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Welding Guidelines
General
This welding machine utilizes a process
known as Shielded Metal-Arc Welding
(SMAW). This process is used to bond
metals by heating them with an electric
arc created between the electrode and
the workpiece.
Electrodes used for shielded metal arc
welding have two parts. The inner core is
a metal rod or wire that should be similar
in composition to the base metal. The
outer coating is called flux. Various types
of flux exist. Each coating is used for a
particular welding situation.
While the metal is molten, it can be
contaminated by elements in the air. This
contamination could weaken the weld.
The flux coating creates a protective
barrier called slag that protects the
molten metal from contaminants.
When current (amperage) flows through
the circuit to the electrode, an arc is
formed between the end of the electrode
and the workpiece. The arc melts the
electrode and the workpiece. The melted
metal of the electrode flows into the
molten crater and forms a bond with the
workpiece as shown in Figure 6.
Wire
Slag
Weld
Figure 6 - Weld Components
NOTE: Discontinue using and discard
electrodes that burn down to 1 to 2
inches from the electrode holder.
STRIKING AN ARC
Attach work clamp to workpiece. The
jaws of the work clamp must make good
contact with clean bare metal of the
workpiece for good welding results.
Place the bare end of the electrode in the
holder. Grip the holder lightly to reduce
tiring of the hand and arm.
NOTE: Always keep the jaws of the
holder clean to ensure good electrical
contact with the electrode.
WARNING
!
or welding bench with the electrode as
this causes arc flashes.
The best method of striking an arc is the
scratching method. Drag the electrode at
an angle along the surface much like
striking a match. Upon contact with the
plate, lift the electrode approximately
1/16" off the surface or it will stick (See
Figure 7).
Same as Electrode Diameter
Figure 7 - Scratching Method
NOTE: Should the electrode stick to the
workpiece, break it loose by quickly
twisting or bending at the holder while
pulling upward. If the electrode does not
break loose, disengage the electrode by
releasing it from the holder.
ELECTRODE TYPE AND SIZE
Flux
Two types of electrodes are
recommended for this welder. The
Workpiece
electrodes are designated as follows:
1. E-6013 GENERAL PURPOSE
•
All position, smooth deposit rod with
low spatter.
Crater
•
For all mild steel and general purpose
work.
2. E-7014 FAST FILL
•
Smooth bead and fast deposition
•
Ideal for joints with poor fitup and
general repair work
NOTE: E-6011 and E-7018 are not
recommended for use with these
welders. Recommended electrode
diameter is 1/16" or 5/64". Call
1-866-220-2097 for availability.
Arc Welding Basics
Four basic techniques affect weld
quality. These are: amperage setting,
weld angle, arc length, and travel
speed. Proper use of these techniques is
necessary for good weld quality.
Be careful not to
AMPERAGE SETTING
touch the workpiece
The correct amperage involves the
adjustment of the welding machine to
the required amperage setting. This is
regulated by selecting the appropriate
high or low setting. The amperage
required depends on the size
(diameter) of electrode used and the
thickness of the workpiece.
Excessive currents burn through light
metals and the weld bead is flat and
porous (See Figure 9). The bead
appears high and irregular if the
current is too low.
WELD ANGLE
1/16"
Weld angle is the angle at which the
electrode is held during the welding
process. Using the correct angle ensures
proper penetration and bead formation.
Electrode angle involves two positions -
travel angle and work angle (See Figure
8).
Figure 8 - Weld Angle
Travel angle is the angle in the line of
welding and may vary from 5º to 45º
from the vertical, depending on
welding conditions.
Work angle is the angle from
horizontal, measured at right angles to
the line of welding.
For most applications, a 45º travel
angle and 45º work angle is sufficient.
For specific applications, consult an arc
welding handbook.
5
WS0973, 58-8023-2
5
o
- 45
o
Travel Angle
Work Angle
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