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43 Cards in this Set
- Front
- Back
SMAW or Stick Welding
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- The addition of filler metal from the electrode adds reinforcement and increases the strength of the weld - It can be performed on almost any type of metal 1/8 inch thick or thicker |
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Striking an arc
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- Striking an arc in the incorrect spot may cause damage to the base metal. |
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Welding with too low of a current (amperage)
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- the weld may have slag or gas inclusions, because the molten weld pool was not fluid long enough for the flux to react. - the arc length has too very short; a very short arc length results in frequent shorting and sticking of the electrode |
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Welding with too high of a current ( amperage) |
- the spatter is excessive and is mostly hard. - the electrode covering is discolored more than 1/8 in. to 1/4 in from the end of the electrode. - it can cause the electrode to discolor, crack, glow red, or burn. |
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Hard spatter |
- it is called _____ because it fuses to the base plate and is difficult to remove |
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1/8 in. E6010 welding range
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- 70-130 amps |
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1/8in. E6011 welding range
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- 85-125 amps |
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1/8in. E6013 welding range
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- 70-120 amps |
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1/8in. E7018 welding range
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- 90-165 amps |
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3/32in. E6010 welding range |
- 40-80 amps |
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3/32in. E6011 welding range |
- 50-70 amps |
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3/32in. E6013 welding range |
- 40-85 amps |
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3/32in. E7018 welding range |
- 70-110 amps |
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Do not change the current settings during welding
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- a change in the setting may cause arcing inside the machine, resulting in damage to the machine. |
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Small diameter electrodes
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- the deposition rate is slower - more time is required when welding on thicker plate. |
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Large diameter electrodes |
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To correct an overheating problem
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- a welder can turn down the amperage - use a shorter arc length - travel at a faster rate - use a chill plate - use a smaller electrode at a lower current setting. |
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The term " heat and amperage"
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- EX: turn up the heat is the same as turn up the amperage. |
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Arc length
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- is the distance the arc must jump from the end of the electrode to the plate or weld pool surface. |
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Chill Plate
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- a large piece of metal used to absorb excessive heat. |
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Arc jumping and how to prevent it
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- joints that are too deep or narrow may pull the arc to one side and not to the root causing poor fusion. - If a very short arc is used, the arc is forced into the root for better fusion. |
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Shorter arcs
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-using this technique, metal as thin as 16 gauge can be arc welded easily. - higher arc settings are required to maintain a short arc. |
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Amperage range
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- the lower and upper limits of welding power, in amperage, that can be produced by a welding machine or used with an electrode or by a process. |
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Electrode angle |
- the term used to identify the electrode angle is affected by the direction of travel, generally leading or trailing. |
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Leading angle |
- when welding in the flat position, caution must be taken to prevent cold lap and slag inclusions. - a leading angle can be used to minimize penetration or to help hold molten metal in place for vertical welds. |
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Suggestions for preventing cold lap and slag inclusions:
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- ensure that the arc melts the base metal completely - use a penetrating type electrode that causes little buildup - move the arc back and forth across the molten weld pool to fuse both edges. |
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Trailing angle
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- as the molten metal is forced away from the bottom of the weld, the arc melts more of the base metal, which results in deeper penetration. |
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What does electrode manipulation help control when welding?
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- buildup - width - porosity - undercut - overlap - and slag inclusions |
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Weave pattern
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- the movement of the welding electrode as it progresses. |
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The circular pattern
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- is often used for flat position welds |
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The C and square patterns
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- are both good for most 1G (flat) welds but can also be used for vertical (3G) positions. |
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The J pattern |
- this pattern allows the heat to be concentrated on the thicker plate. |
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The T pattern
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- works well with fillet welds in the vertical (3F) and overhead (4F) positions. |
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The straight step pattern
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- can be used for stringer beads, root pass welds, and multiple pass welds in all positions. - For this pattern, the smallest quantity of metal is molten at one time as compared to other patterns. Therefore the weld is more easily controlled. |
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The figure 8 and the zigzag pattern
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- Do not weave more than 2 1/2 times the width of the electrode. - a shelf can be used to support the molten weld pool with these patterns. |
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Arc welding electrodes
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- are grouped into three filler metal (F number) classes according to their major welding characteristics. |
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E6010 and E6011 Electrodes
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- have cellulose-based fluxes. - these electrodes have a forceful arc with little slag left on the weld bead. |
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E6012 and E6013 Electrodes |
- have rutile- based fluxes, giving a smooth, easy arc with a thick slag left on the weld bead. |
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E7016 and E7018 Electrodes |
- have a mineral-based flux. The resulting arc is smooth and easy, with a very heavy slag left on the weld bead. |
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Electrodes with rutile based fluxes
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- are easier to control and are used for flat stringer beads and butt joints. |
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Electrodes with mineral based fluxes
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- make welds with good appearance, but strong welds are hard to obtain. |
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Stringer bead
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- they are the most commonly used type of bead for vertical, horizontal, and overhead welds. |
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