 0.035 (0.9)
I I I I
DCEP I12/18
I
12/18 I518
I
518 I661110
I
661110 I96/112
I
96/112 115117
I
15/17
14 (1.994) ER70S-6 0.035 (0.9) DCEP 12/16 5/7 771120 102/115 16119
12 (2.753) ER70S-6 0.035 (0.9) DCEP 10115 416 881130 1081117 18/20
11 (3.132) ER70S-6 0.035 (0.9) DCEP 10114 416 941135 112/118 18/20
10 (3.510) ER70S-6 0.035 (0.9) DCEP 8/12 315 1001140 1 151120 18120
GAS:
Composition: 75% Argon, 25% Carbon Dioxide
Flow Rate: 20 to 40 f 3/h (9-18 h i n . )
TABLE 2-18
Shielded Metal Arc Weldina (SMAW) of Galvanized Steel
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
11 (3.132) E6010 3/32 (2.4) DCRP 8/14 3/6 64/88 94/91
TABLE 2-19
Shielded Metal Arc Welding (SMAW) of Carbon Steel
I BASEMETAL I ELECTRODE I CURRENT I TRAVELSPEED I AMPERES I
11 (3.132) ER70S-X 3/32 (2.4) EWTh-2 1/8 (3.2) 66/95 115/120 DCEN
10 (3.500) ER70S-X 3/32 (2.4) EWTh-2 1/8 (3.2) 70/1O0 125/130 DCEN
TABLE 2-22
Gas Tungsten Arc Welding (GTAW) of Carbon Steel
TUNGSTEN
ELECTRODE
Ga. (mrn) Class Dia. (in) (mrn) Dia.' (in.) (mm.) Groove Fillet Tme/Polaritv
I 1
~~
14 (1.994) ER7OS-X 3/32 (2.4) EWTh-2 I 1/8 (3.2) 57/81 I 86/91 I DCEN
-
12 (2.753) ER7OS-X
I
I 3/32 (2.4) EWTh-2 I 118 (3.2) 63/90 I 105/110 I DCEN
11 (3.132) ER70S-X 3/32 (2.4) EWTh-2 1 118 (3.2) 66/95 I 115/120 I DCEN
10 (3.510)
~
ER70S-X 3/32 (2.4) EWTh-2 1 1/8 (3.2) 70/100 I 125/130 I DCEN
GAS:
Cornposition: Argon (welding grade)
Flow Rate: 15 to 25 f 3/h (7-12 Wmin.)
'max.
- 10 (3.510) ER3XX 3/32 (2.4) EWTh-2 1/8 (3.2) 70195 125/130 DCEN
2.28 --`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
The Managers Guide for Welding Second Edition
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1 1 1 I
SMACNA T I T L E M M G U 93 8189350 0005032 0 8 2
TABLE 2-24
Gas Tungsten Arc Welding (GTAW) of Aluminum
Material
Thickness 1 Type of
Weld I Tungsten
Electrode
Filler
Rod
N F Shkkng Welding r ; uN
Current
Travel
Speed
I Gage I Decimal I I Dia.
Dia. Amps AC-HF Passes IPM
1 :: 1 1 I 1 ::
14 .O64 Fillet 3/32 3/32 5116 15 70-90 1 9
1 1 1 I
.250 Fillet 3116 3116 112 30 230-250 10
1
~ ~
A-4-
Dia. (mm) Dia. ID (mm) Ilmin. Amps AC-HF Passes MM/S
(mm)
(4) 160-180
groove
6.350 Fillet 230-250 1 1 4
6.350 (4) (4) 200-220
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Chapter 3
WELDING EQUIPMENT
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
3.8 Seam Welders
3.9 Turning Rolls
3.1O Welding Positioners, Tail Stocks, Turn Tat: 2s & h,anipula .ors
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SMACNA TITLErMGW 9 3 8189350 0005034 955
3.1 TYPES OF EQUIPMENT however, the three-phase current provides greater
electrical efficiency and the best welding conditions.
A very wide choice of welding equipment is DC power sources perform well for "out of position"
available to the sheet metal contractor, ranging from weld situations. Constant current DC power sources
very simple alternating current (AC) transformer type operating from three-phase current provide the most
power sources to very sophisticated systems that are desirable power source for SMAW.
mechanized. AC-DC power sources are basically transformer
The contractor considering the purchase of type welding machines with a rectifier, operating from
welding equipment should be sure that the equipment a single phase primary current. The rectifier's
will perform satisfactorily on the metals to be welded, function is to change AC to DC. All AC-DC welding
using the most efficient and least costly process power sources are of the constant current type. The
available. Equipment should be considered that may addition 3f a rectifier and the necessary DC circuitry
be used for more than one process. make it possible for the welding operator to select
Supplies for welding power in the form of AC, DCSP or DCRP by the turn of a switch. AC-DC
alternating (AC) or direct current (DC) can be power sources are used for SMAW and GTAW
supplied from power lines or another source of processes.
electricity. This power is converted to usable current Some AC-DC power sources are specifically
at the welding arc. designed for GTAW by having built-in high frequency,
gas and water solenoid valves, a primary contactor,
Classifications of Power Supplies a control circuit and possibly a rheostat control. An
illustration is shown in Figure 2-6.
Types of Sources of Power The use of AC-DC inverters which convert current
Current Electricity Conversion to high frequencies permits the use of smaller trans-
AC/DC Power line Transformer formers which reduces weight. Welding processes
Generator Rectifier are controlled by electronics which provide control of
Alternator Inverter the static and dynamic attributes of the process.
Transformer rectifiers can be characterized to perform
The last classification of power supplies is the ability like an inverter. Inverters can change output quickly
to provide constant current or voltage. because of the use of solid-state electronics and the
ability to provide high frequencies.
3.2 POWER SOURCE, APPLICATIONS AND LIMI- Because of the elimination of mechanical parts,
TATI0 NS invertors are smaller; respond faster: and cut input
power by up to 75%. Normally inverters are more
Alternating current (AC) transformer type power expensive than transformer power sources.
sources are the most economical of all welding power
sources and are best suited for stick electrode Portable Welding Machine
welding (SMAW) in the flat or horizontal position.
These machines always operate off a single phase
primary current which is an advantage for many sheet
metal shops. Initial cost is low and since they have
no moving parts, require little maintenance. These
power sources designed for SMAW process are of
the conventional "Constant Current" type.
Direct current (DC) generator power sources are
available as electric motor-drivengenerators operated
from an AC three-phase primary current or as
generators driven by fuel-powered engines using
gasoline, propane or diesel fuel. The latter type is
referred to as a portable welder and normally is used
when electrical service is not available. Portable type
power sources also produce limited power for Figure 3-1
Photo courtesy of Hobart Brothers Company
electrical tools and lights.
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
these features will increase the cost of the power material and size. As a general rule, both the
source but they are essential in welding aluminum amount of short circuiting current and the amount of
and stainless steel. inductance needed for ideal operation are increased
as the electrode diameter is increased.
VOLTAGE - Welding voltage has an important Providing power to more than one welding station
effect on the type of process variation or metal can be done using a multiple-operator welding power
transfer desired. Short arc welding requires relatively source. These are normally high current and high
low voltages while spray transfer requires higher voltage power sources that feed station consoles.
voltage. The use of one welding machine with multiple
welders helps reduce equipment cost and reduces
SLOPE - The addition of slope control allows the the need to move units. Individual station output and
operator to fine tune the power output. Slope in there number must match the capacity of the main
GMAW is used during short circuit transfer to limit the power source. Constant current is provided at the
short circuit current so that spatter is reduced when arc and the machine must provide a constant voltage.
short circuits between the wire electrode and It is important to know that all power sources are
workpiece are momentarily interrupted. The greater divided into three general classifications as listed in
the slope, the lower the short circuit current and the National Electrical Manufacturer's Association
within limits, the lower the spatter. The amount of (NEMA) Standard EW-I. NEMA Class 3 power
short circuit current must be high enough (but not too sources have a limit on the maximum amount of
high) to detach the molten drops from the wire. primary amperage they may draw from a given
When little or no slope is present in the welding primary source. Under the NEMA Class 3 rating,
circuit, the short circuit current rises to a very high these welders have a 20% duty cycle. This means
level and a violent but miniature reaction takes place. they can be operated at rated amperage for 2
THIS CAUSES SPATTER. minutes out of every 10 minutes. During the other 8
When a short circuit current is limited to minutes, the machine must be permitted to idle and
excessively low values by use of too much slope, the cool. These power sources are sometimes referred
wire electrode can carry the full current and the short to as utility or farm welders.
circuit will not be interrupted. In this case, the wire NEMA Class 2 power sources may have 30%,
either piles up or sticks to the workpiece and may 40% or 50% duty cycle ratings. There is no limit on
flash off. When the short circuit current is at the the amount of primary amperage they may draw.
correct value, the parting of the molten drop from the Secondary amperage welding on these power sourc-
wire is smooth with very little spatter. es is normally limited to ratings of 300 amperes or
less.
INDUCTANCE - Power supplies do not respond NEMA Class 1 power sources are designed for
instantly to load changes. The current takes a finite heavy duty industrial type operations. Duty cycle
time to attain a new level. Inductance in the circuit is may be rated at 6O%, 80% or 100% at a specific
responsible for this time lag. The maximum amount amperage output. Secondary amperage on these
of current attainable during a short is determined by power sources can be as high as 2000 amps.
the slope of the power supply.
Allowable
Example:
20% x 180 80%
(90 )
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
SPIRAL
LATERAL
Figure 3-2
Reprinted from 1992/93 Welding & Fabricating Data Book A99
Welding cables should be correctly sized. (See A variety of wire feeders for the GMAW and the
Table 3-1) Cables should be equipped with proper FCAW processes are available with the ability to feed
terminal lugs and ground clamps. soft and hard wires as well as cored-type wires.
The positive ground connection is as important as Some wire feeders are limited in the diameter of wire
the lead connection. A positive screw clamp (e.g. they can feed as well as wire feed speed. Most
Lenco) is much preferred over an alligator clamp. quality wire feeders feature such items as:
Grounding to building steel on a project is common * Gas testing system - allows operator to purge
practice, however, in the shop, a ground floor grid is gas lines or quickly check gas flow.
recommended. * Anti-stick circuit - gives precise control of
Cable splices should be made with approved burnback and prevents wire-freeze in weld
connectors. High amperage weld processes may pool.
*
require special ground clamps to assure consistent Cold wire inching - a safety feature which
quality welds and prevent ground cable heat-up. permits the welding wire to be advanced
Loose, poorly designed connections, poor ground through the torch without weld current being
clamps, too-small or worn-out cables all contribute to applied. It can also be used to check wire
unwanted heat and energy loss. feed speed by feeding wire for a measured
Use terminals made for welding cable and check length of time and then measuring inches of
connectors for overheating. Prevent cables from wire fed.
freezing and overheating. Do not permit cables to be * Low voltage circuitry for torch trigger - pro-
hit, cut or scraped and keep cables from becoming vides additional operator safety.
emerged in liquid or overloaded. Some wire feeders have an optional feature that
permits arc spot welding but special arc spot welding
nozzles must be used on the welding torch.
TABLE 3-1
Suggested Copper Cable Sizes
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
I
Machine I I Cable Sizes for Combined Lengths
Size in Duty of Electrode and Ground Cable
Amperes Cycle
O to 50 Ft. 50 to 100 Ft. 100 to 150 Ft. 150 to 200 Ft. 200 to 250 Ft.
(O to 15 m) (15 - 30 m) (30 to 46 m) (46 to 61 m) (61 to 76 m)
1O0 20 6 4 3 2 1
180 20-30 4 4 3 2 1
200 60 2 2 2 1 1/o
200 50 3 3 2 1 1/o
250 30 3 3 2 1 1/o
300 60 1/o 1/o 1/o 210 310
400 60 2/0 2/0 210 310 410
500 60 2/0 2/0 310 310 410
600 60 2/0 2/0 310 410 2x30*
in parallel
Reprinted from AWS Welding Handbook - Vol 2, 8th Edition, Pg 851
Also available are combination feeders and spool gun to pull the wire, rather than push the wire,
torches referred to as spool on gun wire feeders may achieve better results. Other torches can draw
(Figure 3-3). These units offer 30 and 50 foot service wire from an existing wire feeder by using a "push-
line from a portable control box and use either two or pull" system (Figure 3-4),which will permit buying filler
one pound spools depending on the alloy. For soft metals at a lower cost.
filler metal such as aluminum, a
Figure 3-3
Photo Courtesy of Hobart Brothers Company
Figure 3-4
Photo courtesy of Hobart Brothers Company
Copyright SMACNA
Provided by IHS under license with SMACNA Licensee=Army Hdqrtrs/7838506107
No reproduction or networking permitted without license from IHS Not for Resale, 05/30/2006 00:56:33 MDT
SMACNA T I T L E r M G W 9 3 8389350 0005039 437
3.5 BOOMS FOR GMAW AND FCAW PROCESS Since these torches have a number of parts that
need periodic replacement, the contractor would be
This accessory is available as a stationary, floor- wise to standardize when purchasing torches. This
mounted unit or as a moveable cart-type. The floor- could eliminate the need to stock parts for different
mounted unit contains facilities for holding hoses, brands.
power lines, etc., as well as holding the wire feeder. Heavy duty torches used for automatic welding
The cart-type can carry the complete welding may be air or water-cooled. Torches of this type
equipment package to include water ballast tank and would be used on seam welders or other mechanized
circulating pump for a water-cooled torch if desired. equipment.
These booms greatly increase the working range of
welding equipment and keep cables and hoses off
the floor. 3.7 TORCHES FOR GTAW PROCESS
POWER CABLE
CONTACTOR
Figure 3-5 LEADS
ELECTRODE
GAS LINE
Figure 3-7
Photo Courtesy of Pandjiris Inc.
Figure 3-8
Photo Courtesy of Teledyne Readco
Welding Positioner
Figure 3-9
Photo Courtesy of Teiedyne Readco
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
Figure 3-10
Photo Courtesy of Phoenix Products Co.
least 16 feet (4.88m) high with no barriers or or other metal cannot short out across the terminals.
partitions to impede air flow. Welding in smaller Keep cable and connectors in good condition.
areas, or if exposures cannot be kept below
Improper or worn electrical connections can cause
permissible exposure levels (pels) set by O.S.H.A. short circuits and increase the chance of electrical
calls for forced ventilation.
shock. Repair or replace worn, damaged or bare
Use of local or spot exhausters can avoid the need
cable. Splice welding cable with approved
for massive recirculation and make-up air systems.
connectors only and insulate the splice properly.
Work inside confined spaces or welding that
Make no splice within 1 O feet (3.05m) of the electrode
generates material such as lead, cadmium, beryllium,
holder. Use the correct cable size. Continued
mercury, or fluorine compounds calls for air supplied overloading leads to cable failures, electric shock,
respirators if forced ventilation cannot remove and fire hazard. Make tight electrical connections.
contaminants. Air supplied respirators deliver clean Keep welding current from going through gas
air through a supply hose. If air quality is cylinders, flammable liquid containers, pipes
questionable welders should wear respirators. containing air, steam, gas, flammable liquids,
Welding in a confined space is particularly dangerous
electrical conduit, chains, wire ropes, hoists, metal
because inert gas displaces oxygen. handrails and ladders machine shafts, bearings,
weighing scales, and building structures.
NFPA Standard 515, Standard for Fire Prevention SMACNAs Safety Program includes specific provi-
in Use of Cutting and Welding Processes, lists certain sions for performing welding operations and for con-
specifically segregated responsibilities for managers, ducting safety training on a regular basis. In addition,
supervisors and welders. It is recommended that the programs of the National Training Fund
contractors obtain and study this document for incorporate safety considerations. Investigations of
guidance. Among the many published standards and these programs is highly recommended.
procedures dealing with the subject of safety, two
other documents should be owned and understood by
managers and those assigned responsibility for
safety: ANSI Standard 249.7, Safety in Welding and
Cutting, sponsored by the American Welding Society
and OSHA Regulation Section 1910.252 Subpart Q
- Welding. Both have elaborate prescriptions for
dealing with hazards and protecting personnel and
property. The contractors library should also contain
a copy of the annually published Welding and
Fabricating Data Book, Penton/l PC, Inc. This text is
a useful compilation of manufacturers, products, local
sources and engineering data. Substantial portions
of it illustrate safety equipment and safety
precautions. The contractor must also be familiar
with the requirements of local building and fire codes.
Local agencies may have jurisdiction over welding
operations.
Special Training
Special Inspection
Equipment Maintenance
Signs, Markers
Barricades
Fire Watch
Ventilation
Chapter 5
JOINT DESIGN
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
can sometimes be turned over or jigged into various they represent are shown in Figures 5-4 through 5-10.
positions. In the field, however, welds are almost
always made with the joint in its final and only possible
position. For this reason, the problem of accessibility is
usually of greater importance in the field. The designer
must locate field welds so that they are clear of all
obstructions such as adjacent duct work, piping or
building steel. The welder must have clear access to
the entire joint.
Edge preparation is an especially important design
consideration since the configuration and condition of
the edges to be welded will directly affect the depth of
penetration, porosity and inclusion of impurities in the
I
FINISH SYMBOL
CONTOUR SYMBOC $/ GROOVE ANGLE. INCLUDED ANGLE
OF COUNTERSINK FOR PLUG WELDS
ROOT OPENING, DEPTH OF FILLING
GRM)VE WELD SIZE 7 ,,/-FOR PLUG AND SLOT WELDS
DEPTH OF BEVEL. SIZE OR
u ,/ ,,- -
LENGTH OF WELD
FIELD WELD
SPECIFICATION
PROCESS OR
OTHERREFERENCE , \ WELD ALL-
AROUND
SYMBOL
TAIL (OMITTED
IS NOT USED) / I / \
REFERENCE LINE
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
WELD SYMBOL
REFERENCE LINE TO
ARROW SIDE MEMBER
OF JOINT OR ARROW
c
OR PROJECTION WELDS SIDE OF JOINT
Figure 5-1
Reprinted from AWS A2.4-93
The Eight Basic Tvpes of Welds and Their Associated Weld Svmbol
h i
SPOT OR PROJECTION FLANGE WELD
WELD
Used for light gage metal
Used without prepared holes
joints
Use arc or resistance
SEAM WELD
Continuous-use arc or
resistance
GROOVE WELD
Second most popular-may
be single or double-has
many variations
A l5ZF3
Figure 5-2
Reprinted from AWS A2.4-93
5.3 WELDING POSITIONS
As mentioned in Chapter 5.1, the position in which AWS has defined the four basic welding positions as
a weld must be made is an important design FLAT, HORIZONTAL, VERTICAL and OVERHEAD.
consideration. It may affect the choice of welding These four basic positions, as applied to both fillet
process to be used and the skill required of the and groove welds, are illustrated in Figure 5-9.
welder using that process. Also, any welding Examination of the basic positions shown in
- procedure must Figure 5-9 reveals that the flat and horizontal position
indicate the position in which the welding is to be welds can be tipped or rotated into either vertical or
- performed. It is therefore important that the various overhead position.
welding positions be clearly defined. The
ROOVE
TYPES SINGLE SYMBOI DOUBLE (CYMBOI
CONVERSIONS
;QUARE O" TO 'la"
UP TO 3/16"
I I
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
V
I__- --
Li----
4
BACKING O" TO 'Is"
rtf
1 314 44
FLARE
V
FLARE
BEVEL
Figure 5-3
There are five basic types of joints used for Examples of weld joint designs for various metal
welding; these five basic joints are shown in Figure 5- thicknesses with edge preparation indicated when
1o. required, are shown in Figure 5-11.
Each of these five joints can be welded using
several different types of welds, thus giving the 5.5 WELD STRENGTH
designer a wide range of combinations from which to
choose. Stress analysis, if required, would ordinarily have
Edge preparation such as beveling is usually been performed by the designer and would have
required only when welding metals thicker than 10 resulted in a design specification for welding. If the
gage (3.51Omm). The need for edge preparation is sheet metal contractor is responsible for weld design
based on the need to provide access to the weld and must determine weld strength, qualified
area so that adequate weld preparation can be designers for stress analysis must be used.
achieved. In some instances, a root opening alone or
a root opening with a backing strip can be used
instead of a mechanically prepared joint. This should
be given serious consideration by the designer
because of the labor costs involved in edge
preparation.
EDF- %6"
(8mm)
SYMBOL
of single-fillet weld
'/2"
cL!G+-
(13mm)
(1Ornm)
DESIRED WELD
SYMBOL
(1Omm)
l/,'
Y4" x fi"
(6 X 13mm)
ORIENTATION
SHOWN ON
DRAWING
DESIRED WELDyy SYMBOL
....
~. ' Note: %" (13mm) leg
h-(D) Site of fillet weld having unequal legs on member B
G
n
SYMBOL
DESIRED WELD
(E) Continuous fillet weld
Figure 5-4
4" 4"
-(102mm)- (1 02mm)-
b(127mm)- (254mm) -
.............
................. ...............
.................
................ .................
I 1
..............
................... ...............
................
................ .................
I
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
SECTION A-A
L A
WELD CROSS SECTION SYMBOL
G A
SECTION A-A
Figure 5-6
SYMBOL SYMBOL
WELD CROSS SECTION
JOINT DETAILED JOINT NOT DETAILED
(8)OTHER-SIDE EDGE-FLANGE WELD SYMBOL
Figure 5-7
- -
.....
.....
.....
._....
...... \
SYMBOL
JOINT DETAILED
Figure 5-8
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
/
PLATES AND AXIS PLATES VERTICAL PLATES VERTICAL AND PLATES AND AXIS OF
OF WELD HORIZONTAL AND AXIS OF WELD AXIS OF WELD WELD HORIZONTAL
HORIZONTAL VERTICAL
Figure 5-9
Stress analysis is addressed in the following Such documents describe the design of welds in
publications: terms of an allowable stress which is the maximum
AWS D.l Structural Welding Code force per unit of area that can be applied in one type
AISC Specification for Design, Fabrication and of load or a combination of loads. Loads are
Erection of Structural Steel for Buildings normally described in terms of tension, compression,
AISI Cold Formed Structural Steel (Light Gage) bearing, bending, shear or torsion. Any welded
Aluminum Association Specification for Aluminum assembly would have to be analyzed for the manner
Structures in which such loadings would apply to the physical
AISI Stainless Steel Cold Formed Structural arrangement of the structure and the properties of the
Design Manual metal.
ASME Boiler and Pressure Vessel and Piping
Codes
American Petroleum Institute Standard on Piping
in Tanks
APPLICABLE WELDS
SQUARE-GROOVE FLARE-V-GROOVE
V-GROOVE FLARE-BEVEL-GROOVE
BEVEL-GROOVE EDGE-FLANGE
U-GROOVE BRAZE
J-GROOVE
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
APPLICABLE WELDS
FILLET FLARE-BEVEL-GROOVE
SQUARE-GROOVE EDGE-FLANGE
V-GROOVE CORNER-FLANGE
BEVEL-GROOVE ROOT
U-GROOVE PROJECTION
J-GROOVE SEAM
FLARE-V-GROOVE BRAZE
APPLICABLE WELDS
FILLET FLARE-BEVEL-GROOVE
PLUG ROOT
SLOT PROJECTION
SQUARE-GROOVE SEAM
BEVEL-GROOVE BRAZE
J-GROOVE
APPLICABLE WELDS
FILLET FLARE-BEVEL-GROOVE
PLUG ROOT
SLOT PROJECTION
BEVEL-GROOVE SEAM
J-GROOVE BRAZE
APPLICABLE WELDS
SQUARE-GROOVE EDGE-FLANGE
BEVEL-GROOVE CORNER-FLANGE
V-GROOVE SEAM
U-GROOVE EDGE
J-GROOVE
EDGE JOINT
Figure 5-10
+
I T Max. = 'h" (3.1mm)
E-PIC Partial penetrating, open square groove weld, weld one side:
+
transverse loads.
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
Partial penetrating square groove weld, weld one side:
B-PId
/-Il- I. Effective throat thickness shall be taken as 85% the thickness of the
thinner part joined up to 3/16" (4.8mm) maximum thickness.
2. Effective throat thickness for 1/4" (6.4mm) thickness shall be taken
0-1/16"max. (1.6mm) as 118" (3.2mm).
3. Shall not be used when root of weld is subject to tension.
T Max. = Y4" (6.4mm)
8-Llb
Open square groove weld, weld both sides:
r-H+
1. Effective throat thickness shall be taken as 100% of the thinner part
joined.
2. Gouging or chipping out of the back side of the root pass is not
necessary.
T Max. = fi" (6.4mm)
6-PPa
e I
\ y -
4
O-%" m&. (3.2mm)
T Max. = 95'' (13mm)
O-YS min. (0.8mm)
Partial penetrating single vee groove weld, welded from one side:
1. The effective throat thickness shall be taken as three fourths the
thickness of the thinner part joined.
2. Shall not be used when root of weld is subject to tension bending.
3. Shall not be used when subject to fatigue, impact loading or service
at low temperature.
4. Preparation and welding relatively inexpensive.
BP4 Partial penetrating, single bevel groove weld, welded from one side:
1. May be used for horizontal joints.
O-%" max.
(3.2mm) 2. Effective throat thickness shall be taken as three fourths the
thickness of the thinner part joined.
O-%'' min. 3. Shall not be used when root of weld is subject to tension bending.
(2.4mm) 4. Shall not be used when subject to impact and/or fatigue loads.
5. Should be used only where design of the stmcture will resist
Lower edge for horizontal angular distortion of the joint or where angular distortion is not
.Lposition detrimental.
T Max. = %" (13mm)
CORNER AND TEE JOINTS (C AND T)
Square Groove weld, welded both sides:
pc+
TC-L1
1 . Suitable for all types of loading except fatigue loading.
2. Economical in preparation and welding.
3. The root of the first weld should be back gouged to sound metal
(3.2mm) before depositing the second weld.
TC-L4b + Single bevel groove weld, welded both sides, with skewed angle not
less than 45':
1. Good for most types loading.
2. Economical for thicknesses between 1/4and 3/4inch (6.4-19mm)
from the standpoint of welding required.
5-90" 3. Shall not be used when tension due to bending is concentrated at
45" min. the root of weld.
4. Should not be used when subject to fatigue, impact loading or
service at low temperatures.
5. To obtain maximum strength, root of first weld should be gouged to
sound metal before depositing second weld.
6 . Difficult to obtain sound weld due to perpendicular groove face.
TC-P5b Double fillet welded tee joint:
I . Efficiency determined by weld size.
2. When greater strength is required a beveled joint should be used.
3. Shall not be used when subject to impact and/or fatigue loads when
the direction of loading is other than parallel to the axis of the
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
weid.
4. Single fillet weld may be used when root of weld will not be
subject to tension bending.
S = % rnax. (16mm)
Figure 5-11
Reprinted from AWS D1.l-92
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
Partial penetrating square groove comer joint, inside fillet weld:
1. Efficiency determined by weld size.
2. Used intermittent welds whenever possible.
3. Shall not be used whenever root of weld is subject to tension
bending.
T Min. = 16 gage (1.613mm) 4. Should be used whenever good appearance of the outside comer
T Max. = I"/' (6.4mm) must be maintained.
C-Pla
Partial penetrating square groove weld, welded from one side:
d= 1. Shall be used only when the inside of the joint is inaccessible for
welding or when the appearance of the outside comer is not critical.
2. Should not be used when root of weld is subject to tension bending.
C-Plb x7T-- Partial penetrating open square groove weld, welded form one side:
1. The effective throat thickness shall be taken as 3/4 T.
2. Shall not be used when root of weld is subject to tension bending.
3. Should be used only when surface across joint is required to be
relatively flush.
c-Plc
Figure 5-11
Reprinted from AWS D1.l-92
Chapter 6
STANDARDS, CODES
and SPECIFICATIONS
~~
S M A C N A TITLEUMGW 9 3 8389350 O005063 756
6.1 STANDARDS, CODES AND documents were very difficult for the sheet metal
SPECIFICATIONS HISTORY contractor to use since the materials and thickness
addressed within these documents were beyond the
In the early 1900's the manufacturing and scope of sheet metal fabrication and erection. Even
engineering communities recognized that the steel D1.3, although written for sheet steel, being for
pressure vessels and structural steel assemblies for structural use, worked poorly when used for the
buildings and bridges were being fabricated and welding of ducts, hoods and architectural items.
erected in accordance with each individual However, since publication of AWS D9.1-80, the
manufacturer's or engineer's requirements. The lack sheet metal contractor has been able to develop
of standard rules of construction caused concern that welding procedures, qualify welders and perform
minimum rules of safety were not being met. As a welding operations to a specification developed
result, committees were formed to develop standards, specifically for sheet metal welding.
codes and specifications. These documents were There is still a large volume of welded fabrication
written to provide a level of quality to assure that the and erection being performed by sheet metal
product being fabricated would meet necessary contractors to the requirements of project
engineering requirements. These codes Set-up specifications that reference either the AWS
standard criteria that tells the fabricator how to Structural Welding Code-Steel or the ASME Boiler
prepare a welding procedure, test and qualify and Pressure Vessel Code. The difference in
welders, inspect the quality of the work and in very requirements between these documents and the
specific language sets forth all of the requirements for AWS D9.1 are substantial and failure to understand
making sound, high quality weldments. These codes these differences could result in extensive repairs or
give the welding industry the controls needed by the even refabrication of the items. The contractor
owner and the designer to assure the safety and the required to work in accordance with the provisions of
satisfactory performance of the product. these other codes must be familiar with these
Two commonly referred to codes for welded differences and perform the work within the code's
fabrication and erection are the ASME, Boiler and requirements. It is recommended, that if the welding
Pressure Vessel Code and the AWS Structural of sheet metal has incorrectly been specified to a
Welding Code-Steel. In addition, there are numerous structural or boiler code, that the contractor ask that
standards, codes and specifications for the welding of the specifications be amended to use AWS D9.1.
pipe, sheet metal, sheet steel in buildings, structural AWS D1.3 became a code in 1981 and AWS D9.1
reinforcing bars, tubular structure, etc. became a code in 1990.
Code welding came late to the sheet metal
industry. Requirements to weld to a Sheet Steel or 6.2 THE MYTH AND MYSTIQUE OF CODE
Sheet Metal Code have been in place for less than WELDING
twenty years. In the mid 1970's, AWS assigned a
committee and undertook the writing of a code Many people in the fabricating industry are fearful
specifically designed for the welding of thin-gage of bidding or taking work that is specified to be
thickness materials. Published in 1978 and welded to a code. This fear is unwarranted. There is
designated AWS D1.3, Specification for Welding nothing magical or mystical about the requirements of
Sheet Steel in Structures, this document established a welding code. In almost every case those
standards for welding procedures and welder requirements are just good common sense or good
qualification tests. And Similar to the other welding managerial practices that may be already in place. If
codes, inspection criteria were also a part of this those controls are not already in place, they should
document. But the big difference is that AWS D1.3 be. These conditions improve your quality and
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
recognizes that welding of sheet thickness steels is productivity for both code and non-code applications.
not the same as welding plate that needs joint Normally, the welder does not understand the
preparation and multi-pass welds. This was the first provisions of the code, and they do not see any
document to recognize these different requirements sense in writing procedures and taking welding tests.
and establish the proper requirements of this unique This attitude is very understandable. That same
part of the welding industry. But it was not the last welder also does not want the manager to stand and
document to do so. watch what they are doing. So the idea that you will
In 1980 the American Welding Society published tell them what size electrode to use, where the
AWS D9.1-80, Specification for Welding of Sheet machine should be set and the travel speed that
Metal. Prior to that time a specification written for should be used will "irk" the average welder who
use in heating, ventilation and air conditioning sheet thinks that they know4their job. But from a
metal welding did not exist. Consequently, project management and control perspective, it makes
specifications usually required the use of one of the excellent sense.
existing codes, standards or specifications. These Listed below are some of the benefits that may be
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
The requirements for the development of essential variables are known, they must be recorded
welding procedures to meet project specifications on a welding procedure specification form similar to
vary according to which of the codes are referenced that shown in Figure 6-1.
for welded sheet metal fabrication and erection.
However, one of the requirements for welding 6.4 WELDING PROCEDURE QUALIFICATION
procedure development common to all the codes, is
defining the essential variables of a welding The methods and requirements for qualification
procedure. of a welding procedure will vary with the code,
The variables referred to, are those ingredients standard or specification to which the welding
that will have a direct effect on the weld, if changed. procedure is being qualified. The ASME Boiler and
Only those ingredients having that effect are Pressure Vessel Code requires mechanical testing of
considered "essential" to the process. For example, test specimens removed from the welded test
you cannot change from 18 ga. (1.31 1mm) material sample. The AWS Structural Welding Code-Steel
to 10 ga. (3.510mm) without changing machine requires visual examination and non-destructive
settings, etc. Therefore, base metal thickness is an testing in addition to the mechanical testing of the
essential variable for any welding procedure. The welded test sample, whereas AWS D9.1 Code for
minimum essential variables to be considered during Welding of Sheet Metal, requires visual inspection of
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
unless there is a specific reason to question the
welders proficiency.
Filler Speed
Metal of
Size Current Range Voltage Range Travel Joint Detail
We, the undersigned, certify that the statements in this record are correct and that the test specimens were
prepared, joined, and examined in accordance with the requirements of ANSVAWS D9.1, Sheet Metal Welding
Code.
Manufacturer or Contractor
Authorized by
Date
Figure 6-1A
Reprinted from AWS 09.1-90
Variables
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
Manuai, stmiautomatic, or automatic
* F imetal class
Electticalcharade
Modc of transfer
of I
Wc,the undersigned, certify that the statements in this record are correct and that the test specimens were prepared,
joined, and cxamkd in accordancc With the requirements of ANSI/AWS D9.1, Sheet Metai Welding Code.
Manufacturer or Contractor B e sk e d . & C U
A
Figure 6-16
Reprinted from AWS D9.1-90
Variables
Base metal
Metal thickness
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
Coating type
Joint preparation
Backing material
Position of welding
Welding process
Manual, semiautomatic, or automatic
*Filler metal spec.
*Filler metal class.
*Weld metal grade
Electrical characteristics ac -cep dcen
Mode of transfer
Shielding gas/combination
Gas flow (CFH)
*See Definitions in Glossary - Chapter 11
JOINT PROCEDURE
We, the undersigned, certify that the statements in this record are correct and that the test specimens were
prepared, joined, and examined in accordance with the requirements of ANSVAWS D9.1, Sheet Metal Welding
Code.
Manufacturer or Contractor
Authorized by
Date
Figure 6-2A
Reprinted from AWS D9.1-90
Electrical characteristics
JOINT PROCEDURE
Power speed
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
of
Voltage Range Travel Joint Detail
We, the undersigned, certify that the statements in this record are correct and that the test specimens were prepared,
joined, and examined in accordance with the requirements of ANSIIAWS D9.1, Sheet Metal Welding Code.
Manufacturer or Contractor
Authorized
Da
Figure 6-2B
Reprinted from AWS D9.1-90
Yes No Yes No
I
I
1
I I
I I
inclusion than 9.23 I I
1 I 1
I I
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
f Weld
I
Braze
Weid
Figure 6-3B
-
Reprinted from AWS D9.1-90
Chapter 7
WELD QUALITY
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
7.1 Quality of Welds
7.2 Pre-Weld Consideration
7.3 Weld Inspection
7.4 Trouble-Shooting Weld Quality
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
Examples of Good and Bad Welds
Figure 7-1
Inspection of welds for material thickness 114 in. UNDERCUT - Undercut may not exceed 15% of
(6.4mm) and lighter shall be in accordance with AWS material thickness of sheet being welded is 3/16 in.
D9.1. Inspection of all production welds shall be (4.7mm) or thinner, or exceed 25% of material
visual without the aid of magnification (prescription thickness when the metal thickness of sheet being
eyeglasses for vision correction are acceptable). welded is greater than 3/16 in. (4.7mm).
Welds should be cleaned before inspection. (See CRACK - There shall be no cracks.
note) The following acceptance criteria for work shall CONFORMANCE - Completed welds shall be
be as follows: visually inspected for location, size, and length in
accordance with the engineering drawing and
FUSION - Complete fusion shall be obtained. specification requirements.
PENETRATION - Required joint penetration as Visual inspection of welding beads is sufficient to
specified for the application shall be present. diagnose elementary problems. Dye penetrant will
REINFORCEMENT OF GROOVE WELDS - A show up surface cracks or pin holes. For heavier
maximum of 1/8 in. (3.2mm) face reinforcement and weldments where structural strength is a requirement,
1/8 in. (3.2mm) root reinforcement shall be the use of radiography, ultrasonic or magnetic particle
acceptable. testing may be required.
THROAT AND CONVEXITY OF FILLET WELDS -
The minimum throat shall be as specified for the 7.4 TROUBLE-SHOOTINGWELD QUALITY
application with maximum convexity not to exceed 1/8
in. (3.2mm). The contractor or welding supervisor trouble-
POROSITY OR INCLUSIONS - Some limited shooting weld quality should first be sure the weld
porosity or inclusion is acceptable. Fusion: process for the particular job is correct. All pre-weld
* One visible pore or inclusion no larger than considerations should be rechecked. Consult the
50% is permitted in any iin. (25mm) of weld. trouble-shooting guide tables for the weld process in
* Three visible pores or inclusions no larger use.
than 25% of material thickness are permitted
in any 1 in. (25mm) of weld. NOTE: f o r cleaning stainless steel welds, use
uncontaminated stainless steel wire brush.
Carbon steel will cause oxidation of stainless
steel base metal.
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
TABLE 7-1
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
SMAW Troubleshooting Guide
Incomplete 1. Faulty joint design 1. Check root opening, root face dimension, included angle
Penetration 2. Welding speed too rapid 2. Reduce welding speed
3. Insufficient welding current 3. Increase welding current
4. Electrode size too large 4. Use smaller electrode
Arc Blow 1. Magnetic field, created when using dc, 1. Use ac welder
causes the arc to wander 2. Counter blow by adjusting electrode angle
3. Rearrange or split ground clamp
4. Replace magnetic work bench
5. Use brass or copper back-up bar
~~
Pinholes 1. Foreign matter in joint 1. Remove rust, scale and other foreign matter from weld area
base metal
I Slag in Weid
Porous
I 1. Joint design; sharp V-shaped recess
2. High viscosity of molten metal, rapid
1.
chilling, too low a weld temperature
Distortion 1. Improper weld design 1. Redesign to allow for expansion and contraction
Warping 2. Overheating 2. Use lower current and more efficient chill bars
3. Welding speed too slow 3. Increase travel speed
4. Improper welding sequence 4. Improve welding sequence - weld heavy sections first
5. Faulty clamping 5. Clamu urouertv to chill bar
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SMACNA T I T L E * M G W 93 LB9350 0005077 240
TABLE 7-2
GMAW Troubleshooting Guide
Arc blow Magnetic field in dc causes arc Rearrange or split ground connection
to wander Use brass or copper backup bars
Adjust gun angle so that arc force helps fill undercut
Replace magnetized bench
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
Undercutting Current too high Reduce current
Welding speed too high Reduce welding speed
Improper manipulation of gun Change gun angle to fill undercut
Arc length too long Shorten arc length
Incomplete Faulty joint design Check design of root opening, root face dimensions, included
penetration Welding speed too rapid angle
Welding current too low Reduce welding speed
Arc length too long Increase current
Improper welding angle Shorten arc length
Change gun angle
~
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SMACNA TITLEsMGW 9 3 W 8189350 0005078 187 =
TABLE 7-2
GMAW Troubleshooting Guide (Contd)
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
Reprinted from Welding and Fabricating Data Book 1992/93,p. A l 8
TABLE 7-3
GTAW Troubleshooting Guide
~~ ~
Unstable Arc 1. Dirty, contaminated base material 1. Use chemical cleaners, wire brush, or abrasives
to clean base material.
2 . Joint is too narrow 2. Make groove wider; bring electrode closer to the
work; decrease voltage
3. Contaminated electrode 3. Cut off end of electrode tip, dress
4. Electrode diameter too large 4. Use smallest electrode diameter that will handle
required current
5. Arc too long 5. Bring electrode closer to work
Rapid 1 . Inert shielding is inadequate, allowing 1. Clean nozzle; bring nozzle closer to work;
Electrode oxidation of the electrode increase gas flow
Consumption 2. Operating on reverse polarity 2. Change to straight polarity or use larger
electrode
3. Electrode too small for required current 3. Use larger electrode - See chart Electrode
Diameter Vs. Current, p . 22
4. Electrode holder is too hot
4. Change collet; use ground finish electrodes;
5. Electrode contamination check for proper collet contract
5. Remove contaminated section of electrode.
Electrode will continue to degrade as long as
6. Oxidation of electrode during cooling contaminants are present.
6 . Continue gas flow for 10-15 seconds after arc
stops.
Rule: 1 second for each 10 amps
~~
Tungsten 1. Touch starting with electrode 1. Use high-frequency starting device; use a copper
Inclusions striking plate
in Work 2. Electrode melts and alloys with base 2. Reduced current or use larger electrode; use
plate thoriated or zirconiated tungsten electrode (they
run cooler)
3. Fragmentation of electrode by thermal 3. Be sure electrode ends are not cracked,
shock especially when using high currents. Use
embrittled tungsten electrode for clean easy
break
Porosity 1. Gas impurities present: hydrogen, 1. Use welding grade inert gas (99.995 percent
nitrogen, air, water vapor pure), purge all lines before striking arc
2 . Use of old acetylene hose 2. Use first-hand hose only. Acetylene impregnates
hose
3. Gas and water hoses interchanged 3. Never interchange gas and water hoses. Use
hoses of different colors
4. Oil firm on base material 4. Clean base material with a chemical cleaner that
does not dissociate in the arc. Do not weld
while material is wet
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~
Chapter 8
ESTIMATING WELDING COSTS
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
stub end loss, the coating or slag loss and the spatter time.
* By reading the welding current from the
loss. A 2" (51mm) stub from a 12" (305 mm)
electrode has a 17% stub loss and from a 14" (356 power supply machine during welding, then
mm) electrode a 14% stub loss. The coating loss referring to a burn-off chart and finding the
can vary from 10% to 50% of the total electrode inches per minute.
weight. For example, the thin covering of an E 6010 TOTAL WELDING COST -
the aggregate cost of
electrode will be approximately 10% of the total variables associated with welding, each variable
electrode weight while the heavier coating of an E having a representative value which should be
7014 will approach 50%. The best average independently developed or verified by each
deposition efficiency is 65% which includes a nominal contractor.
2" (51mm) stub loss. The GMAW process results in a slightly higher
GMAW - In this process the only loss is spatter material cost but a lower total cost than SMAW, a
and a little oxide scale. This process is 90 to 95% labor intensive process. As the welding speed is
efficient. increased, there is a corresponding decrease in labor
FCAW - The flux core and spatter are lost in this costs.
process. This process is 80 to 85% efficient.
GTAW - The filler wire loss is due to the stub
loss, making it possible to attain an efficiency
approaching 90%.
DEPOSITION RATE (Table 8-1) - the rate at
which weld metal is deposited in a joint per unit of
time. Expressed as pounds per hour, this reflects the
TABLE 8-1
Sheet Metal Welding Parameters (U.S.)
Note 1 Parameters are suitable for square groove butt or fillet welds
Note 2 Bronze cold wire (118" [3.2mm]) used with carbon arc welding
Note 3 Multiply in. per min. by 5 for ft. per hr.
Welding
Process
Sheet Metai
Thickness
Filler Rod
Diameter I Electric
Current
Shielding Travel Operator Deposit Electrical
D.C. Gas Flow Speed Factor Rate Melt Rate
Gage mm mm Volts Amps Umin. mds % km. mns.
~
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
10 3.416 3.2 12 145-205 343 5 Varies 0.23-0.91 Varies
3650
10960
4880
3500
10300
4600
3380
9950
4430
3260
9900
4400
3240
9800
4360
3200
*
I
2790 2750 2580 2490 2480 2450
221o 2170 2040 1970 1980 1940
519 51O
.O1 25 285 279
TABLE 8-2M
Conversion Table Meters Per Kilogram of Wire
Material
I .O35 7 0 . 9 I 925 594 I 212 I 204 196 190 183 182 179
I .o40 I 1.0 I 706 455 I 163 1 156 154 145 140 139 137
85 I I
684 I I
65 64 60 58 58 57
190 I 30 I 29 29
.O 125 3.2 72 46 17 16 16 15 I 14 1 14 I 15
m
BUTT WELDS FILLET WELDS
Q I 7
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
Arc Speed-InJMin. ' 24 32 28 22 19 Current-Amps
Polarity
70
AC
105
AC
155
AC
160
AC
210
AC
Lbs. of Elec. of
Weld .O24 .O29 .O26 .O49 .O70 Arc Speed-ln./Min. '$ 15 16 17 16 14
Lbs. of Elec. of
Position* 30-90' Downhill Weld .O45 .O53 .O71 .O79 ,110
Current-Amps 45 75 90 130 150 Position' 30-90' Downhill
Polarity2 DC- DC- DC+ DC+ DC+
Arc Speed-In./ Current-Amps 75 115 165 170 225
Min.' 28 36 30 Polarity AC AC AC AC AC
25 20
Lbs. of Elec. of Arc Speed-In./
Weld .O23 .O28 .O27 .O48 ,073 Min. '$ 16 19 21 20 18
Lbs. of Elec. of
Because design, fabrication, erection and welding variables affect Weld .O42 .O49 .O62 .O70 .lo0
the results obtained in applying this type of information, the
serviceability of a product or structure is the responsibility of this Because design, fabrication, erection and welding variables affect
builderluser. the results obtained in applying this type of information, the
serviceability of a product or structure is the responsibility of this
builderiuser.
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
CORNER WELDS
* 45' downhill position is recommended for easy welding and fast Because design, fabrication, erection and welding variables affect
speeds. Corner welds on 10 gage steel can be welded 5-7 in.lmin. the results obtained in applying this type of information, the
faster when positioned 75' to 90' downhill rather than 45' to 75' serviceability of a product or structure is the responsibility of this
downhill. builderluser.
1. For ft. of weldlhr. multiply i n h i n . by 5. 100% operating factor.
2. For AC welding use: *Data as published by Lincoln Electric Company, Cleveland, Ohio
a. E6011 in place of E601O or 441 17.
E6013 in place of E6012.
b. The same electrode sizes.
CONVERSIONS
9% -
mrn. -
in. -
rnm. -
intmin mm/s -
inlrnin mm/s -
Ib/ a/m
18 1.311 3/32 2.4 12 5.1 28 11.8 ,010-.o20 15-30
16 1.613 118 3.2 14 5.9 29 12.2 ,020-,030 30-45
14 1.994 15 6.3 30 12.7 ,030-,040 45-60
12 2.753 16 6.8 32 13.5 ,040-,050 60-74
10 3.510 17 7.2 33 14.0 ,050-.O60 74-89
18 7.6 36 15.2 ,060-.O70 89- 104
19 8.0 38 16.1 .070-,080 104-119
20 40 16.9 ,080-.o90 119-134
21 8.5 43 18.2 ,090-.1O0 134-149
22 9.3 46 19.5 ,110-.I10 149-164
23 9.7 49 20.7
I 24
25
10.1
10.6
50
53
21.2
22.4
26 11.0 56 23.7
11.4
Gas Cost (per fi.) - Gas Cost ($/CUft) x Flow Rate (CUft/hr)
Weld Travel Speed (idmin) x 5*
EXAMPLE NO. 1
Process: Gas Metal Arc Welding (GMAW) Shop Operation
Objective: Determine the cost of 200 ft. of 1/8" carbon steel
fillet weld with the following given data:
Welder Labor Rate 20.00 $/hr
Overhead Hate 56.75 Yo
Power Cost .O4$/kwhr
Operator Factor (GMAW) .65
Electrode Mild Steel Wire .O35 in. diameter .90 $/lb
Carbon Dioxide Gas .O3 $/cufi
Argon .o9 $/cufi
Wire Speed 280 in/min
Wire Diameter .O35
Amperes (dcrp) 140 amps
Volts 20 volts
Weld Travel Speed 18 in/min
Deposition Efficiency (GMAW) .95
Deposition Rate 4.6 Ibs/hr
Machine Efficiency .95
20.00 $ihr
(1) Labor Cost = - .342 $/ft
18 in/min x .65 x 5
8.8 --`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
The Manager's Guide for Welding Second Edition
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S M A C N A TITLExMGW 9 3 = 8189350 0005088 026
Filler Metal Cost = .O51 Ib/ft x .90 $/lb - .O48 $/ft
.95
4.6 Ibs/hr
= Weld Metal Deposited = .O51 Ibs/ft
18 in/min x 5
EXAMPLE NO. 2
Process: Shielded Metal Arc Welding (SMAW)
Objective: Determine the cost of 200 feet of 1/8" carbon
steel weld with the following given data:
Welder Labor Rate 20.00 $/hr
Overhead Rate 56.75 o/'
Power Cost .O45 $/kwhr
Operator Factor (SMAW) .25
Electrode Cost .55 $/lb
1/8" covered electrode (thin coated) 601O
Deposition Efficiency (SMAW) .65%
Weld Travel Speed 18 in/min
Electrode Diameter 1/8 in
Electrode Burn-off data 12 in/min
Amperes (dcrn) 120 amps
Volts 26 volts
Deposition Rate 2.8 Ibs/hr
SMAW would be computed as follows:
(1) Labor Cost = 20.00 $/hr
- .889 $/fi
18 in/min x .25 x 5
(3) Filler Metal Cost = .55 $Ib/ft x .O31 Ib/ft - .O26 $/fi
.65
(5) Gas Cost (per m) - Gas Cost ($/I ) x Flow Rate (Vhr)
Weld Travel Speed (imm/sec) x 3.6*
EXAMPLE NO. 1
Process: Gas Metal Arc Welding (GMAW) Shop Operation
Objective: Determine the cost of 60.96m of 3.2mm: carbon
steel fillet weld with the following given data:
Welder Labor Rate 20.00 $/hr
Overhead Rate 56.75 %
Power Cost .O4 $/kwhr
Operator Factor (GMAW) .65
Electrode Mild Steel Wire 0.9mm diameter 1.98 $/Kg
Carbon Dioxide Gas 0.899 $/I
Argon 2.547 $/I
Wire Speed 118.4mm/sec
Wire Diameter .09mm
Amperes (dcrp) 140 amps
Volts 20 volts
Weld Travel Speed 7.61mm/sec
Deposition Efficiency (GMAW) .95
Deposition Rate 2.08 Kg/hr
Machine Efficiency .95
8.1 O --`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
The Managers Guide for Welding Second Edition
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SMACNA TITLE*MGW 93 W 8 1 8 9 3 5 0 0005090 784 =
20.00 $Ihr
Labor Cost = - 1.12 $/m
7.61 mm/sec x .65 x 3.6
5675 x 20.00
Overhead Cost = - 0.640 $/m
7.61mm/sec x .65 x 3.6
118.4mm/sec x 3.6
- Deposition Rate = 4.6 Ibs/hr (10.1 Kg/Hr)
204m/kg wire**
** from Table 8-2 - 0.09m & Mild Steel
1.27 kg/hr
-
- 0.0464 kg/m
7.61mm/sec x 3.6
- 1.4205 $/ft
These equations provide the manager/estimator Shop welding is generally more productive and
with the basic tools to calculate cost, however, in less expensive than field welding. Vertical or
some cases, the configuration of the weld will require overhead welding positions are considerably more
that the area of the weld be calculated in order to costly than flat position welding and shop welding in
determine the cost of the filler metal. the flat position can usually be accomplished.
The amount of electrode required for a particular The estimator must be aware of the cost of weld
--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
joint is based on the weight of deposited metal per inspection, certification and/or testing. Even if others
unit length of weld. This is found by computing the are responsible for these activities they could delay
cross-sectional area of the joint in square inches job progress and result in a cost to the contractor.
multiplied by the length to equal the volume of the
deposited metal. This volumetric value can be 8.6 REDUCING WELDING COSTS
converted to weight by multiplying by the metal To reduce welding costs, a cost analysis should be
density. This weight must be divided by the made in three specific areas:
deposition efficiency to determine the amount of Weld Design:
electrode required. Manufacturers of welding filler * Reduce the number of weld joints
metals have tables where this information is *
Reduce the weld cross-sectional area
available. Standard weld shapes can be found from *
Provide accessibility for all welds
a manufacturers chart. * Select readily weldable materials
The cross-sectional area of a weld varies as the * Utility intermittent fillet welds
square of the weld size. The larger the weld size the *
Select a joint design which will require little
greater the cost; therefore, excess filler metal preparation; simple corners or fillet are the
represents wasted money. least expensive.
Weld Procedure:
8.5 OTHER COST CONSIDERATIONS
Written procedures are recommended for all
Although cost comparisons will show the economic jobs.
benefits of the welding operations, there are other Select proper method of application for
factors included in the overall cost of the finished efficient operator factor. Use semi-automatic
product. and automatic welding where possible to take
Weld preparation in excess of normal fit-up must advantage of a higher operator factor and
also be included in the overall cost of the weld. deposition rate.
Certain unusual conditions require temporary internal Reduce electrode stub loss.
bracing and close alignment of the parts to produce Select the weld process with the maximum
a good weld without distortion and burn-through. deposition rate. For SMAW, the correct
Part weld treatment must be given consideration in amperage setting is important to achieve
weld preparation costs. Post-weld treatment consists maximum deposition rate. For GMAW, the
of labor and equipment for such operations as wire feed rate is determined by the welding
grinding, polishing, heat treatment, shot blasting and conditions for an effective speed.
possibly straightening. Cleaning and coating the joint Manufacturing
with protective materials is yet another cost Parts tbe welded must be cut and formed
consideration. accurately to insure optimum fit-up and
Fire welding is generally more expensive than reduce distortion.
shop welding. Field conditions vary greatly: weather, Surface to be welded must be free of grease,
temperature, local codes, accessibility, and scale and other contaminants.
interferences all have a major effect on productivity. Use designs that minimize edge preparation.
Minimize weld spatter to reduce filler metal loss Estimated Cost per
and weld cleanup. Weld spatter may Foot of Weld = 35.00 = 0.78 $/ft
approximate 30% of electrode cost. 90 x 0.50
* Keep post weld cleaning and finishing to a
The method of determining welding costs can be
minimum. Good operator skills can reduce
calculated quickly. The engineer can evaluate
cleaning and grinding.
savings in the cost of welding against the capital
expenditure necessary to change the present
8.7 QUICK METHOD FOR ESTIMATING WELD equipment or to buy new equipment. The cost data
COSTS calculated above should be used for comparison only.
Estimators, designers, shop foreman, and others After deciding which process is to be seriously
tend to be apprehensive about the task of cost considered, careful and complete cost analysis can
estimation because of the many factors that must be be made.
taken into account and the possibility for errors. Also,
the mathematical formulas that have been developed Metric Example
look forbidding, even though they only involve simple
The above example using the data given:
arithmetic processes. Groove butt or fill weld 3mm
Situations that require an accurate analysis of
Material 3.51 Omm
welding costs would require considering methods as Welding speed (Table 8-1M) 27.3m/hr
described in chapter 8.3 and 8.4 of this text. Some Operating factor 15%
situations do not require the accuracy of a careful
Labor and overhead rate 35.00 $/hr
cost analysis. For example, preliminary estimates
would be satisfactory for comparing two similar Estimated Cost per
welding processes doing the same job or the same Meter of Weld = 35.00 $Ihr = 8.55 $/m
welding process with different conditions of material 27.3m/hr x 0.15
handling, fixturing, or positioning. A quick method for
comparison purposes is to disregard the cost of Estimated Cost per
Meter of Weld = 35.00 $1'' = 5.13 $/m
consumables and calculate the costs only on the
labor and overhead, arc speed and operating factor 27.3m/hr x 0.25
using the equation
Estimated Cost per
(1) CL = CR Meter of Weld = 35.00 $Ihr = 2.56 $/m
(S)(OF) 27.3m/hr x 0.50
where:
CL - estimated cost per foot of weld ($/fi)
S - welding speed (feetlhr) or in./min x 5
OF - operating factor (YO)
CR - hourly labor and overhead rate ($/hr)
For example, a particutar application is making a
1/8 inch square groove butt or fillet weld with 1O gage
material. Welding speed is 90 feet per hour (Table 8-
Chapter 9
TRAINING
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9.1 IMPORTANCE OF TRAINING
-.-. _...
LI1ACNA TITLExMGW 93
committing any time or money to it.
8389350 0005094 3 2 T =
The contractor is urged to develop and rely on a
Welder training is the most important ingredient in local facility for basic training needs. Where a local
the whole recipe for making a weld. Just having a facility does not exist, it is recommended that the
welding machine will not assure a good weld. The contractor group set up a training program using
machine has to be set and running right. Just having group funding rather than proceeding independently.
an electrode to weld with will not assure a good weld. Programs would logically be targeted for those
It must match the metal to be welded, be dry and free individuals who are already participating in industry
of other contaminants, etc. Too many people think apprentice training or journeyman levels of
that welding is easy, and anyone can weld. This is involvement.
true, but there is a big difference between making a The National Training Fund has assisted in the
weld and making a good, sound, high quality weld. establishment of welder training programs in many
This difference is welder training. areas of the United States. The NTF programs
Welders should receive formal training to assure include training or journeyman levels of involvement.
good quality welding and achieve high productivity. Where the need for training of welders or welder
It is unlikely that satisfactory skills can be developed instructors is insufficient to make a commitment to a
experimentally or in a self-taught approach to permanent program, special arrangements can be
welding. This does not mean that experience is not made with the National Training Fund, with regional
a vital element. A person of average intelligence and colleges vocational schools or universities having the
mechanical aptitude can be taught to make a basic required capabilities, with consultants who specialize
weld in a few hours. Proficiency, however, will in such activities or with major suppliers who have
develop only after exposure to qualified instruction formal training programs at their facilities. Where
and months of practice. It is important that welders basic welding skills are already possessed by welders
receive instructions from individuals who have both and the need arises for new skills, concentrated
the ability to teach and the ability to weld. courses are available at training centers operated by
Many employers are unwilling to invest in the such companies as Hobart, Lincoln, Linde, Airco, etc.
training of their employees. If the employer chooses A comprehensive welder training program will
to spend the time, the effort and the money to normally involve several hundred hours of schooling
provide proper training for their welders, then the and it may involve several thousand dollars of cost
result will be high quality products, good productivity per student. Training sessions for a particular
and a better bottom line. If the contractor chooses not process and a particular material may range from
to provide the right kind of training, the result will forty to one hundred fifty hours of instruction.
definitely be more rework, more rejects, low
productivity, poor reputation and higher costs. The 9.3 TRAINING FOR QUALIFICATION
employer will pay the bill one way or the other. The
importance of good welder training cannot be Frequently, project specifications will require
overemphasized. An employer can have the best qualification of welders. These specifications may
equipment and facilities available: and the best reference codes or standards that vary in qualification
material and welding procedures. But, if the welder requirements, by the amount and type of inspection
does not know how to weld correctly, then the of weldments, by the amount of record keeping
employer's entire investment is virtually useless. required and by the timeliness of qualification or
When an employer looks at his investment in requalification of welder skills. It should not be
facilities, tools and equipment, the investment in good presumed that a welder who passes a qualification
welder training is an extremely small price to pay in test will maintain the same level of proficiency for
comparison. A price, by the way, that will be extended periods of time.
recovered many times over. Separate qualifications are normally required for
the different categories of sheet metal welding, plate
9.2 RESOURCES FOR TRAINING welding, structural welding, pressure vessel welding,
There are numerous ways to get this training. An etc. Qualification in one category does not mean that
employer can set up an "in house" program which is an individual is qualified in another category. The
designed for a particular operation. Employees special requirements of each must be examined and
might be used as instructors, or outside consultants understood to assure that welders are properly
might be hired to teach the processes and techniques trained in the skills of the project documents and the
for a company's needs. There are also many good contractors' objectives.
technical schools available that can teach a "canned"
course or they can design a course for your specific
needs. Not all technical schools are created equal.
It is recommended that a good, thorough check be
made of a program and its reputation before
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S M A C N A TITLExMGW 9 3 m BLB9350 0005095 266 m
9.4 REQUALIFICATION REQUIREMENTS In summary, each contractor should prepare a set
of interview and test requirements. The interview .
The science and technology of welding are should ask questions about equipment, material,
continually changing; advances in technology and electrodes and shielding gases. The test should
production capability will necessitate that welders and cover only specific processes, materials and positions
instructors be trained in new welding procedures. that will ordinarily be used and the test should be
The frequency and variety of welding are factors that prepared in advance.
influence a welders proficiency.
The importance of having reliable written 9.7 WELDER CERTIFICATION
procedures has been stressed in Section 6.
Provisions within the standards and specifications The number one goal of the Welding Advice,
published by the American Welding Society and other Instruction and Testing (WAIT) Van is to help produce
organizations change frequently. Moreover, federal, person hours by moving throughout its assigned
state and local safety regulations are frequently region as needed by contractors, local unions or
revised. These significantly affect welding processes JATCs. The Van is operated by National Training
and procedures and affect the cost of welding. Fund (NTF) American Welding Society (AWS)
THE CON TRACTOR MUST MAIN TAIN Certified Welding Inspectors (CWls) who are trained
AWARENESS OF INDUSTRY PROGRESS AND to write and qualify procedures, certify welders to
EXAMINE THE NEED FOR RETRAINING AND applicable codes and when necessary, teach specific
REQUALIFICATION OF WELDERS ON A welding techniques. The NTFs CWls will be
REGULAR BASIS. available to work with local instructors of apprentices
and journeypersons to test and certify their welding
9.5 REFERENCES classes when schedules allow.
A NTF Inspector will assist in interpreting welding
The contractor is referred to all other sections of codes and specifications, determine the method of
this guide for greater perception of training needs. testing and then perform the applicable test. Testing
The bibliography lists certain organizations that may can be done in contractors shop, local training
have the resources for training desired. The National centers or if necessary on the job site. The NTFs
Training Fund program relies significantly on the use WAIT mobile testing laboratory is an AWS approved
of audio/visual training aids. A partial list of their testing facility which allows the NTF the opportunity
resources is presented in this manual. If a local of offering the AWS National Certification to the sheet
contractor group wishes to use a training program metal industry.
that departs from the NTF program, a university Some of the many codes are the AWSs D1.l, and
program or one available from a manufacturer- D9.1; ASME and the National Certification. Lengths
affiliated school, it may submit an outline of their of testing varies per code, for example: D1.1,3/8 inch
program to the SMACNA Welding Committee for (10mm) plate, 8 hours per person; D9.1, 2 hours:
comment. ASME, 8 hours; and the National Certification, 3/8
inch (lomm) plate, 8 hours.
9.6 SUPPLEMENTAL TRAINING When the NTFs CWI has completed and
processed all required paper work for welder
The sheet metal contractor should not be expected certification through the NTF Office, then certifications
to provide welder training on company time. Local are issued. The renewal of certifications is the
union labor agreements require that sheet metal responsibility of the individual or contractor. The NTF
workers capable of performing the work be provided. does not accept the responsibility to provide the
Local training programs should be fulfilling all of the means for the continuation and maintenance of these
training requirements for the skills needed. If there is certifications; however, the NTF tries to keep
a problem in this area, it is suggested that it be certifications from expiring. When it means
discussed with the local SMACNA chapter training immediate employment for a job already in progress
committee to assure that the required training will be or helping a contractor secure work for sheet metal
administered. It is also suggested that the contractor workers, the NTF will work to expedite the welder
encourage welders to practice on weekends and certification.
evenings and that they be invited to try new Contractors, local unions and JATCs should
processes and new techniques. The increase in skill contact the NTF as soon as the need for an NTFs
would be beneficial for both the employer and the CWI arises. The services are funded by hourly
employee. contributions to the NTF, but exclude the cost of
consumables needed to practice and perform the
actual testing.
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S M A C N A TITLExMGW 93 8189350 000509b I T 2 m
Chapter 10
HIRING WELDERS
Process: SMAW
GMAW
GTAW
FCAW
Galvanized Steel
Aluminum
Stainless Steel
POSITION
Number of Welds H Vd O
Butt Weld Test #i Shop Shop, Field Field
* Indicate corner joint, tee joint or lap joint for fillet welds
Figure 10-1
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Arc welding. A welding process that fuses material by too wide.
heating it with an electric arc. Buttering. Deposition of weld metal on the joint groove
As-welded. The condition of a weld or weldment after face to provide a transition layer for subsequent layers
welding, before chemical, thermal, or mechanical of weld metal.
treatment. Butt joint. A joint between two members lying in the
Atomization. In thermal spraying, the division of molten same plane.
material at the end of the feed stock, wire or rod, into
fine particles. Car pass. In pipeline welding, final pass of a weld joint.
Autogenous weld. A fusion weld made without filler Carrier gas. In thermal spraying, the gas used to carry
metal. powdered materials from the powder feeder or hopper to
Automatic welding. Welding with equipment that the gun.
performs without constant observation and adjustment of Chain intermittent fillet welding. Two lines of
the controls by an operator. intermittent fillet welding on a joint. The fillet-weld
segments in one line are opposite to those in the other
Back gouging. Removal of base and weld metal from the line.
back side of a partially welded joint to assure a clean Cladding. A layer of material 0.04 in. (1.02mm) or
base for subsequent welding. thicker applied to the base material to improve corrosion
Backhand welding. A welding technique in which the or wear resistance of the part.
torch is tilted in a direction opposite to the direction of Coating. A layer of material 0.04 in. (1.02mm) or less
the weld travel. applied to improve lubrication or resistance to corrosion,
Backing. Material placed over the weld-joint root to high-temperature scaling, or wear.
support molten weld metal. Coating density. In thermal spraying, the ratio of density
Backing ring. Backing in the form of a ring; generally of a thermally sprayed coating to the density of the raw
used for pipe welding. material used for the coating.
Backing strip. Backing in the form of strip; generally used Complete penetration. Weld metal completely fills the
for plate welding. groove and is fused to the base metal through the entire
joint thickness.
Cover glass. Clear glass used in goggles, hand shields, Electric-arc spraying. A thermal-spraying process using
and helmets to shield the filter glass from spatter. an electric arc between two consumable electrodes to
Covered electrode. A filler-metal electrode, used in heat a coating material. Compressed gas atomizes and
shielded-metal-arc welding, consisting of a metal-core propels the material to the base material.
wire with a covering. The covering contains elements Electrode welding. A rod or wire which comprises part of
and compounds that protect the weld puddle from the the welding circuit-the arc strikes from the tip. An
atmosphere, improve the properties of the weld metal, electrode can melt, becoming part of the weld pool, or
and stabilize the arc. remain solid, as does the tungsten electrode in gas-
Crater. In arc welding, a depression at the end of a weld tungsten-arc welding.
bead. Electrogas welding. A vertical-travel gas-metal-arc-
Crater crack. A crack in the crater of a weld bead. welding process that uses molding dams to confine the
molten weld metal in the vertical joint.
Defect. Discontinuities or undesirable geometry that Electro-beam welding. A welding process that fuses
makes a part unacceptable. metals with the heat from a concentrated beam of high-
Deposit. Filler metal added during a welding operation. velocity electrons impinging upon the joint. Welding can
Deposition efficiency. In arc welding, the ratio of take place in a high to medium vacuum (10 to 50 torr),
deposited-metal weight to weight of filler metal or at atmospheric pressure (non-vacuum).
consumed, exclusive of stubs. In thermal spraying, the Electroslag welding. A vertical-travel welding process
ratio of the weight deposit to the weight of the material that uses electrical-resistance heat from a molten slag to
sprayed. melt and fuse filler metal and joint surfaces. The slag
Deposition rate. Speed at which filler metal is added to shields the weld-metal surface.
a joint or deposited on a surface. Explosion welding. Controlled detonation across the top
Depth of fusion. The distance that fusion extends into of one workpiece produces a solid-state bond to another
the base metal from the surface melted during welding. workpiece.
Detonation flame spraying. A thermal spraying process Face of weld. The surface of a weld, made by an arc- or
in which a controlled explosion of a mixture of fuel gas gas-welding process, on the side from which welding
and oxygen melts and propels powdered coating was done.
material to the workpiece.
Diffusion welding. A solid-state welding process that
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Reprinted from Welding and Fabricating Data Book 1992/93, pg. A8-A9
Flash welding. A resistance-welding process that joins IHardfacing. Surfacing applied to a workpiece to reduce
the entire area of abutting surfaces by heat from wear.
resistance to current flow across the surfaces and by lHeat-affected zone. The portion of the base metal
pressure applied after heating is complete. adjacent to the weld that has not melted, but whose
Flat position. Welding performed from the upper side of mechanical properties or microstructure have been
the joint. The weld face is horizontal. altered by heat from welding or cutting.
Flux. Material used to prevent, dissolve, or ease removal Horizontal fixed position. (ASME 5-G) In pipe welding,
of oxides and other undesirable substances. the position of a pipe joint in which the axis of the pipe
Flux-cored-arc welding. A process that welds by heating is horizontal and the pipe is not rotated during welding.
with an electric arc between a continuous tubular filler- Horizontal position. Welding position in which the weld
metal electrode (wire) and the work. Flux within the axis is horizontal and the face of the weld is vertical;
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Laser-beam welding. A welding process that fuses Oxyfuel cutting. Process that cuts by oxidizing the base
materials with the heat from a concentrated coherent metal at high temperatures. Combustion of fuel gas and
light beam impinging upon the members to be joined. oxygen maintains the temperature.
Leg of fillet weld. The distance from the root of the joint Oxyfuel welding. Process that welds by oxidizing the
to the toe of the fillet weld. base metal at high temperatures. Combustion of fuel
Liquidus. Lowest temperature at which a metal or alloy gas and oxygen maintains the temperature.
is completely liquid. Oxygen cutting. Use of oxygen jets to cut parts at high
Load current. Current flow from a power source during temperatures, well above the oxidation temperature of
welding. the metal or alloy.
Load voltage. Voltage between output terminals of a
power source during welding. Peening. Working a metal by impact blows.
Local preheating. Preheating a specific portion of a Penetration. Depth of melting, measured from the
workpiece. original surface of the base metal.
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Plasma-arc cutting. Cutting by means of a hot
Machine welding. Welding with equipment that performs (50,000 F+) (27760 C+) arc, formed by ionizing, with an
under observation and control of a welding operator. electric current, orifice (plasma) gas constricted by a
Manual welding. Welding performed by hand. small-diameter nozzle.
Mask. A device for protecting nearby surfaces from the Plasma-arc welding. Welding by means of a hot arc,
effects of abrasive blasting or from coating adherence. formed by ionizing a stream of gas constricted by a
Mechanical bond. The adherence of a thermal-spray small-diameter nozzle.
deposit to a roughened surface by particle interlocking. Plasma spraying. A thermal-spraying process in which a
Mechanized welding. Welding with equipment set up for nontransferred arc is the source of heat for melting and
a specific limited task. Requires some observation by a propelling the coating material to the workpiece.
welding operator. Piping porosity. Pinholes in a plane passing through the
Melt-through. Visible reinforcement produced on the root of a weld and normal to the weld surface.
opposite side of a joint welded from one side. Plug weld. A circular weld made through a hole in one
Mig welding. See gas-metal-arc welding. member of a lap or T-joint, joining that member to
another.
Neutral flame. A gas flame that is neither oxidizing nor Porosity. Gas pockets or voids in metal.
reducing. Positioned weld. A weld made in a joint that has been
Nontransferred arc. In plasma-arc welding and cutting rotated in space to make welding easier-for example,
and plasma-spraysurfacing, an arc established between rotating a pipe joint under a welding head such that
the electrode and the constricting nozzle. The welding always occurs in the flat position.
workpiece is not in the electrical circuit. Postheating. Application of heat to a weld or weldment
after a welding or cutting operation, often for stress
Open-circuit voltage. The voltage between the output relief.
terminals of the welding machine when no current is Preheating. Application of heat to the base metal before
flowing in the welding circuit. welding or cutting.
Orifice gas. In plasma-arc welding and cutting, the gas Procedurequalification. Demonstrationthat a weld made
that surrounds the electrode in the torch; it ionizes to by a specific procedure can meet given standards.
from the plasma.
Output slope. The relationship between output voltage Reducing flame. A gas flame that has a reducing effect
and current from a power supply as current or voltage (excess fuel).
changes. Reinforcement. Weld metal on the weld face in excess
Overhead positions. Position in which welding is of the metal necessary for the specified weld size.
performed from the underside of the joint; ASME 4-G in Residual stress. Stress remaining in a structure or
pipe welding. member as a result of thermal or mechanical treatment
Overlap. Protrusion of weld metal beyond the bond line or both.
at the weld root or toe. Reverse polarity. Direct-current arc welding in which the
Oxidizing flame. A gas flame that has an oxidizing effect electrode is the positive pole of the welding arc. See
(excess oxygen). direct current electrode positive, the preferred term.
Root crack. A crack at the root of a weld.
Reprinted from Welding and Fabricating Data Book 1992/93, pg. A8-A9
Root of joint. The portion of a joint to be welded where Stickout. Length of electrode wire between the end of a
the members approach closest to each other. welding gun or head and the arc.
Root opening. The distance between the members to be Straight polarity. Direct-current arc welding where the
joined at the root of the weld. work is the positive pole. See direct current electrode
Root of weld. The points, as shown in cross section, at negative, the preferred term.
which the bottom of the weld intersects the base-metal Stress relief cracking. Cracking of metal in the weld
surface. metal or heat-affected zone during postweld heat
treatment or high temperature service.
Seal coat. Material applied to close the pores of a Stress relieving. Thermal or mechanical (peening or
thermal-spray deposit. vibration) treatment of a workpiece after welding to lower
Self-fluxing alloys. See fused spray deposit. the induced stress. For steel weldments, thermal
Semiautomatic welding. Arc welding with equipment treatment entails heating of a part or all of the structure
that controls the filler-metal feed. Welding travel is to below the critical temperature, the temperature at
manually controlled. which austenite starts to form in the microstructure,
Shielded-metal-arc welding. A process that welds by followed by slow cooling. Weldments of aluminum,
heat from an electric arc between a covered metal magnesium, nickel, titanium, molybdenum and tungsten,
electrode and the work. Shielding comes from and their alloys, may also require stress relief.
decomposition of the electrode covering. The filler metal Stringer bead. A weld bead made without transverse
is obtained from the electrode. Also called stick welding oscillation.
Shielding gas. Protective gas used to shield weld pools Submerged-arc welding. A process that welds with the
from atmosphericcontaminationwhile welding proceeds. heat produced by an electric arc between a bare metal
Single-minded butt joint. A butt joint welded from one electrode and the work. A blanket of granular fusible
side only. flux shields the weld.
Size of weld. Substrate. Any material upon which a thermal-spray
Groove weld-Depth of bevel plus the root penetration. deposit is applied.
Fillet weld-For equal-leg fillet welds, the leg length of Surfacing. Position of filler metal on a metal surface to
the largest isosceles triangle which can be inscribed obtain desired properties or dimensions.
within the fillet-weld cross section. For unequal-legfillet
welds, the leg lengths of the largest right triangle that Tack weld. A short weld made to hold parts of a
can be inscribed in the weld cross section. weldment in proper alignment until the final welds are
Slag inclusions. Nonmetallic solid material in weld metal made. Usually made in a series.
or between weld metal and base metal. Thermal spraying. A group of processes in which finely
Slot weld. A weld made in an elongated hole in one divided metallic or nonmetallicmaterials are deposited in
member of a lap or T joint joining that member to the a molten or semi-molten condition to form a coating.
surface of the other member exposed through the hole. Thermal-spray gun. A device for heating, feeding, and
Slugging. Addition of a separate piece of material to a directing the flow of a thermal spraying material.
joint before or during welding (an unsound practice). Throat of weld. Shortest distance from the root of a fillet
Soldering. Welding using a filler metal with a liquidus weld to its face.
less than 840 F (449 C), below the solidus of the base Tig welding. See gas-tungsten-arc welding.
metal. T-joint. A joint between two members at a right angle to
Solidus. Highest temperature at which a metal or alloy is each other.
completely solid. Toe crack. A crack in the base metal at the toe of the
Spatter. In arc and gas welding, metal particles expelled weld.
during welding that do not form part of the weld. Toe of weld. The junction between the face of a weld
Specific gravity. Ratio of weight of a volume of a and the base metal.
material to the weight of the same volume of water. Torch. In gas-tungsten-arc welding the device that grips
Dimensionless. the tungsten electrode. In plasma-arc welding and
Specific heat. The amount of heat required to raise the cutting, the nozzle from which orifice gas emanates.
temperature of a unit of weight of a material one degree. Transferred arc. In plasma-arc welding, an arc between
Expressed in Btu/lb-F. the electrode and the workpiece.
Stick welding. See shielded-metal-arc welding. Tungsten electrode. A non-filler-metal electrode used in
gas-tungsten-arc welding consisting of a tungsten wire.
Reprinted from Welding and Fabricating Data Book 1992/93 pg. A10
Underbead crack. A crack in the heat-affected zone, not Weldability. The capacity of a metal to be welded under
reaching the surface of the base metal. imposed conditions into a specific structure and to
Undercut. A groove melted into the base metal adjacent perform satisfactorily in the intended service.
to the toe or root of a weld, unfilled by weld metal. Weld axis. A line through the length of a weld,
Underfill. A depression on the face of the weld or root perpendicular to its cross section.
surface extending below the surface of the adjacent Weld metal. The portion of a weld which has melted
base metal. during welding.
Uphill welding. In pipe welding, indicates that welding Welder. One who performs a manual- or semiautomatic-
proceeds from bottom to top of the circumferential joint. welding operation.
Pipe is not rotated. Welder qualification. Demonstration of a welders ability
Upset. Deformation from the application of pressure in to produce welds that meet prescribed standards.
welding. Welding operator. One who operates machine- or
Vertical position. semiautomatic-weldingequipment.
Pipe welding-Position in which the axis of the pipe is Welding sequence. The order of making the welds in a
vertical and the welding progresses horizontally. weldment.
(ASME 2-G). Welding technique. The details of a welding operation
Plate welding-The place is vertical, and the welding that are controlled by the welder or welding operator.
progresses upward or downward. (ASME 3-G). Work cable. An electrical lead that connects the
workpiece to the welding-power supply to complete the
Weave bead. Weld bead made with transverse electrical welding circuit.
oscillation.
Weld. A local melting together of metal in which melting
is produced by heating with or without the application of
pressure, and with or without the use of filler metal. The
filler metal has a melting point approximately the same
as that of the base metal.
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Chapter 12
INDEX
A i
alloys, 2.23 equipment inspection, 7.3
aluminum, 2.22, 2.29, 5.10 booms, 3.7 interpretation, vii
A.W.S., 5.10, 6.2 carbon arc, 2.3
amperage, 3.3 flux.cored, 2.1O J
A.I.S.I., 5.10 gas metal arc, 2.8 joints,
A.N.S.I., 4.4 gas tungsten arc, 2.6 basic, 5.11
A.S.M.E., 5.10 miscellaneous, 3.10 butt, 5.12
plasma arc, 2.12 corner, 5.14
B positioner, 3.9 types, 5.4
brazing, 2.3 safety, 3.10 joint design, vi, 5.2
seam, 3.8
C shielded metal arc, 2.4 M
cables, 3.4, 3.5, 4.2 submerged arc, 2.13 magnesium, 2.2
certification, 9.3 tables, 3.9 management, 4.1
codes, 6.2, 6.3 torches, 3.7 material,
committee, iv, 1.1 turning rolls, 3.8 coating, 6.3
copper, 2.23 estimating, requirements, 6.3
costs, 8.1, see estimating considerations, 8.12 metal, 6.3
current, cost, 8.2, 8.12
alternating, 2.5 definitions, 8.2 N
welding, 2.17, 6.4 equations, 8.8 national training fund, 1.1
- cylinders, 4.4 examples, 8.8 noise, 4.3
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--`,,`,``,``,``,``,,,,`,``,,,,,-`-`,,`,,`,`,,`---
Copyright SMACNA
Provided by IHS under license with SMACNA Licensee=Army Hdqrtrs/7838506107
No reproduction or networking permitted without license from IHS Not for Resale, 05/30/2006 00:56:33 MDT