1. Electrodes

2. Welding Terms
Arc
The flow of electrical current from the tip of the electrode holder to the base metal.

3. Electrodes
Metal rods which conduct a current from an electrode holder to the base metal.

4. Arc Length
The distance from the end of the electrode to the point where the arc makes contact with the work surface.
Increased arc length decreases amperage.
Decreased arc length increase amperage.

5. Crater
A depression at the termination of a weld.

6. Face of the Weld the welding was done.
The exposed surface of a weld, made by an arc or gas welding process, on the side from which
the welding was done.

7. Flux A fusible material or gas used to dissolve and/or prevent the formation of oxides, nitrides, or other undesirable inclusions formed in welding.

8. Low Carbon Steel
Steel containing .20% or less carbon.

9. Pass
A single longitudinal progression of a welding operation along a joint or weld deposit.

10. Porosity
Gas pockets or voids in metal.

11. Spatter
The metal particles given off during welding which do not form a part of the weld.

12. Tack Weld
A weld made to hold parts in proper alignment until the final welds are made.

13. Puddle
That portion of a weld that is molten at the place the heat is supplied.

14. Undercut
A groove melted into the base metal adjacent to the weld and left unfilled by the weld process.

15. Weaving
A technique of depositing weld metal in which the electrode is oscillated.

16. Weld Metal
That portion of a weld which has been melted during welding.

17. Whipping
A term applied to an inward and upward movement of the electrode which is used in vertical welding to avoid undercut.

18. AWS
American Welding Society.

19. Tie-in
After running a stringer bead a tie-in is made when another stringer bead parallel to the first, is burned halfway into it. Instead of being two beads side by side, they are intertwined together.
Essential skill for a professional SMAW welder

20. Deposition Rate
The amount of filler metal deposited in any welding process; rated in pounds per hour.

21. SMAW Equipment Welding Machine Electrode Holder with lead
Ground clamp with lead
Helmet with proper filter plate
Gloves
Chipping hammer
Safety glasses
Wire brush
Pliers
Protective clothing

22. Polarity Reverse Polarity(DCRP)
Current flows from base metal to electrode.
Base metal negative, electrode positive.
(Also called DCEP)
Most common current and polarity setting for SMAW processes.

23. Straight Polarity (DCSP)
Current flows from electrode to base metal.
Base metal positive, electrode negative.
(Also called DCEN)

24. Current Flow
Negative to positive.

25. Alternating Current (AC)
current alternates its direction 120 times per second
Direct current (DC)
electrical current that flows in only one direction

26. Welding Circuit

27. Operating Machine Adjustments
Current (amperage) Settings
Increasing amps
- produces more heat
Decreasing amps
- produces less heat

28. Polarity DCRP (direct current reverse polarity)
DCSP (direct current straight polarity)
AC (alternating current)

29. Types of Electrodes Mild Steel Low Hydrogen Non-ferrous Hard surfacing
Cast iron
Stainless steel

30. Electrode Grouping Fast-Freeze
weld puddle and slag solidifies quickly.
Least amount of slag
deep penetration
Exx10
Exx11

31. Fast-Fill weld puddle and slag cools slowly.
thickest flux coating and most amount of slag
limited use to flat groove and fillet welds in the flat and horizontal position
Exx14
Exx24
Exx27

32. Fill-Freeze/fast Follow
characteristics of fast-freeze and fast-fill.
easy to strike an arc
produces a clean weld with minimum amount of spatter
can be welded in all positions
Exx12
Exx13
Exx14

33. Low-Hydrogen characteristics of fast-freeze and fast-fill.
Produce welds with outstanding resistance to cracking under high stresses and vibration-type load conditions
do not contain much hydrogen in the form of moisture in the flux coating or in chemical form
E7018
E7028

34. Moisture Control All mineral-covered electrodes are thirsty
These electrodes will begin absorbing moisture the minute they are unpacked
Must be stored in an electrode oven
Moist electrodes lead to increased arc voltage, spatter loss, undercutting and poor slag removal
Weld deposit may suffer from porosity, underbead cracking and rough appearance resulting in rejects, reworking weldaments and possible product failure
some electrodes moisture control is recommended
Some electrodes it is required…
low hydrogen and hard-facing electrodes ( F)

35. Common Electrode Sizes
Size Range
1/16 to 3/8

36. Common sizes
3/32
1/8
5/32
7/32
1/4
5/16
3/8

37. Determining Electrode Size
Determined by:
the diameter of the bare end of the electrode

38. Purposes Of Flux Coating
Stabilizes the arc
Shields molten puddle from air
Floats impurities out of the puddle
Forms slag and slows cooling process
Provides deoxidizers and scavengers to prevent porosity of the weld zone
Provides alloying elements for higher weld strength
Provides iron powder to increase deposition rate

39. AWS Electrode Classification
Stands for electrode

40. Tensile strength deposited in thousand pounds per square inch
First two digits -(first 3 for a 5 digit number)
Tensile strength deposited in thousand pounds per square inch

41. Indicates weld position
Third digit -
Indicates weld position
1 = all positions
2 = flat and horizontal positions

42. Represents special characteristics
Fourth digit -
Represents special characteristics
1 = current
2 = penetration
3 = type of flux coating

44. AWS Electrode Classification Groups
Group F1
EXX20, EXX24, EXX27
Group F2
EXXX2, EXXX3, EXXX4
Group F3
EXX10, EXXX1
Group F4
EXXX5, EXXX6, EXXX8

45. AWS Filler Metal Specifications
Material Specification number
Carbon steel (mild) A5.1
Low allow steel A5.5
Stainless steel A5.4
Cast iron A5.15
Nickel alloys A5.11
Aluminum alloy s A5.3
Copper alloys A5.6
Surfacing alloy A5.13

46. Factors For Selecting Electrodes
Base metal strength properties
Base metal composition
Weld position
Welding current
Joint design and fit-up
Thickness and shape of the base metal
Service conditions and/or specifications
Production efficiency and job conditions

47. Types of Welds
Bead

48. Fillet

49. Groove

50. Plug

51. Parts of Groove Welds

52. Parts of Fillet Welds

53. Types of Weld Joints
Butt

54. Corner

55. Tee

56. Lap

57. Edge

58. Reasons For Poor Welds Improper machine adjustment
Improper electrode and size
Improper electrode movement
Improper electrode angle
Improper base metal preparation
Improper arc length

59. Parts of Welding Process

60. Welding Positions
Flat = 1

61. Horizontal = 2

62. Vertical = 3

63. Overhead = 4