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DOCUMENT RESUME

ED 078 216 VT 020 499


AUTHOR Fordyce, H. L.; Doshier, tale
TITLE Instructional Guidelines. Welding.
INSTITUTION Department of Justice, Washington, D.C. Federal
Prison Industries, Inc.
PUB DATE [73]
NOTE 218p.
AVAILABLE FROM Supervisor of Education, Federal correctional
Institution, Lompoc, CA 93438 (free until present
supply is exhausted)

EDRS PRICE MF-$0.65 HC-$9.87


DESCRIPTORS Correctional Rehabilitation; *Corrective
Institutions; *Educational Programs; Metals; Metal
Working Occupations; Prisoners; *Teaching Guides;
*Trade and Industrial Education; *Weldifig
ABSTRACT
Using the standards of the American Welding Society
and the American Society of Mechanical Engineers, this welding
instructional guidelines manual presents a course of study in
accordance with the current practices in industry. Intended for use
in welding programs now practiced within the Federal Prison System,
the phases of the program are designed for beginning and advanced
students or metal workers interested in welding as a supplement to
their trade. She guidelines are based on accepted practices of
welding_ instruction, and encourage manipulative skills in using
shielded arc electrodes. The guidelines also outline the process of
oxyacetylene welding and cutting, gas tungsten-arc, and gas metal -arc
welding. The lesson plans include suggested time allotment, an
introduction to and illustration of the type of joint and welding
position covered in the lesson, equipment and materials needed, and
step-by-step procedures for accomplishing the lesson. (SB)
FILMED FROM BEST AVAILABLt. COPY

U S DEPARTMENT OF HEALTH.
EDUCATION A WELFARE
NATIONAL INSTITUTE OF
EDUCATION
THIS OfrUMENT HAS BEEN REPRO
OUCEP C"1CTLV AS RECFIVZO PROM
THE PERSON: OR ORGANIZATION ORIGi%
ATING IT POINTS OF VIEW OR OPINIONS
srA Ito DO NOT hECESSARMY REPRE
sets; r OFFICIAL NATIONAL INSTITUTE 0I-
LOUCATION POSI.04 CT POLICY

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U. S. DEPARTMENT OF JUSTICE
BUREAU OF PRISONS
FEDERAL PRISON INDUSTRIES, INC.
I WASHINGTON, D.C. 20537

I
FOREWORD

I
The social and economic value of training offenders in
career occupations is well known among teachers and other per-
sonnel in correctional institutions. Of equal value is the
development of instructional materials which are pertinent to
the real world of work. Both of these criteria are met in this
welding guideline because its content relates to the actual
technical skills required for working in the welding industry
and allied fields.

This guideline is .representative of what can be achieved


by school staffs who are interested in maintaining up-to-date
instructional techniques in their professional areas of work.
What is more important, however, is the fact that the offender
will be able to seek and hold employment because he was taught
the right kind of skills to match the skill requirements of the
job. Productive work skills are important for upward mobility
in the job market place and the opportunity to share in this
process is essential to the success of the offender when he is
released to the community.

This publication is a timely contribution to the field of


vocational education in the correctional setting and'should
serve as a reference for teaching staffs who are engaged in the
development of instructional activities.

Norman A. Carlson, Director


Bureau of Prisons
U.S. Department of Justice
AMERICAN WELDING SOCIETY
2501 NORTHWEST 7th STREET MIAMI, FLORIDA 33125 (305) 642-7090

The American Welding Society is pleased to endorse this


manual which represents a significant factor in the efforts
of the United States Bureau of Prisons to establish a uniform
approach to the training of welders.

The rapid strides being made in all types of welded fab-


ricatioh require greater skills and competence of the crafts-
men. Good, qualified welders are-and for the immediate future
still will be-in short supply. The program of the United
States Bureau of Prisons, which concerns the standardization
of the training and qualification of welders to recognized
welding codes, including the AWS Structural Welding Code, ap-
pears to be a sound and worthwhile approach.

The American Welding Society wishes to extend its best


wishes to the United States Bureau of Prisons for a most suc-
cessful program of welder training.
Sincerely yours.

R
R.D. Stout
President, AWS

E.A. Fenton
Executive Director, AWS

A NON-PROFIT ORGANIZATION FOUNDED IN 1919 TO ADVANCE THE ART AND SCIENCE OF WELDING
PREFACE

Using the standards of the American Welding Society


and the American Society of Mechanical Engineers, this
welding instructional guidelines manual presents a course
of study in accordance with the current practices in in-
dustry. .

It has been planned for use in welding programs now


practiced within the Federal Prison System. Years of use
with these procedures has shown to increase a man's advan
tages in acquiring code certification as a welder.

The phases are designed for beginning and advanced


students or metal workers interested in welding as a supple-
ment to their trade.

The guidelines are based on accepted practices of weld-


ing instruction, and encourage manipulative skills to stu-
dents interested in becoming certified welders using shielded
arc electrodes. The guidelines also outline the process of
oxyacetylene welding and cutting, gas tungsten-arc welding
(TIG), and gas metal-arc welding (MIG). The type of joint
and welding positions are described in the lesson plan and
includes an illustration of the text.

The author has prepared this manual and arranged the


lessons so that the student is introduced to new experiences
while reviewing the lessons he has previously learned.

The procedures liste4 account for the author's tred


and tested methods, and he does not imply that individual
preferences should not be used when desired.

While this manual deals only with the skills of welding,


other factors of the trade are equally important. It should
not be overlooked that safety and good work habits are taught
parallel to every project, and that pride in workmanship is
basic to craftmanship.

iii
INTRODUCTION

In April of 1971 the Institutional Visitation of


Welding Instructors met at Lompoc, CA and Englewood, CO
under the co-ordinated management of Shelvy Johnson,
Supervisor of Vocational Training.

The purpose of these meetings resulted in determining


standards and guidelines for use in vocational welding pro-
grams that are operational within the federal prison serv-
ice. If the welding programs were to use the same recog-
nized standards, it would be possible to establish uniform,
measurable objectives for all programs. It would also be
possible to determine the number of training hours required
for a student to reach each phase of a uniform standard.
Thus, it would be adaptable to all programs regardless of
their course length or geographical area.

Using Section IX Welding Qualification of the Amer-


ican Society of Mechanical Engineers Boiler & Pressure Code
as the recognized standard, and the testing to be performed
in a reputable testing laboratory, a survey was developed
and mailed to each welding instructor. The results of the
survey are shown in the table below.

Procedures, material specifications, and method of testing were extracted


from Section IX of the American Society of Mechanical Engineers Boiler &
Pressure Code

Procedure & Material Method of *No. of


Name & Position of Test Specifications Testing Training Hrs
Flat Fillet 1F Fig. Q-9-A Q-9-A 58
Horizontal Fillet 2F Fig. Q-9-A Q-9-A 78
Vertical Fillet 3F Fig. Q-9-A Q-9-A 122
overhead Fillet 4F Fig. Q-9-A Q-9-A 177
Glat Groove 1G Fig. (Q-23)(QN-23A) F19(Q-7-2)(Q-8) 356
Horizontal Groove 2G Fig. (Q-23)(QN-23A) P19(Q-7-2)(Q-8) 389
Vertical Groove 3G Fig. (Q-23)(QN-23A) F19(Q-7-2)(Q-8) 453
Overhead Groove 4G Fig. (Q-23)(0-23A) P19(Q-7-2)(Q-8) 573

*Recommended by field survey of welding instructors in Bureau of Prisons

iv
ACKNOWLEDGEMENTS

This writer is grateful toMr. Shelvy E. JAnson,


Supervisor of Vocational Training, UnitedStates Bureau
of Prisons, for inspiration, co-operation, and guidance
without whose farsightedness these welding guidelines
would not have been possible.

Gratitude is also due to F.F. Kenton, Warden and


D.R. Scott, Supervisor of Education for providing the
resources and encouragement to produce this work.

Credit is also due to all the welding instructors


in the Federal Bureau of Prisons for their support and
contributions of data and instructional material.

The author has drawn freely from the code books of


the American Welding Society and the American Society
of Mechanical Engineers, and is especially indebted to
both organizations.

H.L. Fordyce
Senior Welding Instructor
Federal Correctional Institution
Lompoc, California

Dale Doshier, Advisor


Welding Instructor
Federal Youth Center
Englewood, CO

v
CONTENTS

PAGE
Phase I Shielded Metal-Arc Welding 125 hrs

I. Surfacing Weld

A. Starting the arc 3


B. Full width beads S
Multiple pass pads (C thru G) 7

II. Lap Weld Sets

A. Lap welds 17

III. Fillet Weld Sets

A. Flat position 19
.B. Horizontal position (thru D) 21
E. Vertical up position 27
F. Overhead position (thru G) 29
H. 4 position fillet weld test 33

IV. Oxyacetylene Cutting


1

A. Use of the oxyacetylene cutting torch 35

-V. Arc-Air Gouging 1

A. Understanding & using the process 36 1


1

Phase II Shielded Metal-Arc Welding 275 hrs


I. Surfacing Weld

A. Whip Bead flat position 39


B. Weave Bead - flat position 41
1

C. Whip Bead - horizontal position 51


D. Weave Bead horizontal position 67
E. Whip Bead vertical position 73
F. Whip Bead overhead position 97

II. Fillet Weld Sets

A. Horizontal position - AWS-E-6010 53


B. Horizontal position - lacing bead 55
C. Horizontal position - pipe to plate 57 1

i
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D. Horizontal position - multiple corner 59
E. Horizontal position - AWS or ASME test 61
F. Vertical position - weave bead AWS-E-6010 69
1 G. Vertical position - weave bead AWS-E-7018 71
H. Vertical position - weave bead pipe to plate 79
I. Vertical position - AWS or ASME test 81
J. Vertical down position 91
K. Overhead position - AWS-E-6010 99
L. Overhead position - AWS-E-7018 101
M. Fixed position - multiple corner 103
N. Overhead position - AWS or ASME test 105
III. Groove Weld Sets
1
A. Flat position - corner 43
B. Flat position - AWS-E-7024 45
C. Flat position - w/back-up 47
D. Flat position - open 49
E. Horizontal position - w/back-up 63
F. Horizontal position - open 65
G. Vertical position - corner 75
H. Vertical position - 21 passes 77
I. Vertical position w/back-;up 83
J. Vertical position - weave bead AWSE-6010 85
K. Vertical position - weave bead AWS-E-7018 87
L. Vertical position - open 89
f M. Vertical down position - open AWS-E-6010
1
93
N. Vertical position - soundness test AWS-E-7018 &
AWS-E-7024 95
( 0. Overhead position - gdundness test AWS-E-7018 &
1
AWS-E-7024 107
P. Overhead position - w/back-up AWS-E-6010 109
Q. Overhead position - w/back-up AWS-E-7018 111
R. Overhead position - open AWS-E-6010
I 113
S. Four position test 115

1
Phase III - Shielded Metal-Arc Welding Certification 180 hrs
I. A.S.M.E. Test Groove Weld
i
A. Horizontal position w/back-up 119
B. Vertical position w/back-up. 121
C. Overhead position w/back-up 123

I
vii

I_
II. City of Los Angeles Field Certification - Groove Weld
(or city applicable to area)

A. Horizontal position w/back-up 127


B. Vertical position w/back-up 129
C. Overhead position w/back-up 131
D. Vertical position soundness test 133
E. Overhead position soundness test 13S

Phase IV - Oxyacetylene Welding & Cutting 8S hrs

I. Process Familiarization and Equipment Use

A. Stringer beads without filler rod 139


B. Edge weld without filler rod 141

II. Groove Weld

A. Flat position - corner 143


B. Flat position - forehand technique 147
C. Flat position - backhand technique 1SS
D. Vertical up position - corner 157

III. Fillet Weld

A. Lap weld 14S


B. Horizontal position 153
C. Vertical position 159

IV. Oxyacetylene Cutting

A. Use of the handcutting oxyacetylene torch 149


B. Use of the automatic cutting machine 1S1

V. Braze Welds

A. Flat position - groove weld 161


B. Horizontal position - fillet weld 163

VI. Pressure Vessel

A. Final test - oxyacetylene welding 16S

viii
Phase V-a - Gas Tungsten-Arc Welding (TIG) 135 hrs
I. Familiarization with the Process
A. Stringer beads on aluminum 169
B. Stringer beads on stainless steel 181
II. Fillet Weld

A. Horizontal position, lap weld on aluminum 171


B. Horizontal position, fillet weld on aluminum 173
C. Horizontal position, lap weld on stainless steel 183
D. Horizontal position, fillet weld on stainless steel 185
III. Groove Weld

A. Flat position, corner weld on aluminum 175


B. Flat position, square butt weld on aluminum 177
C. Flat position, corner weld on stainless steel 187
D. Flat position, square butt weld on stainless steel 189
IV. Pressure Vessel'

A. Multiple position on aluminum 179


B. Multiple position on stainless steel 191

Phase V-b - Gas Metal-Arc Welding (MIG)


I. Fillet Veld

A. Flat position (spray method)


1- 195
B. Vertical-down position (short circuiting method) 197
C. Flat position on aluminum (spray method) 199
D. Vertical-down position on aluminum (short circuiting
method) 201
II. Groove Weld

A. Flat position 203


B. Vertical-down position 205
C. Flat position on aluminum (spray method) 207
D. Vertical-down position on aluminum (short Circuiting
method) 209
III. Flux Cored Electrode Welding

A. Flat position, fillet weld 211


B. Flat position, groove weld 213

ix
]

COURSE: VOCATIONAL TRADE WELDING

BASIC SHIELDED METAL-ARC WELDING

PHASE I OBJECTIVE

Those trainees participating in the 125 hour course

will develop the skills of arc welding, flame cutting,

and arc-air gouging. Practice in shielded metal-arc


welding will be limited to fillet welds made in all

positions. Use of the cutting torch will be limited


to cutting simple shapes from steel plate one inch or
less in thickness. The arc-air tool will be used to
gouge out welds.

The trainee in this course can expect to develop a level

of skill that will enable him to obtain employment as a

limited welder on steel structures. He also may find use


for this skill in other mechanical trades.

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A. WELD ON BOTH SIDES OF PLATE.

B. FLAT POSITION.

REFERS TO BEAD WIDTH

NAME MILESTONE A MODULE NO. I


SURFACING WELD STARTING AN ARC
FIGURE NO. I

ELECTRODE SIZE I TYPE


W DIA. DC/RP AWS E- 6010
MATERIAL SPEC. AMT SIZE

STEEL MILD -.-3 X 8 X 7


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BASIC SHIELDED METAL-ARC WELDING

Module I. Surfacing Weld

Milestone A, Starting the Arc


Project 1; Time: 3 hours.

INTRODUCTION
The student will establish an arc between the electrode and
the work surface using a scratching motion. After the arc
is started he will deposit shcirt beads, 1-1/2 inches long,
five times in succession without sticking the electrode.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, face shield and gloves.

MATERIAL NEEDED
Scrapped steel plate or used butts, surface weld plates, 1/8
inch E6010 electrodes.

PROCEDURE
1. Clean plate surface with wire brush, place in the flat
position for welding.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on jacket, face shield and gloves.
S. Put electrode in holder.
6. Drop face shield, contact plate with electrode, raise
slightly, in a continuing motion.
7. Lower electrode to the proper arc length, as directed.
8. Deposit a short weld bead, as demonstrated.
9. Use all electrodes down to a stub end 1-1/2 inches long.
10. Raise flip front, place holder in its rest.
11. Clean all slag from the weld bead using the chipping
hammer and wire brush.
12. Repeat this procedure until arc starting can be done
without trouble.
13. Secure equipment as directed.
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PENETRATION

A. WELD ON BOTH SIDES OF PLATE

B. FLAT POSITION

NAME MILESTONE 9 MODULE NO. /


SURFACING WELD RUNNING FULL WIDTH BEADS
FIGURE NO. 2

ELECTRODE SIZE TYPE


DIA DC/RP STEEL AWS-E-6010
MATERIAl. SPEC. AMT. SIZE

STEEL MILD I 3/8 X 8 X 7


BASIC SHIELDED METAL-ARC WELDING

Module I. Surfacing Weld

Milestone B, Full Width Beads

Project 2; Time: 6 hours

INTRODUCTION
The student will demonstrate, to the satisfaction of the
instructor, his ability to make full width beads. Each
weld bead will overlap the previous bead by 50% of its
width. This will be done with straight line travel. Each
bead should have uniform height, width, and ripple.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, face shield, jacket, and gloves.

MATERIAL NEEDED
Scrapped steel plate or used butts and surface weld project
plates, 1/8 inch E6010 electrodes.
PROCEDURE
1. Clean plate with wire brush, place for welding in the
flat position.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on jacket, face shield, and gloves.
5. Put electrode in holder.
6. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
7. Lower electrode to proper arc length.
8. Hold the electrode at 90° to the plate, this is the
work angle. Hold an angle of 20° in direction of
travel, this is the lead angle.
9. Feed electrode into puddle at a controlled rate,
maintaining a constant arc length.
10. Establish rate of travel by maintaining a uniform
puddle and bead width.
11. Deposit weld bead from left to right, if right handed,
as demonstrated.
12. Use all electrodes down to a stub end 1-1/2 inches long.
13. Lift flip from on face shield, place holder in its hanger.
14. Chip and wire brush the bead to remove all slag.
15. Inspect weld bead, discuss its quality with your instructor.
16. Repeat this procedux3 until satisfactory welds are pro-
duced.
17. Secure equipment.

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PENETRATION

A. WELD ON BOTH SIDES OF PLATE.

B. FLAT POSITION.

NAME MILESTONE C MODULE NO. I


SURFACING WELD MULTIPLE PASS PAD /
FIRST LAYER FIGURE NO. 3

ELECTRODE SIZE TYPE


j8 DIA. DC/ RP STEEL. AWS- E- 6010
MATERIAL SPEC. AMT. SIZE

STEEL. MILD I X8X7

6
BASIC SHIELDED METAL-ARC WELDING

Module I. Surfacing Weld

Milestone C, Multiple Pass Pads/First Layer


Project 3; Time: 5 hours

INTRODUCTION
The student will make a surfacing weld on one side of a
steel plate using 1/8 inch E6010.electrodes. The weld
beads should be straight, of uniform height and width,
with an overlap of 50% of each bead.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, face shield, gloves, and jacket.
MATERIAL NEEDED
1 piece 3/8 x 7 x 8 inch steel plate, 1/8 inch E6010 electrodes.

PROCEDURE
1. Clean plate with wire brush, place for welding in the
flat position.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on jacket, face shield, and gloves.
5. Put electrode in holder.
6. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
7. Lower electrode to the proper arc length.
8. Hold the electrode with a leading angle of about 750.
9. Feed electrode into puddle at a controlled rate, holding
a constant a:c length as demonstrated.
10. Establish rate of travel by maintaining a uniform puddle
and bead width.
11. Deposit weld btad in a straight line from left to right,
if right handed, as demonstrated.
12. Use all electrodes down to a stub end 1-1/2 inches long.
13. Raise flip front, put holder in its rest.
14. Clean off all slag with hammer and brush.
15. Inspect bead, discuss its quality with your instructor.
16. Repeat this procedure until the weld beads are consistent.
17. Secure equipment.

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A. WELD ON BOTH SIDES OF PLATE

B. FLAT POSITION

C. LEAVE lu OF FIRST BEAD SHOWING

NAME . MILESTONE D MODULE NO. I


SURFACING WELD
MULTIPLE PASS PAD/
SECOND LAYER WHIP BEAD FIGURE NO. 4

ELECTRODE SIZE TYPE


DC/RP STEEL AWS E 6010
MATERIAL SPEC. AMT. SIZE

STEEL MILD I X8X7

8
BASIC SHIELDED METAL-ARC WELDING

Module I. Surfacing Weld

Milestone D, Multiple Pass Pad/Second Layer - Whip Bead


Project 4; Time: 3 hours

INTRODUCTION
Using the reverse side of the pliiiTrom Project 3, the stu-
dent will make a surfacing weld with electrode manipulation
(Whip Bead). This is a forward and back motion in increments
of about 3/8 and 1/4 inch. The arc length must be held con-
stant. Overlap the weld beads by 50% of their width. The
completed surface must be uniform in depth and appearance.
EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, face shield, gloves and jacket.
MATERIAL NEEDED
Use the plate with a surface weld from Project 3, 1/8 inch
electrodes type E6010.

PROCEDURE
1. Clean plate with wire brush, place for welding in the
flat position.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on jacket, face shield and gloves.
5. Put electrode in holder.
6. Drop face shield, establish an arc, raise the electrode
slightly, move to the starting point.
7. Lower electrode to the proper arc length.
8. Practice the forward and back manipulation described and
demonstrated. Observe how this is an aid to deposit
beads of the desired shape and size.
9. Use all electrodes down to a stub end 1-1/2 inches long.
10. Open flip front, place holder in its rest.
11. Clean off all slag with hammer and brush.
12. Discuss your results with instructor.
13. Save plate for further work.
14. Secure equipment.
1-

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A. WELD ON BOTH SIDES OF PLATE

B. FLAT POSITION

C. LEAVE I" OF SECOND BEAD SI4OWING

NAME MILESTONE E MODULE NO. I


MULTIPLE PASS PAD /
SURFACING WELD THIRD LAYER FIGURE NO. 5

ELECTRODE SIZE TYPE


/I DIA DC/SP STEEL AWS -E- 6013
MATERIAL SPEC. AMT SIZE

STEEL MILD 1 48 X 8 X 7

10
BASIC SHIELDED METAL-ARC WELDING

Module I. Surfacing Weld

Milestone E, Multiple Pass Pad/Third Layer


Project 5; Time: 3 hours
INTRODUCTION
The student will change the current from reversed to straight
polarity, explaining to the instructor why this is done.
The
student will make a surfacing weld with 1/8 inch
E6013 elec-
trodes over the surfacing weld of Project 4. Each weld bead
must be overlapped 50% of the preceeding bead. Even spacing,
uniform height, ripple, and width are the objectives.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, face shield, gloves and jacket.

MATERIAL NEEDED
Surfacing weld plate from Project 3. and 4, 1/8 inch E6013
electrodes.

PROCEDURE
1. Clean plate with wire brush, place for welding
flat position. in the
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on jacket, face shield and gloves.
5. Put electrode in holder.
6. Drop face shield, establish an arc, raise
electrode
slightly, move to the starting point.
7. Lower electrode to proper arc length.
8. Hold the electrode with a leading angle of
about 80°,
feed into puddle at a controlled rate,
arc length. holding a constant
9. Establish rate of travel by maintaining a consistent
puddle and bead width.
10. Move from left to right, if right handed.
11. Weld beads must be parallel and overlapping
by 50%, as
demonstrated.
12. Use all electrodes down to a stub end of
13. Lift flip front, place holder in its 1-1/2 inch.
rest, chip off
all slag, use wire brush as directed.
14. Inspect work, discuss the results with
15. When a satisfactory weld is completed, your instructor.
save plate for
the following project.

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7
REINFORCEMENT

40

4=1%40 4reedeeeeeeeeesweettet<1
ecec.ce4c4s.
IIIIIIIIIIIIKI IllEVAIIIIIII
.

PENETRATION

A. WELD ON BOTH SIDES OF PLATE

8. FLAT POSITION

C. LEAVE 1" OF THIRD BEAD SHOWING

NAME MILESTONE F MODULE NO. I


SURFACING WELD MULTIPLE PASS PAD /
FOURTH LAYER FIGURE NO. 6

ELECTRODE SIZE TYPE


DIA DC/RP AWS - E- 7018
MATERIAL SPEC. AMT. SIZE

STEEL MILD I X8X7

12
BASIC SHIELDED METAL-ARC WELDING

Module I. Surfacing Weld

Milestone F, Multiple Piss Pad/Fourth Layer


Project 6; Time: 3 hours

INTRODUCTION
For this project the student will use reverse polarity,
electrode positive. He will make a surfacing weld on the
plate used in Project 5. The beads must be uniform in
height, width, with uniform ripple. Use 1/8 inch E7018
electrodes.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, face shield, gloves, and jacket.
MATERIAL NEEDED
Plate from Project 5, 1/8 inch E7018 electrodes.
PROCEDURE
1. Clean the plate with wire brush, place for welding in
the flat position.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on jacket, gloves and face shield.
5. Put electrode in holder.
6. Drop face shield, establish an arc, raise the electrode
slightly, move to the starting point.
7. Lower electrode to the proper arc length.
8. Hold the electrode with a leading angle of about 80°.
9. Feed electrode into puddle at a controlled rate while
holding a constant arc length.
10. Establish rate of travel by maintaining a consistent
puddle and bead width.
11. Deposit a straight bead from left to right, if right
handed.
12. Beads must be parallel and have a SO% overlap.
13. Use all electrodes down to a stub end 1-1/2 inches long.
14. Lift flip front, place holder in its rest, clean off
slag with hammer and wire brush.
15. Inspect weld beads, discuss the results with your instructor.
16. When a satisfactory surfacing weld is produced, save it for
the next project.

13
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DIRECTION OF TRAVEL
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REINFORCEMENT 'V

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eteds. cArm.t..-,le,
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PENETRATION

A. WELD ON BOTH SIDES OF PLATE

B. FLAT POSITION

C. LEAVE IN OF OURTH BEAD SHOWING

NAME MILESTONE G MODULE NO. .1


SURFACING WELD MULTIPLE PASS PAD /
FIFTH LAYER FIGURE NO. 7

ELECTRODE SIZE TYPE


DIA DC/RP AWS E 7024
MATERIAL SPEC. AMT SIZE

STEEL MILD I X8X7

14
BASIC SHIELDED METAL-ARC WELDING

Module I. Surfacing Weld

Milestone G, Multiple Pass Pad/Fifth Layer


Project 7; Time: 3 hours

INTRODUCTION
The student will cover the surfacing weld of Project 6 with an
additional layer of weld metal using 1/8 inch E7024 electrodes.
The beads must be overlapped 50%. They will have a uniform
surface and ripple, with an even buildup.
EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, and safety equipment.

MATERIAL NEEDED
Use the surfacing weld plate from Project 6, 1/8 inch E7024
electrodes.
PROCEDURE
1. Clean plate with wire brush, place for welding in the
flat position.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shied and gloves.
5. Put electrode in holder.
6. Drop face shield, establish an arc, raise electrode
slightly, move to starting point.
7. Lower electrode to the proper arc length.
8. Hold the electrode with a leading angle of about 80°.
9. Feed electrode into the puddle at a controlled rate,
maintaining a c.:tirtant arc length, as demonstrated.
10. Establish the rate of.travel by controlling the width of
puddle and bead.
11. Deposit straight beads from left to right, if right handed.
12. Beads should have a 50i overlap.
13. Use all electrodes down to a stub end 1-1/2 inches long.
14. Raise flip front, put holder in its rest, chip and wire
brush weld to remove all slag.
15. Inspect .beads, discuss results with your instructor.
16. Save those properly made surface weld plates for projects
following.

15
* 1 0 ((. (
6
,tt, .A..(3ry

Nal i(( di (((10(1

DIRECTION
sri ,"k(: i , Til

f (IGLOO

_.0.
OF TRAVEL
ZIN(11W1'.( flr.Cf1 'a

3
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r 6

migh WIMI16,
k ( (,(e40,,(4fratoorruovitmocooT(at,ta v
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A. WELD ON BOTH SIDES

Alift
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-

PENETRATION

NAME MILESTONE A MODULE NO.=


LAP WELD SE TS LAP WELDS
FIGURE NO. 8
ELECTRODE SIZE TYPE
DIA. DC/RP AWS E- 6010
MATERIAL SPEC. AMT. SIZE

STEEL MILD 6 16 I X 6
BASIC SHIELDED METAL-ARC WELDING

Module II. Lap Weld Sets

Milestone A, Lap Welds

Project 8; Time: 6 hours

INTRODUCTION
The student will make a lap set to contain 10 welds. These
will be finished on alternate sides until the set is complete.
Each weld should have a leg length equal to plata thickness,
with a flat face and uniform ripple. There should be no ex-
cess reinforcement on top plate or undercut. Use 1/8 inch
E6010 electrodes with a forward and back (Hot Whip) motion.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, and safety equipment.

MATERIAL NEEDED
6 pieces 3/16 x 1-1/2 x 6 inch steel plate, 1/8 inch E6010
electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on safety equipment.
5. Put electrode in holder.
6. Overlap plates 3/4 inch and tack weld at each end of the
joints. Place for welding in the horizontal position.
7. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
8. Lower electrode to the proper arc length.
9. Hold electrode about 45 to the work inclined 60° in the
leading direction.
10. Deposit weld with a forward and back manipulation in small
increments, as demonstrated. Hold a constant arc length.
11. Use all electrodes down to a stub end of 1-1/2 inch.
12. Raise flip front, place holder in its rest, clean off
slag with ahmmer and wire brush.
13. Inspect bead, discuss results with your instructor.
14. Repeat, this procedure until the desired weld is produced.

17
, 'figaminafillarill(110 malacake.,
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LO: ,-1 UMWMO quaNS
Y galciarilor1USC);,

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`-' .. :'
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6

ABC

VW'
PENETRATION
N.

/
12/
I
16
3
gr

A. WELD ALL FOUR CORNERS

N.111011P4C,
V R FLAT POSITION

4 C. WELD SEQUENCE

NAME MILESTONE A MODULE NO.111


FILLET WELD SETS FILLET WELDS
IN THE FLAT POSITION FIGURE NO. 9
ELECTRODE SIZE 73-
I
DC/RP TYPE
DIA. AWS E- 6010
MATERIAL STEEL SPEC.
MILD
T SIZE 7g
3 X ti X 6
STEEL 3
76 X 24-X6
MILD I

18
BASIC SHIELDED METAL-ARC WELDING

Module III. Fillet Weld Sets

I
Milestone A, Fillet Welds in the Flat Position

Project 9; Time: 6 hours

INTRODUCTION
The student will make a fillet weld set to contain four,
6 pass welds. The beads will be deposited to make fillets
of 1/4, 3/8, and 1/2 inch leg lengths progressively. Each
finished weld should have equal leg lengths, a flat face,
with uniform ripple. Use E6010 electrodes with reverse
polarity, electrode positive.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, and safety equipment.

MATERIAL NEEDED
1 piece 3/16 x 2-1/4 x 6 inch, 2 pieces 3/16 x 1-1/2 x 6 inch
steel plate, 1/8 inch E6010 electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld plates at 90° to form a cross; place for
welding in the flat position.
7. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
8. Lower electrode to the proper arc length.
9. Deposit weld, holding electrode at various angleS,
depending on position of the bead.
10. After each bead is complete, clean off slag with hammer
and wire brush.
11. Follow instructor's demonstrated procedure.
12. Repeat this procedure until the desired weld is produced.
13. Check fillet size with gage.
14. Save material for square butt weld.
15. Secure equipment.
x
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DIRECTION OF TRAVEL

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A PENETRATION
16

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A. WELD ALL FOUR CORNERS

II B. HORIZONTAL POSITION
kitit
in= iI

MI
C. WELD SEQUENCE

ill
"C
'

NAME MILESTONE B MODULE NO.111


FILLET WELD SETS FILLET WELDS
IN THE HORIZONTAL POSITION FIGURE NO. 10
ELECTRODE SIZE TYPE
DIA. DC/RP AWS E- 6010
MATERIAL SPEC. AMT SIZE i
STEEL X ii X 6
MILD 2
STEEL MILD I iX 24- X 6

20
BASIC SHIELDED METAL-ARC WELDING

Module III. Fillet Weld Sets

Milestone B, Fillet Weld in the Horizontal Position


Project 10; Time: 12 hours

INTRODUCTION
The student will make a fillet weld set to contain four,
six pass welds. The beads will be deposited to make fillets
of 1/4, 3/8, and 1/2 inch leg length progressively. Each
finished weld should have equal leg lengths, a flat face,
with uniform ripple. Use E6010 electrodes, weld in the
horizontal position.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, and safety equipment.

MATERIAL NEEDED
1 piece 3/16 x 2-1/4 x 6 inch, 2 pieces 3/16 x 1-1/2 x 6 inch
steel plate, 1/8 inch E6010 electrodes.
PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld plates at 90° to form a cross, place for
welding in the horizontal position.
7. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
8. Lower electrode to the proper arc length.
9. Deposit weld, holding electrode at various angles,
depending on position of the beads.
10. After each bead is complete, clean off slag with hammer
and wire brush.
11. Follow instructor's demonstrated procedures.
12. Repeat this procedure until the desired weld is produced.
13. Check fillet size with gage.
14. Save material for square butt weld.
15. Secure equipment.

21
k 6. '
, DIRECTION OF TRAVEL

1
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'III II

PENETRATION
w-/ -00

A. WELD ALL FOUR CORNERS

IIi% a HORIZONTAL POSITION

C WELD SEQUENCE

MI I "C"
2

NAME MILESTONE C MODULE NO.III


FILLET WELD SETS FILLET WELDS
IN THE HORIZONTAL POSITION FIGURE NO. II
ELECTRODE SIZE I TYPE
ib DIA. DC/SP AWS E- 6013
MATERIAL SPA CILD AMT SIZE Ti
STEEL .
2
XI X6
3
STEEL MILD 1 rg X 24 X 6

22
BASIC SHIELDED METAL-ARC WELDING

Module III. Fillet Weld Sets

Milestone C, Fillet Weld in the Horizontal Position Using


E6013 Electrodes
Project 11; Time: 6 hours

INTRODUCTION
The student will make a fillet weld set to contain four,
6 pass welds. The beads will be deposited to make fillets
of 1/4, 3/8, and 1/2 inch leg lengths progressively. Each
finished weld should have equal leg lengths, a flat face,
with uniform ripple. Use E6013 electrodes with straight
polarity, electrode negative.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, and safety equipment.

MATERIAL NEEDED
1 piece 3/16 x 2-1/4 x 6 inch, 2 pieces 3/16 x 1-1/2 x 6
inch steel plate, 1/8 inch E6013 electrodes.
PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put r'lectrode in holder.
6. Tack weld plates at 90° to form a cross, place for
welding in the horizontal position.
7. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
8. Lower electrode to the proper arc length.
9. Deposit weld, holding electrode at various angles,
depending on position of the beads.
10. After each bead is complete, clean off slag with hammer
and wire brush.
11. Follow instructor's demonstrated procedures.
12. Repeat this procedure until the desired weld is produced.
13. Check fillet size with gage.
14. Save material for square butt weld.
15. Secure equipment.

23
(,4c,

-ti,'.4 .----...
DIRECTION OF TRAVEL

N 0
0\1\

\
\' t!;'1.. I, t tCr' 0 'if ,JT.f Q rote, u. 1.. ,, k (

4 ,114111, c Mil, C
1 41111111iAlk( .., .. L
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A B C-D-E
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me
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ii, ,,,,,, .,,,,(,, Ili
.
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1.
II
CV

L__
PENETRATION

A. WELD ALL FOUR CORNERS.

a HORIZONTAL POSITION

411uttrtt ;14\41tie
ta4iti
gorilla
C. WELD SEQUENCE

411 4 I D. FIRST SIX BEADS 6013

E. LAST SEVEN BEAD-7024

"C "

NAME MILESTONE D MODULE NO. 71L


FILLET WELD SETS FILLET WELDS
IN THE HORIZONTAL POSITION FIGURE NO, 12

ELECTRODE SIZE I TYPE


13 DIA. DC/RP AWS - E- 7024 6013
MATERIAL SPEC. AIAT. SIZE -
STEEL MILD 16
XI X6

STEEL MILD I it X 24- X 6

24
BASIC SHIELDED METAL-ARC WELDING

Module III. Fillet Weld Sets

Milestone D, Fillet Welds in the Horizontal Position Using


E7024 Electrodes.
Project 12; Time: 3 hours

INTRODUCTION
The student will use a completed weld set from Project 11,
to add seven passes with 1/8 inch E7024 electrodes. These
will be deposited as follows: first, 3 beads; second, 4
)f
beads. This will increase the fillets from 1/2 inch to 3/4
inch size. The finished weld will have a flat face, equal leg
lengths:, and a uniform ripple.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, and safety equipment.

MATERIAL NEEDED
Completed sets from Project 11, 1/8 inch E7024 electrodes.
PROCEDURE
1. Clean welds with wire brush, place for welding in the
horizontal position.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
7. Lower electrode to the proper arc length.
8. Electrode angle will change with each bead, depending
on its position.
9. Clean off all slag after completing each pass.
10. Practice as demonstrated.
11. Repeat this procedure until the desired weld is produced.
12. Check work with fillet gage, as directed.

25
#1.

.1(

AO
6A90O #&
.
411W

PENETRATION OA
9.,
eli \ \PI .
v-
,

'AB CD I

5
c.
:'io
I
cc A. WELD ALL FOUR CORNERS

to .;
:-- -...,
_i
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B. VERTICAL POSITION
6-
-...
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.- 1

.__ _. C. WELD SEQUENCE


,... _. es
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D. DIRECTION OF TRAVEL JP

NAME MILESTONE E MODULE NO.=


FILLET WELD SETS FILLET WELDS
IN THE VERTICAL UP POSITION FIGURE NO. 13

ELECTRODE SIZE TYPE


s1, DIA. DC/RP AWS E- 6010
MATERIAL SPEC. AMT SIZE
STEEL MILD 2 it X 1-1- X6

STEEL MILD I ii, X 24- X 6

26
O

BASIC SHIELDED METAL-ARC WELDING

Module III. Fillet Weld Sets

Milestone E, Fillet Welds in the Vertical-Up Position


Project 13; Time: 15 hours
INTRODUCTION
The student will make a fillet set to contain four, 6 pass
welds. These will be deposited to make fillets of 5/16, 1/2,
and 5/8 inch leg lengths progressively. These welds will have
a flat face, equal leg lengths and a uniform ripple.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, positioner, and safety equipment.
MATERIAL NEEDED
1 piece 3/16 x 2-1/4 x 6 inch, 2 pieces 3/16 x 1-1/2
x 6 inch
steel plate, 1/8 inch E6010. electrodes.
PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld plate at 90° to form a cross, place in positioner
for vertical welding.
7. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
8. Lower electrode to the proper arc length.
9. Deposit bead moving upward with an up and down manipulation.
Follow demonstration procedures.
10. The increments of motion are about 3/8 inch up and 1/4 inch
down, holding a constant arc length.
11. Clean off all slag from each completed bead.
12. Repeat this procedure until the desired weld
produced.
13. Check fillet dimension with gage.

27
I we DIRECTION OF TRAVEL
41.k
ir ,
I

. PENETRATION"
r - :

I ill
10,11
itry
I/co

A. WELD ALL FOUR CORNERS

B. OVERHEAD POSITION

C. WELD SEQUENCE

NAME miasma! F MODULE NO.III


FILLET WELD SETS FILLET WELDS
IN THE OVERHEAD POSITION FIGURE NO. 14

ELECTRODE SIZE TYPE


! e DIA DC/RP AWS-E- 6010
MATERIAL
STEEL
SPEC. AM T. SIZE 1.i. x 1 6
MILD 2
STEEL MILD 1 iixzixe

28
BASIC SHIELDED METAL-ARC WELDING

Module III. Fillet Weld Sets

Milestone F, Fillet Welds in the Overhead Pc:ition


Project 14; Time: 9 hours

INTRODUCTION
The student will make a fillet set to contain four, six
pass welds. These will be made in the overhead position,
using E6010 electrodes. The beads will be deposited to
make fillets of 1/4, 3/8, and 1/2 inch leg size progressively.
The finished welds will have a flat face, with uniform ripple.
EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, positioner, and safety equipment.

MATERIAL NEEDED
1 piece 3/16 x 2-1/4 x 6 inch, 2 pieces 3/16 x 1-1/2 x 6
inch steel plate, 1/8 inch E6010 electrodes.
PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld plates at 90° to form a cross, place in
positioner for overhead welding.
7. Drop face shield, establish an arc, lower electrode
slightly, move to the starting point.
8. Raise electrode to the proper arc length.
9. Practice as demonstrated, use a slight "C" motion for
better puddle c)ntrol and penetration. Hold a constant
arc length.
10. Clean off slag after completing each pass.
11. Repeat this procedure until the desired weld is produced.
12. Check fillet size with gage.

29
miIi -O. I7
3 6
Id
1
I DIRECTION OF TRAVEL

MUilk
wte
MI
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PENETRATION/

2-
r A-B-C

ief
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ill 1
,41.7
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A. WELD ALL FOUR CORNERS

B. OVERHEAD POSITION

C. WELD SEQUENCE

NAME MILESTONE G MODULE NO. III


FILLET WELD SETS FILLET WELDS
IN THE OVERHEAD POSITION FIGURE NO. 15

ELECTRODE FAZE ii.. TYPE


'8' D/ A. DC/SP A WS E 6013
MATERIAL STEEL
SPEC.
MILD
AMT.
2
SIZE 1X li X 6
STEEL MILD I 136 X 24 X 6

30
BASIC SHIELDED METAL-ARC WELDING

Module III. Fillet Weld Sets

Milestone G, Fillet Welds made in the Overhead Position.

Project 15;. Time: 6 hours

INTRODUCTION
The student will make a fillet set to contain four, six
pass welds. These will be made in the overhead position
using E6013 electrodes. The beads will be deposited to
make fillets of 1/4, 3/8, and 1/2 inch leg size
progressively.
The finished welds will have a flat face, with uniform ripple.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, positioner, and safety equipment.
MATERIAL NEEDED
1 piece 3/16 x 2-1/4 x 6 inch, 2 pieces 3/16 x 1-1/2 x 6
inch steel plate, 1/8 inch E6013 electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld plates at 90° to form a cross, place in
positioner for overhead welding.
7. Drop face shield, establish an arc, lower electrode
slightly, move to the starting point.
8. Raise electrode to the proper arc length.
9. Practice as demonstrated, use a slight "C" motion for
better puddle control and penetration.
10. Clean off slag after completing each pass.
11. Repeat this procedure until the desired weld is produced.
12. Check fillet size with gage.

31
r2 -12 -2

--ft. or.th I

r .

INow.lh I

Oa
417
--kt
rep
#

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0 ,,,, ,,, , ... . ...
,,12,, ,.,nduirtrerroi4fuo^,11(''' :(/')'!(,100
.,:ivtiana 1 loa,viaaa,fc am...7, r r evc0((r,c,
'. 'u147(114(2"[(104 I-011.1 4 11(01(;)
U

PENETRATION 6

ABCDF
2
r
E D

Al.l 1k
moo afati
Isom RimolI

Illra P,V -,,re'cii,k,

qe:
F a

A. WELD ALL FOUR CORNERS

B. WELD SEQUENCE

C. FLAT POSITION

D. HORIZONTAL POSITION

E. VERTICAL POSITION

F. OVERHEAD POSITION

NAME MILESTONE H MODULE NO.III


FILLET WELD SETS FILLET WELDS TEST
IN THE FOUR POSITIONS FIGURE NO 16

ELECTRODE SIZE I TYPE


77- DIA DC/RP AWS -E- 6010
MATERIAL
STEEL SPEC. AMT SIZE T-6
3 X Ii X 6
MILD 2
STEEL MILD I i X 241 X 6

32
BASIC SHIELDED METAL-ARC WELDING
J
Module III. Fillet Weld Sets

Milestone H, Fillet Weld Test in 4 Positions


Project 16; Time: 80 minutes

INTRODUCTION
The student will make a fillet weld set to contain four, six
pass welds. These will be made in the flat, horizontal, ver-
tical-up, and overhead positions using 1/8 inch E6010 elec-
trodes. The finished welds will be to specified size with
flat face, equal leg lengths with a uniform appearance.
Original plates issuerwill be returned to instructor in 80
minutes for grading./
EQUIPMENT REQUIR
Direct current' iding machine, slag hammer, wire brush,
tongs, positioner, and safety equipment.

MATERIAL NEEDED
1 piece 3/16 x 2-1/4 x 6 inch, 2 pieces 3/16 x 1-1/2 x 6 inch
steel plate, 1/8 inch E6010 electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
S. Put electrode in holder.
6. Tack weld plates at 90° ,to form a cross.
7. Place for welding in the flat position, deposit a 6 pass
1/2 inch f-llet weld.
8.' Place for welding in the horizontal
position, deposit a
6 pass 1/2 inch fillet weld.
9. Place for welding in a vertical position, deposit a 6 pass
5/8 inch weld.
10. Place for welding in an overhead position, deposit a 6
pass 1/2 inch weld.
11. Cool and clean welds.
12. Present your work to the instructor for inspection and
grading.

33
g

CUTTING
LINE
co

7"

NOTE:

1. FLAME CUT INTO I" STRIPS


2. ALTERNATE EDGE CUTS AT 90 a 45
"~45'
o

I I v 1 1

NAME MILESTONE A MODULE NO.=


OXYACETYLENE CUTTING USE OF THE OXYACETYLENE
CUTTING TORCH FIGURE NO. /7

ELECTRODE SIZE TYPE

MATERIAL
STEEL
SPEC.
MILD
AMT
I
SIZE
y3 X 8 x 7
BASIC SHIELDED METAL-ARC WELDING

Module IV. Oxyacetylene Cutting


Milestone A, Use of the Oxyacetylene Cutting Torch
Project 17; Time: 6 hours

INTRODUCTION
The student will demonstrate his ability to assemble the
oxyacetylene cutting torch, select the proper tip size for
the metal thickness being cut, and test for gas leaks in
system. the
He will use this equipment to cut one inch strips
from used butt weld plates. A successful cut is made to
dimension, with a clean kerf. Separation must be complete.
EQUIPMENT REQUIRED
Oxyacetylene pressure regulators, cutting torch, tips, wrench,
hose, flint lighter, goggles, gloves, square, tongs.

MATERIAL NEEDED
Used butt weld plates.

PROCEDURE
1. See that the hose and fittings are in good servicable
condition.
2. Hold torch with valve wheels upward, attach hose, use
wrench on union nuts.
3. Select proper sized tip, attach to torch; use wrench on
union nut.
4. Close torch valves.
5. Turn regulator adjusting screws counterclockwise until
tension is released.
6. Open line or cylinder valves.
7. Turn regulator adjusting screws clockwise, adjust for the
required pressures.
8. Close line or cylinder valves, watch for
any pressure drop
which indicates leakage. Correct for any leaks.
9. Reopen line or cylinder valves.
10. Put on cleaned goggles.
11. Open oxygen and acetylene torch valves
about 1/4 turn,
ignite with flint lighter.
12. Adjust to a neutral condition with
the proper flame length.
13. Hold torch in left hand, guide and work
right hand. oxygen valve with
14. Hold flame at edge of plate
on guide line with the flame
tips touching plate.
15. When plate becomes red, slowly depress
to full open; raise torch slightly. oxygen cutting valve
16. Immediately move along guide line
at a constant rate,
.maintain good clearance between flame and
17. Rate of travel is governed by plate.
cutting effect. Too slow
results in oxide buildup; too fast will stop burning
proper rate makes a clean cut with parallel sides. action;
18. Repeat this procedure until good
19. Secure equipment. cuts are produced.
35
BASIC SHIELDED METAL-ARC WELDING

Module V. Arc-Air Gouging

Milestone A, Understanding and Using the Process

Project 18; Time: 3 hours

INTRODUCTION
The student will assemble the arc-air equipment, and use
it for removing the weld deposit from fillet and butt weld
sets. After gouging the weld from the joints, the pieces
should separate and have edges that can be rewelded without
further work.

EQUIPMENT REQUIRED
Direct current welding machine, compressed air outlet, arc-
air equipment, slag hammer, wire brush, tongs, and safety
equipment.

MATERIAL NEEDED
Fillet and butt weld sets from previous projects,. carbon
electrodes.

PROCEDURE
1. Clean welds with wire brush.
2. Adjust the amperage and polarity as directed.
3. Attach power cable and air hose to the arc-air fittings,
open the air valve at source.
4. Start welding machine.
5. Put on face shield and gloves.
6. Put carbon electrode in holder so that about 3 inches
extends from the grooved button to the pointed end.
This will leave 9 inches above the button.
7. The air discharge holes must be below the carbon so that
air passes to plate at point of arcing.
8. Open air valve on holder.
9. Drop face shield.
10. Make contact to establish the arc, move immediately along
the weld at a rapid rate. Hold the electrode at an angle
of 10 degrees from the plate.
11. Remove metal in small amounts of about 1/4 inch deep for
each pass.
12. Repeat gouging until the desired depth is reached. Move
the electrode down in the holder as it is burned away.
13. Chip away all slag from the edges of the gouge.
14. Secure equipment.

36
COURSE: VOCATIONAL TRADE WELDING
ADVANCED SHIELDED METAL-ARC WELDING

PHASE II OBJECTIVE

After the successful completion of the basic


shielded
metal-arc welding course the student has the option to

continue to practice in the Advanced Course.

Of those electing to participate in Phase II of


the pro-
gram, 80% of the students will have taken and passed the

fillet weld tests, and are familiar with the groove weld

plate test similar to the A.W.S. D1-0-72, Welding in

Building Construction or Section IX of the American So-

ciety of Mechanical Engineers Boiler & Pressure Vessel

code test.

This standard .is equal to, or surpasses, the


requirements
commonly used by industry for evaluating shielded metal-arc
weldors. Eighty-percent of the students completing the
course will possess a marketable skill.

37
. 'la iffwawaroive6maiwalalt:j
A
caleaccayeggao
a asgaCGO
6.(e'

At( gC;;-
,C DIRECTION OF TRAVEL
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REINFORCEMENT

'OW AB
--ic0
-

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tr)103

PENETRATION

A WELD BOTH SIDES.

B. FLAT POSITION.

NOTE: REFERS TO BEAD WIDTH

NAME MILESTONE A MODULE NO. I


SURFACING WELDS
SURFACING WELD WHIP BEAD FIGURE NO. I

ELECTRODE SIZE TYPE


%2 DIA. DC/RP AWS E- 6010
MATERIAL SPEC. AMT SIZE

STEEL MILD I 1X8X7


ADVANCED SHIELDED METAL-ARC WELDING

Module I. Surfacing Weld

Milestone A, Surfacing Welds in the Flat Position with


Electrode Manipulation (Whip Beads)
Project 1; Time: 6 hours

INTRODUCTION
The student will deposit stringer beads with a SO% overlap.
To cover the surface of a steel plate, use S/32 inch E6010
electrodes with a forward and back motion. This manipulation
is made in small increments while holding the arc to a con-
stant length. The completed deposit should be uniform in
1 thickness and appearance.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, face shield, and gloves.

MATERIAL NEEDED
I
1 piece 3/8 x 7 x 8 inch steel plate.
PROCEDURE
1. Clean plate with wire brush, place for welding in the
flat position.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
S. Put electrode in holder.
6. Drop face shield.
7. Establish the arc, raise electrode slightly, move to
the starting point.
8. Lower electrode to proper arc length.
9. Make beads with forward and back motion in the direction
of travel while holding a constant arc length.
10. Use electrodes down to 1-1/2 inch stub.
11. Chip and wire brush the deposit until it is'completely
cleaned.
12. Arc should be directed at the edge of each previously
deposited bead for the SO% overlap.
13. Save this specimen for the following project.

I 39

I
im1110iittl%04tImwl,
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co

7
REINFORCEMENT

...Fr A B

Hop

4(gLeiLMENLZiaMag
mi 03

PENETRATION
A. WELD BOTH SIDES

a FLAT POSITION

NOTE, REFERS TO BEAD WIDTH

NAME MILESTONE B MODULE NO. I

:
SURFACING WELDS
SURFACING WELD WEAVE BEAD FIGURE NO. 2

ELECTRODE SIZE TYPE


,DIA. DC/RP
5.3
AWS-E- 6010
MATERIAL SPEC. AMT SIZE
I

STEEL MILD I X8X7

40
ADVANCED SHIELDED METAL-ARC WELDING

Module I. Surfacing Weld


i Milestone B, Surfacing Welds with a Weaving Manipulation in
the Flat Position
Project 2; Time: 3 hours

INTRODUCTION
Use the plate from Project 1 to make a second surfacing
weld deposit. This will also be done in the flat position
using S/32 inch E6010 electrodes. Make a deposit of from
2 to 3 times the width of a stringer bead by weaving the
electrode from side to side. A short dwell time at each
side with rapid motion across the d6posit will make a flat
weld with even ripple. Advance each time by 50% of the
width of the deposit.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, face shield, and gloves.

MATERIAL NEEDED
Use the plate from Project 1.

PROCEDURE
1. Clean plate with wire brush.
2. Position for welding in the flat position.
3. Set amperage and polarity as directed.
4. Start welding machine.
S. Put on face shield and gloves.
6. Put electrode in holder.
7. Drop face shield.
8. Establish the arc, raise electrode slightly, move to the
starting point.
9. Lower electrode to the proper arc length.
10. Practice the use of a side-to-side motion in straight lines
across the direction of travel. Keep the puddle narrow
while it overlaps the preceding deposit.
11. This manipulation should make a well about 3/4 to 1 inch
wide.
12. Use electrodes down to a stub 1-1/2 inches long.
13. After completing each pass, open flip front of face
shield and chip and wire brush the weld.
14. Repeat this procedure until the desired weld is obtained.
1S. Save this plate for use in other surfacing weld practice.
1

41
I

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A. WELD ON ONE SIDE ONLY.

dr _
>
12'
B. FLAT POSITION.

,
Tg ROOT GAP ft-- -
4
NOTE: SAVE FOR NEXT PROJECT.

NAME MILESTONE A. MODULE NO. /II


GROOVE WELD
CORNER WELDS
IN THE FLAT POSITION FIGURE NO. 3

ELECTRODE SIZE 5. TYPE


/32 DIA. DC/RP AWS-E- 6010
MATERIAL SPEC. ANT SIZE

STEEL MILD 3 IX ih- X6

42
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld

Milestone A, Corner Weld in the Flat Position


Project 3; Time: 3 hours

INTRODUCTION
The student will make a corner weld in the.flat position. The
deposit sequence will be: first, a single 100% penetration
bead; second, two filler beads; third, a weave bead cover
pass. The surface should be slightly convex with a uniform
ripple with no excessive reinforcement on either side of joint.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, face shield, and gloves.

MATERIAL NEEDED
3 pieces 3/8 x 1-1/2 x 6 inch steel plate, 5/32 inch E6010
electrodes.

PROCEDURE
1. Clean the plate with the wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine,
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Stand the plates on end at 90%, making an outside corner.
Drop face shield and tack weld.
7. Place this assembly for welding in the flat position.
8. Establish the arc, raise electrode slightly, move to the
starting point.
9. Lower electrode to the proper arc length.
10. Deposit penetration bead with forward and back motion;
hold constant arc length.
11. Chip and wire brush after each pass.
12. Make the succeeding passes with two filler beads and the
weave bead cover.
13. Repeat this procedure until a satisfactory weld is pro-
duced.
14. Save this weldment for use in the next project.

43
a
r °. ,r.e. a 7-/ Y
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A- B
: --.x.r--

... W ..........
A. WELD ON ONE SIDE ONLY

B. FLAT POSITION

-1.- PENETRATION
I6

NAME MILESTONE B MODULE NO. III


GROOVE WELD "V" GROOVE WELD
IN THE FLAT POSITION FIGURE NO. 4
ELECTRODE SIZE t DIA. DC/RP TYPE
AWS E - 7024
MATERIAL SPEC. AMT. SIZE

STEEL MILD 3 1XIiX6

44
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld

Milestone B, 'V' Groove Weld in the Flat Position


Project 4; Time: 3 hours

INTRODUCTION
The student will make a flat groove weld by using a corner
weldment salvaged from Project 3. He will invert this
assembly to weld on the root side. Use 1/8 inch E7024
electrodes for multiple passes until this back side is
filled. The deposit must be free from slag inclusions,
undercut, and pinholes. The deposit should fill out to
plate ends.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, face shield, and gloves.

MATERIAL NEEDED
Salvaged weldment from Project number 3, 1/8 inch E7024
electrodes.

PROCEDURE
1. Clean the plate with the wire brush.
2. Support the weldment for welding in the flat position.
3. Set amperage and polarity as directed.
4. Start welding machine.
5. Put on face shield and gloves.
6. Put electrode in holder.
7. Drop face shield.
8. Establish the arc, raise electrode slightly, move to
starting point.
9. Lower electrode to the proper arc length.
10. Make all the beads in a straight forward motion; hold
a leading angle on the electrode of about 20°.
11. Clean off the slag after each pass; continue depositing
beads until groove is filled.
12. Repeat this procedure until the desired weld is produced.
13. Secure the equipment.

45

1
, TA.

.
,..).
.
EC i f
:KW (Dome -( .c ,
H
N
-<..,4-
.,

,....

8 .
60°
LI --60°
6

alIkk -103

mo
Mlqa 2
i j

REINFORCEMENT

PENETRATION INTO

II.1 BACK-UP STRIP.

A. FLAT POSITION

ROOT GAP

NAME MILESTONE C. MODULE NO. III


GROOVE WELD
I'V' GROOVE BUTT WELDS W/ BACK UP
IN THE FLAT POSITION FIGURE NO. 5
4
ELECTRODE SIZE _5_ TYPE
32 DIA. DC/RP AWS E 6010
MATERIAL SPEC. AMT SIZE 1 X 1 X 7
STEEL
MILD 2
STEEL MILD 3 X2X6

46
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld

Milestone C, 'V' Groove Butt Welds with Backing Strip in


the Flat Position
Project 5; Time: 3 hours

INTRODUCTION
The student gill make a groove weld with backing strip in
the flat position. The beads will be placed as follows:
Root bead fuses the three pieces together, the beveled
edges to the backing strip; second, a weave bead; third,
a weave bead; fourth, a weave bead cover pass that is
slightly convex with a uniform pattern and tight ripple.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs, and
safety equipment.

MATERIAL NEEDED
3 pieces 3/8 x 2 x 6 inch, and 2 pieces 1/8 x 1 x 7 inch
steel plate, 5/32 inch E6010 electrodes.

PROCEDURE
1. Clean the plate with the wire brush.
i 2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Assemble plates face down, the beveled edges gapped
3/16 inch, cover with the backing strip and tack weld
at each side.
I 7. Turn this assembly face up for welding in the flat
position.
8. Make the first bead fusing both beveled edges and the
1
backing strip.
9. Clean away slag completely after each pass.
10. Weave additional beads, pass across quickly and dwell
at each side for good fusion.
I 11. The completed reinforcement should not be higher than 1/8
inch above plate thickness or wider than 1/16 inch at
each side of the groove.
12. Repeat the procedure until a satisfactory weld is produced.
13. Show work to your instructor; discuss the results.
14. Save this material for practice beads.
I

I 47

I
,
. ..
, .,_-
aust 13' ANKAA:feco& ,c,,z.

A-8

60°
1/4.1 0°
6

el
AIMEMTIMMER i .\
IN/
332-i L 2

Alik
REINFORCEMENT

PENETRATION

tverA. FLAT POSITION.

B. WELD FROM ONE SIDE ONLY.

ROOT FACE ROOT GAP

NAME MILESTONE D MODULE NO. 311


GROOVE WELD "V" GROOVE BUTT WELDS
IN THE FLAT POSITION FIGURE NO. 6
ELECTRODE SIZE TYPE
3-2 DIA. DC/RP AWS -E 6010
MATERIAL SPEC. AMT SIZE

STEEL MILD 3 X I- X 6

48
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld

Milestone D, 'V' Groove Butt Welds in the Flat Position


(When available, substitute pipe for plate)
Project 6; Time: 6 hours

INTRODUCTION
The student will make a groove weld without a backing strip.
This is done in the flat position. The first stringer bead
must penetrate the root completely. Two filler beads are
deposited over this root pass. The cover is a weave bead,
slightly convex, without undercut.

EQUIPMENT REQUIRED
DC welding machine,. slag hammer, wire brush, tongs and
safety equipment.

MATERIAL NEEDED
3 pieces 3/8 x 1-1/2 x 6 inch steel plate beveled on one side
to 30°, 5/32 inch E6010 electrodes.

PROCEDURE
1. Clean plates with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Put the plate face down with the beveled edges aligned
and gapped to 3/16 inch'. Tack weld.
7. Turn this assembly face up for welding in the flat
position.
8. Establish an arc, raise electrode slightly, move to
the starting point.
9. Lower electrode to the proper arc length.
10. Deposit the first bead with full penetration. Use a
forward and back motion; concentrate arc at the root gap.
11. Clean each pass completely with chipping hammer and wire
brush.
12. Place the two filler beads, then the weave bead cover.
13. The reinforcement must not be more than 1/8 inch above.
plate thickness, or wider than 1/16 inch at each side
of the groove.
14. Repeat this procedure until the desired weld is produced.
15. Show work to your instructor; discuss the results.
16. Save the material for practice welding.

49

I
,
P-
, A!
o0
cP Sa A. WELD BOTH SIDES

,
, (S ,ite
`' iL
t.,t-;.4t,,,I.4.
p . tckvi
B. HORIZONTAL POSIT ION

NOTE: REFERS TO BEAD WIDTH

rolco

REINFORCEMENT

6N
(.WRIAMLWRIUMNaiNglaaa e
MI GI li MUM (I IMAM Web
0 MICIMIWO

co

ti1
INco

PENETRATION cn

NAME MILESTONE C MODULE NO. I


SURFACING WELD SURFACING WELDS
IN THE HORIZONTAL POSITION FIGURE NO. 7
ELECTRODE SIZE 5/32 DIA. DC/RP TYPE AWS * E - . 6010

MATERIAL SPEC. AMT. SIZE

STEEL MILD I 3i X 8 X 7

50
ADVANCED SHIELDED METAL-ARC WELDING

Module I. Surfacing Weld

Milestone C, SurfaCing Welds in the Horizontal Position


Project 7; Time 6 hours
INTRODUCTION
The student will make surface weld beading on steel plate
in the horizontal position using 5/32 inch E6010
electrodes.
A forward and back (whip) motion will be used to deposit
these beads. Make a 50% overlap.
Cover both sides of the
plate to a uniform depth.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.

MATERIAL NEEDED
1 piece 3/8 x 7 x 8 inch steel plate, 5/32 inch E6010
electrodes.
.
PROCEDURE
1. Clean the plate with wire brush, place in position for
horizontal welding.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Establish an arc, raise electrode slightly, move to
the starting point.
7. Lower the electrode to the proper arc length.
8. Hold electrode at about 5° slope upward while welding.
9. Make a small forward and back motion, move along the
length of the bead with a constant arc length.
10. Use all electrodes down to a stub end 1-1/2
11. Clean slag away completely after each pass. inches long.
1
12. Continue this procedure until the entire plate has
been
covered with weld metal.
13. Save material for surface weld in the vertical
position.
1

I
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3
8 PENETRATION

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A. WELD ALL FOUR CORNERS

tilltik
fir' B. HORIZONTAL POSITION

C. WELD SEQUENCE

MillII
n n I411
C

NAME MILESTONE A MODULE NO.=


FILLET WELD FILLET WELDS
IN THE HORIZONTAL POSITION FIGURE NO. 8

ELECTRODE SIZE _§... TYPE


32 DIA. DC/RP AWS E 6010
MATrRIAL SPEC. AMT. SIZE
STEEL MILD 2 -1---X 6
4
STEEL MILD 2 XIiX6

52
ADVANCED SHIELDED METAL-ARC WELDING

Module II,, Fillet Weld

Milestone A, Fillet Welds in the Horizontal Position


Project 8; Time: 6 hours

INTRODUCTION
The student will make a fillet weld set for welding in the
horizontal position. This set will contain four welds with
six beads in each. The first bead will make a 5/16 inch,
the second and third beads will make a 1/2 inch and beads
fourth, fifth and sixth will complete-the fillets to 5/8
inch. These should have a flat face, equal leg length and
uniform ripple.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.
MATERIAL NEEDED
1 piece 3/8 x 2-1/4 x 6 inch, 2 pieces 3/16 x 1-1/2 x 6 inch
steel plate, 5/32 inch E6010 electrodes.

PROCEDURE
1. Clean the plate with the wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves
5. Assemble and tack weld pieces to form a cross; place in
the positioner for horizontal welding.
6. Drop face shield.
7. Establish an arc, raise electrode slightly, move to the
1
starting point.
8. Lower, electrode to the proper arc length.
9. Make the weld as demonstrated, use a small forward and
back motion, holding a constant arc length.
10. Clean away slag completely after each pass.
11. Continue depositing and overlapping beads until the
fillets are of the proper size.
12. Repeat this procedure until the desired weld is produced.
13. Check dimension of the fillet with gage.
14. Save this material for the next project.

i.
53

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8 PENETRATION

se-

A. WELD ALL FOUR CORNERS

N.
IAl1 lidIRIMEN, B. HORIZONTAL POSITION

MI
P.
WELD SEQUENCE

"C"i
NAME MILESTONE B FILLET WELDS MODULE NO. IL
FILLET WELD IN THE HORIZONTAL POSI TION
WITH LACING BEADS FIGURE NO. 9

ELECTRODE SITE _5_ TYPE


m DIA. DC/RP AWS -E 6010
MATERIAL AMT. SIZE v3 X
STEEL SPIRED 21 X 6
STEEL MILD 2 4 X I4- X 6

54
ADVANCED SHIELDED METAL-ARC WELDING

Module II. Fillet Weld

Milestone B, Fillet Welds in the Horizontal


Position with
Lacing Bead
Project 9; Time: 9 hours
INTRODUCTION
The student will use the stringer bead fillet
Project 8 to practice this lacing bead in the welds of
position. This cover pass is deposited on the horizontal
down stroke,
only. The upstroke is made quickly, no metal is deposited,
and the electrode is advanced to the position
down stroke. Overlap about 50% each time down.for the next
The com-
pleted weld will have a 3/4 inch leg dimension with
face, and a smooth surface. a flat

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush,
safety equipment. tongs, and

MATERIAL NEEDED
Cruciform from Project 8, S/32 inch E6010
electrodes.
PROCEDURE
1. Clean the Project 8 welds with hammer and wire brush,
completely.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
S. Put electrode in holder.
6. Establish an arc, raise electrode slightly, move to the
starting point.
7. Lower electrode to the proper arc length.
8. Make welds as demonstrated by your instructor.
Keep
the ripples close together.
9. Repeat this procedure until the desired weld
10. Use gage to measure depth of deposit. is produced.
11. Save material for square groove butt joint.

55
A A

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7 Mlao
A. HORIZONTAL POSITION

B. WELD ALL FOUR PIPES


PENETRATION

kIliti% C. WELD SEQUENCE


11111101I
111/ li 41

NAME MILESTONE C MODULE Nair


PIPE TO PLATE FILLET WELDS
FILLET WELD IN THE HORIZONTAL POSITION FIGURE NO. 10

ELECTRODE SIZE TYPE


DIA. DC/RP AWS E 6010
MATERIAL SP ECILD
. AMT SIZE
STEEL MILD I X8X8
STEEL PIPE MILD 4 '.?° X 1

.1--

56
ADVANCED SHIELDED METAL-ARC WELDING

Module II. Fillet Weld

Milestone C, Pipe to Plate Fillet Welds in the Horizontal


Position

Project 10; Time: 6 hours

INTRODUCTION
The student will make a pipe to plate fillet weld set by
joining four pipe nipples to each side of a steel plate.
Welding will be done with the pipe nipples in the vertical
position. Six beads will be required to make a fillet with
a 5/8 inch leg. The fillets should have a flat face, equal
leg length and no undercut.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs, and
safety equipment.

MATERIAL NEEDEP
1 piece 3/8 x 8 x 8 inch steel plate, 4 pipe nipples 2 x 1-1/2
inches long, 5/32 ihch E6010 electrodes.
PROCEDURE
1. Clean material with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
S. Put electrode in holder.
6. Tack weld four pieces of 2 inch pipe to the plate 2 inches
in from the plate edges. See drawing No. 10.
7. Place assembly for welding in the horizontal position.
8. Establish an arc, raise the electrode slightly, move to
the starting point.
9. Lower the electrode to the proper arc length.
10. Weld half way around pipe in one pass, clean off slag,
weld second half to complete root bead.
11. Complete these root beads on each nipple before completing
any single fillet.
12. Clean off slag, continue welds until six beads have been
deposited on each weld.
13. Practice as demonstrated; use a small forward and back
motion.
14. Repeat this procedure until the deiired weld is produced.
15. Use gage to check weld size.
16. Show work to your instructor; discuss the results.

57
t
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DETAIL A

!!, 41011111
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DETAIL 8

41
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C. WELD ALL EIGHT CORNERS


i-!iV
ii: gli
IR li I II I I Ii D. WELD ALL AROUND

E. HORIZONTAL POSITION
PENETRATION

NAME MILESTONE D MODULE NO. IE


MULTIPLE CORNER FILLET WELDS
FILLET WELD
IN THE HORIZONTAL POSITION FIGURE NO. II

ELECTRODE SIZE 5_ TYPE


3-2 DC/RP AWS-E 6010
MATERIAL
STEEL
SPEC. Mr SIZE A-$ X8X8
MILD

STEEL MILD I i- X Ik X 6
STEEL MILD 4 i X1fX 21
ADVANCED SHIELDED METAL-ARC WELDING

Module II. Fillet Weld

Milestone D, Multiple Corner Fillet Welds in the Horizontal


Position
Project 11; Time: 6 hours

INTRODUCTION
The student will make a multiple corner set to contain six
outside corner welds, four unobstructed corner, and four
obstructed corner welds. Each will require six passes to
make fillets with 5/8 inch legs, a flat face, uniform ripples,
and no undercut.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs, fillet
weld gage, positioner and safety equipment.

MATERIAL NEEDED
1 piece 3/8 x 8 x 8 inch, 1 piece 3/8 x 1-1/2 x 6 inch, 4
pieces 3/8 x 1-1/2 x 2-1/2 inch steel plate, 5/32 inch E6010
electrodes.

PROCEDURE
1. Clean plate with wire brush.
r
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld 3/8 x 1-1/2 inch bars to the 3/8 x 8 x 8 inch
plate as shown in the drawing. A model is kept on dis-
play board.
7. Position this assembly for horizontal welding.
8. Establish an arc, raise electrode slightly, move to the
starting point.
9. Lower electrode to the proper arc length.
10. Deposit root bead in all corners on both sides of the
plate before completing any single weld.
11. After completing each fillet, clean off all slag.
12. Weld as demonstrated, use a forward and back motion with
a constant arc length.
13. Repeat this procedure until the desired weld is produced.
14. Show the work to your instructor; discuss the results.

59
AXIS OF WELD

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PENETRATION
A. TEST, FILLET WELD

B. HORIZONTAL POSITION

NAME MILESTONE E MODULE NO. 1I


FILLET WELD FILLET WELD TEST
AWS - ASME FIGURE NO. 11-A

ELECTRODE SIZE 1 TYPE


32 DIA. DC/RP AWS E 6010
MATERIAL SPEC. AMT SIZE

I
STEEL MILD 2 g- X 12 X 3
ADVANCED SHIELDED METAL-ARC WELDING

Module II. Fillet Weld

Milestone E, Fillet Welds Performed According to ASME-AWS


Specification.
Project 11-A

INTRODUCTION
The student will demonstrate his ability to pass the fillet
weld test as described in the ASME Fired and Unfired Pressure
Vessel Code, Section IX. The test illustrated in Figures
Q-4 (6). The AWS also illustrates this test in D1.0-72,
Figure A-3, 2F (b).

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs, fillet
weld gage, and safety equipment.

MATERIAL NEEDED
2 pieces 1/4 x 3 x 12 inch ASTM A-36 steel plate, 5/32 inch
electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld plates to form a 'T' joint, position for
horizontal welding.
7. Establish an arc, raise electrode slightly, move to
the starting point.
8. Lower electrode to the proper arc length.
9. Deposit a 1/4 inch fillet weld. Each weld must be stopped
and restarted at the midpoint of the bead.
10. There is no wrap around or return around corner deposit.
11. Test weld according to the ASME procedure.

61
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A. HORIZONTAL POSITION
CIAI
ON)
B. WELD SEQUENCE 0
NAME MILESTONE E MODULE NO. EL
GROOVE WELD nV" GROOVE BUTT WELDS WI BACK UP
IN THE HORIZONTAL POSITION FIGURE NO. 12

ELECTRODE SIZE TYPE


DIA. DC/RP AWS- E- 6010
MATERIAL SIZE I
STEEL
SPEC.
MILD
AMT.
2 wX 7 XI
STEEL MILD 3 X6X2

62
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld

Milestone E, 'V' Groove Butt Welds with Backing Strip in


the Horizontal Position
Project 12; Time: 12 hours

INTRODUCTION
The student will make a groove weld with backing strip. Use
5/32 inch E6010 electrodes and stringer beads. These will
be deposited in this order; first, root bead fusing the three
pieces; second, pass a single filler bead; third, pass three
overlapping beads; fourth, a three bead cover. The cover
pass will be free of undercut, and have a flat or slightly
convex face.

EQUIPMENT REQUIRED
Direct current welding machine, slag hammer, wire brush,
tongs, positioner, and safety equipment.
MATERIAL NEEDED
3 pieces 3/8 x 2 x 6 inch steel plate beveled to 30° on one
side, 2 pieces 1/8 x 1 x 7 inch steel for backing, 5/32 inch
E6010 electrodes.

PROCEDURE
1.. Clean pla-1-1 with wire brush.
2. Set ampei ,e and polarity as directed.
3. Start weld ag machine.
4. Put on face shield and gloves.
5. Assamble plate for a groove butt joint with a 3/16
inch root opening against the backing strip. Place
this assembly face down so that tack welding can be
done on back side.
6. Position for welding in the horizontal position.
7. Drop face shield, establish an arc, raise the electrode
slightly, move to the starting point.
8. Lower the electrode to the proper arc length, make the
root bead.
9. Move along the joint to fuse the beveled edges and the
backing strip together.
10. Clean away slag by chipping and brushing.
11. Deposit the additional beads as directed by your
instructor.
12. The three bead cover pass should not be more than 1/8 inch
above the plate thickness, or wider than 1/16 inch beyond
each side of the groove.
13. Repeat this procedure until the desired weld is produced.
14. Show your work to your instructor, discuss the results.
15. Save material for beading practice.

63
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32

I
REINFORCEMENT PENETRATION

ROOT GAP

NAME MILESTONE
&
111
F
ROOT FACE

MODULE NO. Br
"V" GROOVE BUTT WELDS
GROOVE WELD
IN THE HORIZONTAL POSITION FIGURE NO. 13

ELECTRODE SIZE TYPE


DIA. DC/RP AWS-E- 6010
MATERIAL SPEC. AMT SIZE

STEEL MILD 3 +X2X6


ADVANCED SHIELDED METAL-ARr WELDING

Module III. Groove Weld

Milestone F, 'V' Groove Butt Welds in the Horizontal


Position
Project 13; Time: 12 hours

INTRODUCTION
The student will make a groove weld, without backing
strip,
in the horizontal position. This will require 4 beads
to
complete. The first bead should have consistent root
penetration; the 2 filler beads should fill the plate almost
flush. The lacing bead cover pass will have no undercut
and
no sag at the bottom of the bead.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner, and safety equipment.

MATERIAL NEEDED
3 pieces 3/8 x 2 x 6 dnch steel plate with 30°
side, 5/32 inch E6010 electrodes. bevel on one

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Put:the plates face down with the beveled edges parallel
and gapped to 3/32 inch. Tack weld on the back
7. Place this assembly in the positioner for side.
welding. horizontal
8. Drop face shield, establish an arc, raise
electrode
slightly,move to the starting point.
9. Lower the electrode to the proper arc length.
10. Deposit the root bead with a forward and back
motion,
concentrate the arc at the gap. Hold a constant arc
length.
11. Clean away slag after each bead is
completed.
12. Use lacing manipulation for completing the
13. The reinforcement should not be weld.
more than 1/8 inch above
plate thickness, or wider than 1/16 inch
the groove. at each side of
14. Repeat this procedure until an acceptable weld
15. Show work to your instructor for a discussion is produced.
16. Save material for beading practice. of results.

65
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...w .

16

REINFORCEMENT

I P PENETRATION

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A. WELD BOTH SIDES

B. VERTICAL POSITION

NAME MILESTONE D SURFACING WELDS MODULE NO.1


SURFACING WELD IN THE VERTICAL POSITION -
WEAVE BEADS FIGURE NO. 14

ELECTRODE SIZE j_ DIA. DC/RP


TYPE AWS-E- 6010
32
MATERIAL SPEC. ANT SIZE

STEEL MILD I 18 X 8 X 7
ADVANCED SHIELDED METAL-ARC WELDING

Module I. Surfacing Weld

Milestone'D, Surfacing Welds with Weave Beads in the Vertical


Position
Project 14; Time: 6 hours
INTRODUCTION
The student will make weave beads, vertically,
on steel plate.
These beads will alternate in width, one of 1/2
inch wide
followed by a 1 inch bead until the plate is covered.
Beads
will be straight with a tight uniform ripple and
pattern.
EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner, and safety equipment.

MATERIAL NEEDED
1 piece 3/8 x 7 x 8 inch steel plate, 5/32 inch
E6010 electrodes.
PROCEDURE
1. Clean plate with wire brush and place in the positioner
for vertical welding.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
7. Raise electrode to the proper arc length.
8. Deposit the weave bead moving upward.
9. Make the beads 1/2 inch and 1 inch wide, the rippling must
be uniform, each weave should overlap the preceding
10. Use all electrodes down to a stub end 1-1/2 pass.
inch long.
11. Clean off slag after completing each bead.
12. Show work to your instructor for a discussion to the
results.

67
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PENETRATION
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1 -J
im A. WELD ALL FOUR CORNERS
a
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B. VERTICAL POSITION
zo
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W C. WELD SEQUENCE
CC

Al. a

NAME MILESTONE F FILLET WELDS MODULE NO. 3/


FILLET WELD IN THE VERTICAL POSITION -
WEAVE BEADS FIGURE NO. 15

ELECTRODE SIZE 5 TYPE


32- DIA. DC/RP AWS E 6010
MATERIAL STEEL SPEC. AMT SIZE i X 2 4- X 6
MILD

STEEL . MILD 2 4 x ii X 6
ADVANCED SHIELDED METAL-ARC WELDING

Module II. Fillet Weld

Milestone F, Multiple Pass Fillet Welds in the Vertical


Position
Project 15; Time: 9 hours

INTRODUCTION
The student will make a fillet weld set to contain four welds.
These will be made with weave beads 5/16, 1/2, 5/8 & 7/8 inch
leg dimensions. Welding will be in the vertical
position,
travel up. All welds will have equal leg lengths, flat face,
and no undercut.

EQUIPMENT REQUIRED
DC welding machine, slag hammr.tr, wire brush, tongs,
positioner, and safety equipment.

MATERIAL NEEDED
1 piece 3/8 x 2-1/4 x 6 inch, 2 pieces 3/8 x 1-1/2 x 6 inch
steel plate, 5/32 inch E6010 electrodes.
PROCEDURE
1. Clean plates with wire brush.
2. Set amperage and polarity to specification.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld plates at 90° to form a cross, place in the
positioner for vertical-up welding.
7. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
8. Lower electrode to the proper arc length.
9. Deposit the first bead with an up and down motion in
small increments.
10. Clean away all slag after completing each pass.
11. Use weave motion, crossing in the upward direction, to
complete the weld.
12. Repeat this procedure until a weld of specified size and
shape is produced.
13. Check the results with fillet weld gage.
14. Secure the equipment.

'69
...

e 4INIAii.IW
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PENETRATION
\ OA
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Z
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...1".'... --
°4

NAME MILESTONE G FILLET WELDS MODULE NO..


FILLET WELit IN THE VERTICAL. POSITION -
WEAVE BEADS FIGURE NO. 16 1

ELECTRODE SIZE i DIA. DC/ RP TYPE


AWS -E -7018
MATERIAL STEEL AMT. SIZE 73 X 2+ X 6
SPEALD

STEEL MILD 2 ii X 4 x6
ADVANCED SHIELDED METAL-ARC WELDING

Module II. Fillet Weld

Milestone G, Multiple Pass Fillet Welds in the Vertical


Position
Project 16; Time: 6 hours

INTRODUCTION
The student will make a fillet weld set to contain four
welds. These will each be made with 4 weave beads in the
vertical position. Use 1/8 inch E7018 electrodes. The
welds will measure 5/16-1/2-5/8-7/8 respectively. All
welds will have a flat face,, uniform ripples, no undercut,
and equal leg lengths.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.

MATERIAL NEEDED
1 piece 3/8 x 2-1/4 x 6 inch and 2 pieces 3/16 x 1-1/2 x 6 inch
steel plate, 1/8 inch E7018 electrodes.
PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
S. Put electrode in holder.
6. Tack weld the platesat 90° to form a cross, place in
positioner for vertical-up welding.
7. Drop face shield, establish an arc, raise slightly,
move to the starting point.
8. Lower electrode to proper arc length.
9. Use weave motion to deposit bead upward.
10. Clean slag from weld after each pass.
11. Continue welding until the fillet is of the specified
size and shape.
12. Repeat this procedure until a proper weld is produced.
13. Check weld with the fillet gage.
14. Secure the equipment.

71
REINFORCEMENT

PENETRATION
AB

co

7 J
A. WELD BOTH SIDES

B. VERTICAL POSITION

NOTE : - * REFERS TO BEAD WIDTH


NAME MILESTONE' E SURFACING WELDS MODULE NO. I
SURFACING WELD IN THE VERTICAL POSITION -
WHIP BEADS FIGURE NO. 17

ELECTRODE SIZE 1. TYPE


32 DI A . DC/ RP AWS E 6010
MATERIAL SPEC. AMT. SIZE

STEEL MILD I 1 X8X7


ADVANCED SHIELDED METAL-ARC WELDING

Module I. Surfacing Weld

Milestone E, Surfacing Welds in the Vertical Position


Project 17; Time: 3 hours

INTRODUCTION
The student will make a surfacing weld with stringer beads
in the vertical position. Use an 8-inch square steel plate,
cover both sides with-be-ads with over lapping of SOS. Make
is uniform thickness of deposit with even ripple.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner, and safety equipment,

MATERIAL NEEDED
1 piece 3/8 x 7 x 8 inch steel plate, 5/32 inch 56010
electrodes.

PROCEDURE
1. Clean plate wich wire brush, put in positioner for
vertical-up welding.
2. Set amperage and polarity as directed.
3. Put on face shield and gloves.
4. Start welding machine.
S. Put electrode in holder.
6. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
7. Lower electrode to the proper arc length.
8. Practice vertical welding manipulation. This is a short
up and down whip motion while holding a constant arc
length.
9. Deposit the beads with a 50S overlap so that the new
welded surface is uniform in appearance and depth.
10. Clean away slag after finishing each bead.
11. Repeat this procedure until the desired-weld is produced.
12. Show work to your instructor, discuss the results.
13. Save this plate for Project 20.

73
k ADO T GAP -es le-

.c9°14-

PENETRATION
16
I
rg REINFORCEMENT

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a VERTICAL - UP POSITION
TACK

C. SAVE FOR NEXT PROJECT

NAME MILESTONE G MODULE NO.=


GROOVE WELD CORNER WELDS
IN THE VERTICAL POSITION FIGURE NO. 18

ELECTRODE SIZE TYPE


DIA. DC/RP AWS E 6010 _

MATERIAL SPEC. AMT. SIZE

STEEL MILD 3 I X6

74
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld

Milestone G, Corner Welds in the Vertical Position

Project 18; Time: 3 hours

INTRODUCTION
The student will make a corner weld with four beads. The
first, root bead; second and third, 2 filler beads; fourth,
a weave bead cover. This weld will be made in the vertical
position; it should have a slightly convex face with a
uniform appearance, and no excessive reinforcement on either
side of the joint.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner, and safety equipment.

MATERIAL NEEDED
3 pieces 3/8 x 1-1/2 x 6 inch steel plate, S/32 inch E6010
electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
S. Put electrode in holder.
6. Tack weld plates for a 90° corner weld, place in posi-
tioner for vertical-up welding.
7. Drop face shield, establish an arc, raise electrode
slightly, move to the starting' point.
8. Lower electrode to the. proper arc length.
9. Make first bead using an up and down motion in small
increments. Hold a constant arc length.
10. This bead should fully penetrate the join"..
11. Clean away all slag after each nass.
12. Place the two overlapping beads over the root pass.
Finish with a weave bead:
13. Repeat this procedure until a proper weld is produced.
14. Secure the equipment.

75
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ADVANCED SHIELDED METAL-ARC WELDING

Module III. GroOve Weld

Milestone H, 'V' Groove Welds in the Vertical Position


Project 19; Time: 6 hours

INTRODUCTION
The student will make a multiple bead 'V' groove weld on
the reverse side of the corner weld project, number 18.
This will require a minimum of 20 beads. There should be
no evidence of slag inclusions, pinholes, or porosity.
The ends of the joints must be full and straight. Use
5/32 inch E6010 electrodes. Weld in the vertical position.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner, and safety equipment.

MATERIAL NEEDED
Use reverse of Project 18 weldment, 5/32 inch E6010 electrodes.
PROCEDURE
1. Wire brush the plate, pie In positioner for vertical
welding.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves. _-
5. Put electrode- in holder.
6. Drop face shield, establish an arc, raise electrode
slightly, move to starting point.
7. Lower electrode to proper ar length.
8. Place the root bead; use alt and down motion in the
direction of travel.
9; Up 3/8 and down 1/4 inch are the approximate increments
of movement. Hold a close arc.
10. Clean off slag after depositing each bead.
11. Repeat this procedure until the desired weld is produced.
12. Have the instructor see your work, discuss the results
with him.

77
2 2

I I
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.
PENETRATION
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8 a FIXED POSITION

C. WELD ALL FOUR PIPES

D. WELD SEQUENCE
cati)
MIIIIIIIM,
IIIIIW
NAME MILESTONE H FILLET WELDS MODULE NO. Ir
FILLET WELD IN THE FIXED POSITION
PIPE TO PLAYE FIGURE NO. 20
ELECTROW SIZE A
32 DIA. DC/RP
TYPE
AWS E - 6010
MATERIAL SPEC. AMT. SIZE 2 X 8 X C
STEEL
MILD I 8
STEEL PIPE MILD 4 20 X.,, I'
ADVANCED SHIELDED METAL-ARC WELDING

Module II. Fillet Weld

Milestone H, Fillet Welds in the Fixed Position - Pipe to


Plate

Project 20; Time: 6 hours

INTRODUCTION
The student will make a pipe to place set. He will tack
weld four pipe nipples to each side of a steel plate.
With this plate held in vertical plane, the fillet welds
formed will be welded with 6 passes, each. The weld will
measure-5/8 inch, have a flat face, and equal leg lengths.
EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner, fillet gage, and safety equipment.
MATERIAL NEEDED
1 piece 3/8 x 8 x 8 inch steel plate, 4 pieces 1-1/2 x 2 inch
steel pipe, 5/32 inch E6010 electrodes.

PROCEDURE
1. Clean the material with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld the 4 pieces of pipe on one side of the plate
1 inch in from the edge, and on 4 inch centers. Place
in positioner for vertical welding.
7. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
8. Lower electrode to the proper arc length.
9. Start each bead at position 7 o'clock, move vertically
upward to position 12 o'clock in a clockwise direction.
10. Clean off slag.
11. Start second half of this bead at the beginning of the
first half, at position 7 o'clock. Move counterclockwise
under and up to position 12 o'clock.
12. Repeat this procedure until consistent results are obtained.
13. Check work with fillet gage for the proper weld contour and
size.
14. Show work to your instructor for a discussion of the
results.

79
PENETRATION

11101
A-B
AXIS OF 4
WELD
3

1414Ssio.

69
cv
.E.-
-,a

t=1
...e--

Z`..-. / CV
C:=V

gJ czo
t=
11 I, V

A. TEST, FILLET WELD

PLATE IS IN VERTICAL
B. VERTICAL POSITION
POSITION FOR TEST.

NAME MILESIONE I MODULE No. 71


FILLET WELD FILLET WELD TEST
AWS ASME FIGURE NO. 20-A

ELECTRODE SIZE 5 TYPE


DIA. DC/RP AWS -E 6010
32
MATERIAL SPEC, AMT SIZE

I
STEEL MILD 2 ---
q
X 12 X 3
. .
ADVANCED SHIELDED METAL-ARC WELDING

Module II. Fillet Weld

Milestone I, Fillet Weld Test in the Vertical Position


Project; 20-A

INTRODUCTION
The student will demonstrate his welding ability by performing
the ASME fillet weld test shown in Fig. Q-4 (C) in the ASME
Fired and Unfired Pressure Vessel Code, Section IX. This is
also shown in AWS code D1.0-72, Fig. A-3, 3F (C).

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner, fillet weld gage, and safety equipment.

MATERIAL NEEDED
2 pieces 1/4 x 3 x 12 inch ASTM A36 steel plate, 5/32 inch
E6010 electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld plates in a 'T' joint for fillet welding.
7. Place in positioner for vertical-up welding.
8. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
9. Raise elect ode to the proper arc length.
10.(Weld from tne bottom up; use the technique practiced in
Project 18.
11. Each pass mast-be stopped and restarted at the midpoi::t.
12. Clean away slag before restarting the weld.
13. There is no weld around the plate ends.
14. See the ASME testing procedure; make this test on the weld.

81
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ROOT GAP

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PENETRATION dcr,
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I -01

REINFORCEMENT
"Bit

NAME MILESTONE II,- MODULE NO. -III


"Ii" GROOVE* BUTT WELDS W/ BACK UP

i
GROOVE WELD .4'.
IN THE '`VERTICAL POSITION FIGURE NO. 21

ELECTRODE SIZE DIA. DC/RP TYPE AWS ' E 6010


MATERIAL SPEC AMT. SIZE I
STEEL MILD 2 XIX7
STEEL MILD 3 131- X Ii X 6

......

82
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld

Milestone I, 'V' Groove Butt Welds with Backing Strip,


in the Vertical Position
Project 21; Time: 18 hours

INTRODUCTION
The student will make a 'V' groove weld with a backing
strip in the vertical position. Use 5/32 inch E6010
electrodes to make this 6 pass weld. 'First, pass in root
to fuse backing and beveled edges; second, a single bead;
third, two filler beads complete with a two bead cover pass.
The cover pass will have a uniform ripple and no evidence
of undercut.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner, and safety equipment.

MATERIAL NEEDED
3 piece:, 3/8 x 1-1/2 x 6 inch steel plate, beveled to 30°
on on6 side, 2 pieces 1/8 x 1 x 7 inch plate, 5/32 inch
E6010 electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and. gloves.
5. Place beveled plates face down with parallel alignment
and a root opening of 3/16 inch. Put backing strip
over this joint. lack weld.
6. Place in positioner for welding in the vertical-up
position.
7. Establish an arc; raise the electrode slightly, move to
the starting point.
8. Lower the electrode to the proper arc length.
9. Make the rcot bead, fusing the beveled edges and the
backing strip
10. Chip and wiry brush to completely remove slag after
finishing eacH pass.
11. Place ad,liticaal beads as directed.
12. The finished reinforcement should not be more than 1/8
inch above base metal thickness, or wider than 1/16 inch
at each side of the groove.
13. Repeat this procedure until an acceptable weld is
prodliced.
14. Show work to your instructor, discuss the results.
15. Save material for beading practice.

83
ROOT GAP

TACK 1._
16

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Vi Pr
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Z
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B. WELD SEQUENCE U
Li
cc
O
PENETRATION

iimilMgmili
1W4111111101.11

REiNFORCEMEN
iv

NAME MILESTONE J MODULE No. lir


GROOVE WELD "V" GROOVE BUTT NELDS W/BACK UP
IN THE VERTICAL POSITION FIGURE NO. 22

ELECTRODE SIZE _5,_ TYPE


32 DIA. DC/RP AWS -E - 6010
MATERIAL
STEEL SPEC,
MILD
AN T
2 SIZE -I g-XIX 7
, STEEL MILD 3 11 X I-I X 6

84
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld


I
Milestone J, 'V' Groove Butt Welds with BaCking Strip in
the Vertical Position
Project 22: Time: 6 hours

INTRODUCTION
'Me student will make a groove weld with backing strip in
-he vertical position. Place the beads as follows: First,
root bead fusing, the beveled edges to the backing strip;
second, two filler beads; third, a weave bead cover. The
cover pass will have a uniform pattern with a flat light
ripple and no undercut.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner, and safety r nipment.
MATERIAL NEEDED
3 pieces 3/8 x 1-1/2 x 6 inch steel plate beveled on one
side to 30°, 2 pieces 1/8 x 1 x 7 inch steel strip, 5/32
inch E6010 electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Put on face shield and gloves.
4. Put electrode in holder.
5. Assemble plate by placing the beveled pieces face down,
the edges parallel with a 3/16 inch gap. Place backing
strip over this gap, tack weld to each side.
6. Position for vertical-up welding.
7. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
8. Lower electrode to the proper arc length.
9. Make root pass using an up and down mot:on, hold a
constant arc length.
10. Clean away slag after each bead is completed.
11. Place additional stringer beads, the cover bead is a
weave pass.
12. The reinforcement should not be more than 1/8 inch
above plate thickness, or wider than 1/16 inch at
each side of the groove.
13. Repeat this proceare until an acceptable weld is
produced.
14. Save material for beading practice.

85
ROOT GAP

/ TACK 2 i
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lay 16 1

to
Oft
wainjiimir
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PENETRAT161
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REINFORCEME
ne

NAME MILESTONE K MODULE NO. MI


GROOVE WELD . "V" GROOVE BUTT WELDS W/BACK UP
* IN THE VERTICAL POSITION FIGURE NO. 23

ELECTRODE SIZE 1 TYPE


DIA. DC/RP AWS -E- 7018
MATERIAL SPEC AMT. SIZE wi
STEEL MILD 2 XI X7
STEEL MILD 3 if X If X 6

86
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld


Milestone K, 'V' Groove Butt Welds with Backing Strip in
the Vertical Position
Project 23; Time: 6 hours

INTRODUCTION
The student will make a groove weld with backing strip in
the vertical position. Use 1/8 inch E7018 electrodes to
deposit beads as follows: first, a root pass fusing the 3
plates together; second and third, 2 filler beads; fourth,
a weave bead cover pass. The cover pass will have a uni-
form pattern with tight flat ripples and no evidence of
undercut.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.

MATERIAL NEEDED
3 pieces 3/8 x 1-1/2 x 6 inch steel plate beveled to 30° on
one side, 2 pieces 1/8 x 1 x 7 inch steel for backing
strip, AWS 1/8 E7018 electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld 3/8 inch beveled plates to backing strip in
parallel alignment leaving a root opening of 3/16 inch.
Place in positioner for vertical-up welding.
7. Establish an crc, raise electrode slightly, move to the
starting point.
8. Lower electrode to the proper arc length.
9. Make the root pass with a small weave motion. Concentrate
arc to fuse the three plates together.
10. Remove slag after each pass is completed.
11. Weave additional beads as directed.
12. Make the cover pass. It should not be more than 1/8 inch
above plate thickness, or wider than 1/16 inch at each
side of the groove. -
13. Repeat this procedure until an acceptable weld is produced.
14. Show work to your instructor, discuss the results.
15. Save material for beading practice.
Note: The root opening may vary according to local practice
or design. This may require a greater number of beads
for completion of the joint.

87
ROOT GAP

32

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A. VERTICAL POSITION
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B. WELD SEQUENCE 0
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C. SUBSTITUTE 6" PIPE


IF AVAILABLE
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32
ROOT FACE

REINFORCEMEN
iv

NAME MILESTONE L MODULE NO. Xi


GROOVE WELD "V" GROOVE BUTT WELDS
IN THE VERTICAL POSITION FIGURE NO. 24'

ELECTRODE SIZE TYPE AWS E 6010


32 DIA. DC/RP
MATERIAL SPEC. AMT SIZE

STEEL MILD 3 X IT X 6

88
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld


Milestone L, 'V' Groove Butt Welds in the Vertical Position
(When available, substitute 6 inch pipe)
Project 24; Time: 6 hours

INTRODUCTION
The student will make a 'V' groove weld without a backup
in the vertical position. Use 5/32 inch E6010 electrodes.
Place the beads as follows: first-, a root pass with full
penetration; second pass, single bead; third, two over-
lapping beads; fourth, two bead cover. The cover will have
tight uniform ripples and no evidence of undercut.

EQUIPMENT kEQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.

MATERIAL NEEDED
3 pieces 3/8 x 1-1/2 x 6 inch steel plate beveled on one
side to 30 , 5/32 inch E6010 electrodes.

PROCEDURE
1. Clean the plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld the beveled plates with a root opening of 3/32
inch, place in positioner for vertical-up welding.
7. Drop face shield, establish an arc, raise electrode
slightly, move to the starting point.
8. Lower electrode to the proper arc length.
9. Deposit root bead, use an up and down motion with a
short arc.
10. Clean off slag completely after each pass.
11. Whip the remaining passes as demonstrated.
12. The cover bead must not exceed the plate thickness by
more than 1/8 inch or be wider than 1/16 inch at each
side of the groove.
13. Repeat this procedure until the required weld is produced.
14. Secure the equipment.

89
II II

rr
11
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.
f,..:
,_._
PENETRATION -
4.

16

I
A-B

Itilt A. WELD ALL FOUR CORNERS

up 4.
0 Bo VERTICAL POSITION
Z
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..-,---.. rc;
Lu C. WELD SEQUENCE
-1, I7

NAME MILESTONE J MODULE NO. 31


FILLET WELD FILLET WELDS
IN THE VERTICAL DOWN POSITION FIGURE NO. 25

ELECTRODE SIZE 5 TYPE


37 DIA. DC/RP AWS E- 6010
MATERIAL SPEC. AMT SIZE 3
STEEL MILD I -g X2TX 6 1

3
STEEL MILD 2 fa X I2-I X 6

90
ADVANCED SHIELDED METAL-ARC WELDING

Module II. Fillet Weld

Milestone J, Fillet Welds in the Vertical Down Position


Project 25; Time: 3 hours

INTRODUCTION
The student will make a fillet weld set to contain four,
four pass welds. These will be deposited as weave beads
in thevertical down position. Use 5/32 inch E6010 elec-
trodes. The beads will have a fine, smooth texture, flat
face, and no evidence of pinholes or porosity.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.

MATERIAL NEEDED
1 piece 3/8 x 2-1/4 x 6 inch, 2 pieces 3/16 x 1-1/2 x 6 inch
steel plate, 5/32 inch E6010 electrodes.
PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld plate to form a cross, place in the positioner
for vertical welding.
7. Establish an arc, raise electrode slightly, move to the
starting point.
8. Lower electrode to the proper arc length.
9. Hold electrode to a 60° angle downward from the joint,
make a rapid weave motion while moving down.
10. Clean away all slag after each pass is completed.
11. Continue weaving beads for 3 more passes to fill the
joint to the required dimension.
12. Repeat this procedure until the desired weld is produced.
13. Show work to your instructor, discuss results.

91
ROOT

32 12'1
1
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32
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u..
o
B. WELD SEQUENCE zo
i-
v14
ct
o
PENETRATION

P1k c

--4- ROOT FACE


32
REINFORCEMEN
"Bs,

. .

NAME MILESTONE M MODULE NO. XI


GROOVE WELD "V" GROOVE BUTT WELDS
IN THE VERTICAL DOWN POSITION FIGURE NO. 26

ELECTRODE SIZE 5 TYPE


32- DIA. DC/RP AWS E 6010
MATERIAL SPEC AMT SIZE

1
STEEL MILD w 12- X 6

92
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld

Milestone M, 'V' Groove Butt Welds in the Vertical Down


Position

Project 26; Time: 3 hours

INTRODUCTION
The student will make a groove butt weld in the vertical down
position. This four pass weld consists of two stringer beads,
finished with two weave beads. Use S/32 inch E6010 electrodes.
The cover pass will have a fine smooth ripple and no evidence
of pinholes, porosity, or undercut.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.

MATERIAL NEEDED
3 pieces 3/8 x 1-1/2 x 6 inch steel plate beveled to 30° on
one side, S/32 inch E6010 electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld plates with 3/32 inch gap between the beveled
edges, place in the positioner for vertical welding.
7. Establish an arc, raise electrode slightly, move to the
starting point at the top of the joint.
8. Lower the electrode to the proper arc length.
9. Hold electrode at a 60° angle downward from joint, move
down with a fast weave bead.
10. Clean away slag completely after each pass.
11. Make a weave bead for each succeeding pass until groove
is filled.
12. Repeat this procedure until the desired weld is produced.
13. Show work to your instructor, discuss the results.

93
15
16

c.

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mico !....---- -

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AWS-E- 7024
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443
A. AWS-E- 7018 FILLET WELD
0O a ,.
VERTICAL POSITION.
I= --J .:.. ..
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ec
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B. AWS-E- 7024 GROOVE WELD
OPTIONAL POSITION.

1....1

NAME MILESTONE N MODULE NO. mr


GROOVE WELD WELD SOUNDNESS
IN THE VERTICAL POSITION FIGURE NO. 27
ELECTRODE SIZE I TYPE
Ti- DIA.. DC/RP AWS-E- 7018 / AWS -E- 7024
MATERIAL SPEC. AMT SIZE 73-
3 X Ily X 7
STEEL MILD I
3
STEEL MILD 2 11- X3X6

94
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld

Milestone N, Weld Soundness, Vertical Position

Project 27; Time: 9 hours


INTRODUCTION
The student will make a weld on square cut plates tack
welded to a backing strip so that there will be two fillet
welds at each side of the groove. These will be made in the
vertical position, using E7018 electrodes. The remaining
weld beads are deposited in the flat position using E7024
electrodes until the fillets are covered and the groove is
filled.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.
MATERIAL NEEDED
2 pieces 3/8 x 3 x 6 inch, 1 piece 3/8 x 1-1/2 x 7 inch steel
plate, 1/8 inch E7018 and E7024 electrodes.

PROCEDURE
1. Clean plates with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Assemble plates for a double lap joint with a 15/16 inch
opening between the plates. Tack weld these to the
backing strip on the backside.
7. Place in the positioner for vertical welding.
8. Use 1/8 inch E7018 electrodes to make two fillets at each
side of the groove.
9. Place in the flat position, remove slag completely.
10. Use 1/8 inch E7024 electrodes to fill the groove with over-
lapping beads. There should be ro evidence of slag in-
clusions, pinholes, or porosity. The ends of the joints
must be full and straight.
11. Repeat this procedure until the desired weld is produced.
12. Save the material for practice welding.

95
PENETRATION

1-Cazzzzacc===zstrewerticccormsvi 4---L6
1
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ico Plitt

A B

REINFORCEMENT

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0 .

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NOTE: REFERS TO BEAD WIDTH 7

NAME MILESTONE F MODULE NO. I


SURFACING WELD . WELDS
SURFACING
IN ME OVERHEAD POSITION FIGURE NO. 28
ELECTRODE SIZE 5 TYPE
.371 WA. DC/RP AWS - E 6010
MATERIAL SPEC. AMT SIZE

3
STEEL MILD 1 -if XTX8

96
ADVANCED SHIELDED METAL-ARC WELDING

Module I. Surfacing Weld

Milestone F, Surfacing Welds in the Overhead Position


Project 28: Time: 6 hours
INTRODUCTION
The student will deposit surfacing welds on both sides of a
steel plate. This will be done in the overhead position,
using S/32 inch E6010 electrode, overlap each bead by 50%.
The surface should be uniform in buildup and appearance.
EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.

MATERIAL NEEDED.
1 piece 3/8 x 7 x 8 inch steel plate:, 5/32 inch E6010 electrodes.
PROCEDURE
1. Clean plate with wire brush, place in positioner for
overhead welding.
2. Set amperage and polarity ass directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Establish an arc, lower the electrode slightly, move to
the starting point.
7. Raise electrode to proper arc length.
8. Hold electrode 90° to the plate, the work angle, and with
a leading angle of 45°.
9. Use a forward and back motion in small increments, arc
length should not change.
10 Use all electrodes down to a stub 1-1/2 in,:hes long.
11. Clean off all slag after each pass is completed.
12. Repeat until plate is covered with a uniform surface.
13. Show work to your instructor for a discussion of the
results.
14. Save material for further projects,

97
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if.

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1 .

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411111
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PENETRATION
AB c
8
Fel

11111:11 .

Itc te ' ff'f, 'et?


fOrtifee 4I
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eft

A. WELD ALL FOUR CORNERS

B. OVERHEAD POSITION

C. WELD SEQUENCE

NAME MILESTONE K MODULE NO. Z


FILLET WELD FILLET WELDS
IN THE OVERHEAD POSITION FIGURE NO. 29

ELECTRODE SIZE 1... TYPE


32 DIA. DC/RP AWS -5..-- 6010

MATERIAL
STEEL SPEC. AMT. SIZE a6 X I ri X 6
MILD 2
STEEL MILD 1 116 X 24-1 X 6
ADVANCED SHIELDED METAL-ARC WELDING

Module II. Fillet Weld

Milestone K, Multiple Pass Fillet Welds in the Overhead


Position

Project 29; Time: 6 hours

INTRODUCTION
The student will make a fillet weld set for welding in the
overhead position. This set will contain 4 welds with six
beads each. The first bead will make a 5/16 Inch weld.
The second and third beads will make a 1/2 inch weld. The
fourth, fifth, and sixth beads will complete the fillets
to 5/8 inch. These should have a flat face, equal leg
length, and uniform ripple.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.

MATERIAL NEEDED
2 pieces 3/16 x 1-1/2 x 6 inch, 1 piece 3/16 x 2-1/4 x 6 inch
steel plate, 5/32 inch E6010 electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld plates to form a cross, place in positioner for
overhead welding.
7. Establish an arc, lower electrode slightly, move to the
starting point.
8. Raise electrode to the proper arc length.
9. Deposit beads with a forward and back motion in small
increments, hold a constant arc length.
10. After each bead is completed remove all slag.
11. Continue welding, overlapping each bead, until the 5/8
inch leg length is reached.
12. Repeat this procedure until a proper weld is produced.
13. Check the weld dimension with gage.

99
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1

PENETRATION

5 Pr
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tell
'tiff
11c11
rf
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4

A. WELD ALL FOUR CORNERS

B. OVERHEAD POSITION

C. WELD SEQUENCE

NAME MILESTONE L MODULE NO. E


FILLET WELD FILLET WELDS
IN THE OVERHEAD POSITION FIGURE NO. 30

ELECTRODE SIZE 1 TYPE


DIA. DC/RP AWS-E- 7018
8
MATERIAL
STEEL SPEC. AMT. SIZE ii X ii. X6
MILD 2
STEEL MILD I -11- X 24. X 6

100
ADVANCED SHIELDED METAL-ARC WELDING

Module II. Fillet Weld

Milestone L, Multiple Pass Fillet Welds in the Overhead


Position

Project 30; Time: 6 hours

INTRODUCTION
The student will make a fillet weld set for welding in the
overhead position. This set will contain 4 welds with six
beads each. The first bead will make a 5/16 inch weld.
The second and third beads will make a 1/2 inch weld. The
fourth, fifth, and sixth beads will complete the fillets
to 5/8 inch. These should have a flat face, equal leg
length, and uniform ripple.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.

MATERIAL NEEDED
2 pieces 3/16 x 1-1/2 x 6 inch, 1 piece 3/16 x 2-1/4 x 6 inch
steel plate, 1/8 inch E7018 electrodes.
PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Assemble and tack weld pieces at 90° to form a cross,
plate in the positioner for overhead welding.
7. Establish an arc, lower electrode slightly, move to the
starting point.
8. Raise electrode to the proper arc length.
9. Practice as demonstrated by the instructor using a "C"
motion for better puddle control and penetration.
10. After each bead is completed, remove slag completely.
11. Continue welding, overlapping each bead until the 5/8
inch leg dimension is reached.
12. Repeat this procedure until a proper weld is produced.
13. Check fillet dimension with gage.

101
PENETRATION

in10 Asoft. DETAIL 'A"


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C. WELD ALL EIGHT CORNERS

I
D. WELD ALL AROUND

41- li-÷- E. VERTICAL FIXED POSITION


8

NAME MILESTONE M MODULE NO. I


FILLET WELD CORNER WELDS
IN THE VERTICAL FIXED POSITION FIGURE NO. 31

ELECTRODE SIZE 5.2 TYPE


DIA. DC/RP AWS-E-60I0
MATERIAL SPE AMT SIZE
STEEL MILD ..B-- X 8 X 8

STEEL MILD I a8 X 1k X 6
STEEL MILD 4 I8 X I X 2'
102
ADVANCED SHIELDED METAL-ARC WELDING

Module II. Fillet Weld

Milestone M, Corner Welds in the Vertical Fixed Position


Project 31; Time: 12 hours

INTRODUCTION
The student will make a multiple corner fillet weld set. This
will have six outside corner welds, four unobstructed corner
welds, and four obstructed corner welds. Use six passes for
each weld with 5/32 inch E6010 electrodes. All welds will
have equal leg lengths of 5/8 inch with a flat face and no
undercut.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.

MATERIAL NEEDED
1 piece 3/8 x 8 x 8 inch, 1 piece 3/8 x 1-1/2 x 6 inch, 4
pieces 1/8 x 1-1/2 x 2-1/2 inch steel plate, 5/32 inch E6010
electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
S. Put electrode in holder.
6. Tack weld the pieces together as shown in the drawing. A
sample is on the display board.
7. Place this assembly in the positioner for vertical welding..
8. Establish an arc, raise the electrode slightly, move to
the starting point.
9. Lower the electrode to the proper arc length.
10. Deposit the root beads in all of the joints on both sides
of the plate before completing any one weld.
11. Chip and wire brush the welds to completely remove slag.
12. Practice welding as demonstrated by your instructor, use
an up and down motion in small increments.
13. Repeat this procedure until consistent welds are produced.
14. Show work to your instructor for a discussion of the
results.

103
PENETRATION

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AXIS OF WELD
414114%Siso,.
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IS Pr
POSITION FOR TEST.

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1

A. TEST, FILLET WELD.

B. OVERHEAD POSITION.

NAME MILESTONE N MODULE NO. Z


FILLET WELD FILLET WELD TEST
AWS - ASME FIGURE NO. 31 -A

ELECTRODE SIZE 5 TYPE


32 DIA. DC/ RP AWS E 6010
MATERIAL SPEC. AMT SIZE

STEEL MILD X 12 X 3

104
ADVANCED SHIELDED METAL-ARC WELDING

Module II. Fillet Weld

Milestone N, Fillet Weld Test, Overhead Position


Project 31-A

INTRODUCTION
The student will demonstrate his ability t, pass the ASME
fillet weld test as it is described in the ASME Fired and
Unfired Pressure Vessel Code, Section IX, Fig.Q4(d), or the
AWS fillet weld test described in the D1.0-72, Fig.A-3, 4F(d).

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.

MATERIAL NEEDED
2 pieces 1/4 x 3 x 12 inch ASTM A36 steel plate, 5/32 inch
E6010 electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld plate to form a 'T' joint, place in positioner
for overhead welding.
7. Establish an arc, lower electrode slightly, move to the
starting point.
8. Raise electrode to the proper arc length.
9. Weld from left to right, using a forward and back motion,
with a constant arc length. Each bead must be stopped
and restarted at the midpoint of the bead.
10. The completed weld should have equal leg length of 1/4
inch.
11. There is no wrap around weld or return at the corners.
12. Test this weld as shown in the ASME procedure.

105
15
16 rnio3

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1

VIMIIII t AWS-E-70 18
I A
I

no WM2011111
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-6-
AWS-E-7024
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G,; N
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,i
N
OVERHEAD POSITION

.
1 Z:

t
B. AWS-E- 7024 GROOVE WELD
OPTIONAL POSITION

Li 2

NAME MILESTONE 0 MODULE NO. IID


GROOVE WELD WELD SOUNDNESS
IN THE OVERHEAD POSITION FIGURE NO. 32

ELECTRODE SIZE ./.. TYPE


DIA. DC/RP AWS E- 7018 / AWS -E- 7024
MATERIAL'
STEEL
SPEC. AMT 1 X7
SIZE A X 12
MILD I 8
STEEL MILD 2 8X3X6

106
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld

Milestone 0, Weld Soundness, Overhead Position


1

Project 32; Time: 3 hours

INTRODUCTION
The student will make a weld on square cut plates which are
tack welded to a backing strip. This forms a groove for two
fillet welds at each side. These will be made in the overhead
position using E7018 electrodes. The remaining weld beads
will be deposited in the flat positon using E7024 electrodes
to complete filling the groove.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.

MATERIAL NEEDED
1 piece 3/8 x 1-1/2 x 7 inch, 2 pieces 3/8 x 3 x 6 inch square
cut steel plate, 1/8 inch E7018 and E7024 electrodes.
PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld the plates to form a double lap joint with the
backing strip. Leave an opening of 15/16 inch between
the square cut pieces.
7. Place in the positioner for overhead welding.
8. Weld the two fillets using E7018 electrodes. Direct the
arc to the corners for good penetration.
9. Place in the flat position, clean away all slag, complete
the weld by filling the groove with overlapping beads.
Use E7024 electrodes for this.
10. Repeat this procedure until the desired weld is produced.
11. Save material for weld practice.
i tft
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REINFORCEMENT
PENETRATION
HB,,
A. OVERHEAD POSITION

B. WELD SEQUENCE

NAME MILESTONE P MODULE NO.=


GROOVE WELD "V" GROOVE BUTT WELDS W/ BACK UP
IN THE OVERHEAD POSITION FIGURE NO. 33

ELECTRODE SIZE _5_ TYPE


3-2 DIA. DC/RP AWS E 6010
MATERIAL
STEEL SPEC. AMT SIZE ir
3 I X 6
X 12-
MILD 4
I
STEEL MILD 3 7i- X I X7

108
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld

Milestone P, 'V' Groove Butt Welds with Backing Strip, in


the Overhead Position
Project 33; Time: 9 hours

INTRODUCTION
The student will make a 'V' groove with backing strip in
the overhead position. Use S/32 inch E6010 electrodes.
Place beads in the following order: first, root bead;
second, single bead; third, two overlapping beads; fourth,
three bead cover. The cover pass will have a uniform
appearance and no undercut.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner, and safety equipment.

MATERIAL NEEDED
4 pieces 3/8 x 1-1/2 x 6 inch steel plate beveled to 30°
on one side, 3 pieces 1/8 x 1 x 7 inch steel strip, S/32
inch E6010 electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
S. Put electrode in holder.
6. Assemble the plates for a 'V' groove butt joint with
a 3/16 inch root opening. Tack weld these to the
backing strip. Place in the positioner for overhead
welding.
7. Establish an arc, lower electrode slightly, move to the
starting point.
8. Raise electrode to the proper arc length.
9. Make the first bead, fusing the two beveled edges to
the backing strip. Use a forward and back motion with
a constant arc length.
10. Clean away slag completely when each pass is finished.
11. Continue depositing stringer beads for the succeeding
passes and the cover.
12. The reinforcement should be slightly convex, uniform
in appearance. It should not be more than 1/8 inch
thicker than the plate or more than 1/16 inch wider
at each side of the groove.
1- 13. Repeat this procedure until the desired weld is produced.
14. Show work to your instructor, discuss the results.
1S. Save material for weld practice.

109
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REINFORCEMENT
PENETRATION
"B"
A. OVERHEAD POSITION

B. WELD SEQUENCE

NAME MILESTONE 0 R MODULE NO. AL


GROOVE WELD "V" GROOVE BUTT WELDS W/ BACK UP
IN THE OVERHEAD POSITION FIGURE NO. 34
ELECTRODE SIZE
r I
DIA. DC/RP TYPE
AWS - E- 7018
MATERIAL
STEEL SPEC.
MILD
AMT.
4
SIZE ...
8
x 42 X6
STEEL MILD 3 1X 1 X7

110
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld

Milestone Q, 'V' Groove Butt Welds with Backing Strip, in


the Overhead Position
Project 34; Tine: 9 hours

INTRODUCTION
The student will make a 'V' groove butt joint with backing'
strip weld in the overhead position. Use 1/8 inch E7018
electrodes in the following sequence: first, root bead;
second, single bead; third, two overlapping beads; fourth,
three bead cover. The cover will have a uniform appearance
and no undercut.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.

MATERIAL NEEDED
4 pieces 3/8 x 1-1/2 x 6 inch steel plate bevel,pd to 30° on
one side. 3 pieces 1/8 x 1 x 7 inch steel for the backing
strip, 1/8 inch E7018 electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Assemble plate for a groove joint with 3/16 inch root
opening, tack weld to backing strip. Place in the po-
sitioner for overhead welding.
7. Establish an arc, lower electrode slightly, move to the
starting point.
8. Raise electrode to the proper arc length.
9. Make root bead, fusing the beveled edges together and
to the backing strip. Use a small weaving motion with
a constant arc length.
10. After completing each bead, clean all slag from metal.
11. Place additional beads as directed until the groove is
filled.
12. The reinforcement should not be more than 1/8 inch
thicker than the plate, or wider than 1/16 inch at each
side of the groove.
13. Repeat this procedure until an acceptable weld is produced,
14. Show work to your instructor for a discussion oZ results.
15. Save material for welding practice.
Note: The root opening may vary according to local practice
or design. This may require a greater number of beads
for completion of the joint.

111
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AB C
32
60' A'
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TACK

co
A ROOT FACE

1 1 1
Allak
Eir:41b t it 1 I
fta
A. OVERHEAD POSITION

REINFORCEMENT
B. WELD SEQUENCE
le
C. SUBSTITUTE 6 IN. PIPE
IF AIIAILABLE

NAME MILESTONE R MODULE NO. liE


GROOVE WELD "V" GROOVE BUTT WELDS
.---; IN THE OVERHEAD POSITION FIGURE NO. 35
.
ELECTRODE SIZE _§.. TYPE
32 DIA. DC/ R P AWS E 6010
MATERIAL
STEEL SPEC. AMT SIZE 6
3 X IfI X 6
MILD 4

112
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld

Milestone R, 'V' Groove Butt Welds in the Overhead Position


(When availare, substitute 6 inch pipe)
Project 35; Time: 6 hours

INTRODUCTION
The student will make a groove butt weld without backup
strip in the overhead position. Use 5/32 inch E6010 elec-
trodes. Beads will be placed: root bead with full pene-
tration; second, single bead; third, two overlapping beads;
fourth, three bead cover. Inspect the sample weld on the
display board for guidance.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,
positioner and safety equipment.

MATERIAL NEEDED
4 pieces 3/8 x 1-1/2 x 6 inch steel plate beveled to 30° on
one side, 5/32 inch E6010 electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity as directed.
3. Start welding machine.
4. Put on face shield and gloves.
I 5. Put electrode in holder.
6. Assemble the plates and tack weld together with a root
opening of 3/32 inches. Place in the positioner for
overhead welding.
7. Establish an arc, lower electrode slightly, move to the
starting point.
8. Raise electrode to the proper arc length.
9. Deposit a root bead with full penetration, drag electrode
on plate edges.
10. After each pass is completed remove all slag.
11. Deposit succeeding beads as directed. The reinforcement
should not be more than 1/8 inch above plate thickness,
or wider than 1/16 inch at each side of the groove.
12. Repeat this procedure until the desired weld is produced.
13. Show work to your instructor, discuss the results.
14. Save material for practice welds.

113
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ig

A. FLAT POSITION

B. HORIZONTAL POSITION

44/i11),'';17'
C. VERTICAL POSITION .2/ ,Ii/41

D. OVERHEAD POSITION

NAME MILESTONE S MODULE NO. .TIL


GROOVE WELD "V" GROOVE BUTT WELDS
TEST IN FOUR POSITIONS FIGURE NO. 36

ELECTRODE SIZE 8 TYPE


32 DIA. DC/RP AWS-E- 6010
MATERIAL
STEEL S PEC. AMT SIZE 8
1 X Ik X 6
MILD 5
STEEL MILD 4 8
1
X I X7

114
ADVANCED SHIELDED METAL-ARC WELDING

Module III. Groove Weld

Milestone S, 'V' Groove Butt Weld Test in Four Positions

Project 36; Time: 3 hours

INTRODUCTION
I
The student will prepare beveled plates for welding four
groove welds with backing strips. These are described in
Section IX of the ASME Code, Fig. Q23, 1G(a), 2G(b), and
4G(c). After completing the welds, they will be machined
1
to plate dimension; 1-1/2 inch coupons will be taken for
bend testing. One face and one root bend will be made for
each welding position. The student will prepare and bend
I these specimens. This project is only for training and
not for certification.

IEQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs, and
safety equipment. The use of a shaper and bending press
will also be required.

MATERIAL NEEDED
4 pieces 1/8 x 1 x 7 inch, 5 pieces 3/8 x 1-1/2 x 6 inch
steel plate with a 30° bevel on each side, 5/32 inch E6010
electrodes.

PROCEDURE
1. Clean plate with wire brush.
2. Set amperage and polarity to specifications.
3. Start welding machine.
4. Put on face shield and gloves.
5. Put electrode in holder.
6. Tack weld the plates to form 4 'V' groove butt weld joints
with 3/16 inch root opening. Place consecutively in the
positioner for flat, horizontal, vertical and overhead
welding.
7. Weld each joint with stringer beads at the root; clean
and complete following the specifications shown on the
drawing. Full fusion of the beveled and backing strips
is required. Guard against slag inclusions, and pinholing.

115
SHIELDED METAL-ARC WELDING

CERTIFICATION

PHASE III PART A OBJECTIVE

Foliating the completion of both the basic and advanced

arc welding programs, the trainee is given the opportunity

to participate in arc certification practice for 180 hours


(Part A). Eighty-percent of those students who take part
in this work will have the ability to pass the American

Society for Mechanical Engineers groove weld with backing

strip test. The procedure is described in section IX


Figure Q-23 (A) and Figure Q-3 position 2G, 3G, and 4G of

the ASME boiler and pressure vessel code. The American


Welding Society also describes the test in the AWS Manual

D1.0-72, Code for Welding in Building Construction, Figure

A-14, and positioned according to Figure A-2, 2G(b), 3G(c),


4G(d).
1co

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ril 11

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,

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A. HORIZONTAL POSITION

0
B. WELD SEQUENCE

NAME MILESTONE A MODULE NO. I


ASME -AWS GROOVE WELD TESTS "V" GROOVE W/ BACK UP
IN THE HORIZONTAL POSITION FIGURE NO. /
ELECTRODE SIZE 5 TYPE
32
DIA. DC/ RP AWS- E 6010
MATERIAL SPEC. SIZE 3
STEEL
MILD
A2 TM.
8
X4X8
STEEL MILD I X I X9

118
SHIELDED METAL-ARC WELDING

CERTIFICATION TEST

Module I. ASME or AWS Groove Weld Tests

Milestone A, 'V' Groove with Backing Strip in the Horizontal


Position
Project 1; Time: 12 hours

INTRODUCTION
The student will make a 'V' groove weld with backing strip
in the horizontal position, using 5/32 inch E6010 electrodes.
The beads to be deposited as follows: first pass, penetration;
second pass, single bead; third pass, three beads; fourth pass,
three bead cover. The finished weld must be of test quality to
be used for qualifying the weldor's skill.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs, safety
equipment, and shaper.

MATERIAL NEEDED
2 pieces 3/8 x 4 x 8 inch steel plate, beveled on one side to
30°, 1 piece 1/8 x 1 x 9 inch for the backing strip, 5/32 inch
E6010 electrodes.

PROCEDURE
1. Clean the plates with wire brush.
2. Set the amperage and polarity to specification.
3. Start welding machine.'
4. Put on face shield and gloves.
5. Place electrode in holder.
6. Drop face shield.
7. Tack weld the back side of the plates to the backing strip
with a root opening of 3/16 inches.
8. Place this assembly in the positioner for welding in the
horizontal position.
9. Establish an arc, raise electrode slightly, move to the
starting point.
10. Power electrode to proper arc length.
11. Place the first pass using a forward and back motion in
small increments.
12. After each pass is completed, chip and wire brush the weld
so that it is completely clean of slag.
13. Place the succeeding beads as directed by your instructor.
14. Concentrate the arc on the edges of the previous bead.
15. Place the cover beads so that the total reinforcement will
not exceed the plate thickness by more than 1/8 inch, nor
be wider than 1/16 inch at each side of the groove.
16. Show work to your instructor for a discussion of the results.
17. Prepare for testing; remove all metal at the face and root
of the weld down to plate thickness. Cut out 1-1/2 inch
coupons for the bend test.

119
8 il
3
16

mop-ime

A-B

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co

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8

l AM
I
A. VERTICAL POSITION Alf.."
And
4:1111.>
NON

B. WELD SEQUENCE

NAME MILESTONE B MODULE NO. I


ASMEAWS GROOVE WELD TESTS "V" GROOVE W/ BACK UP
IN THE VERTICAL POSITION FIGURE NO. 2

ELECTRODE SIZE 5 TYPE


6010
32 I A. DC/RP
DIA. AWS - E
MATERIAL
STEEL SPEC. AMT. SIZE -8-
3 X4X8
MILD 2
STEEL MILD I ir x I x 9

120
SHIELDED METAL-ARC WELDING

CERTIFICATION TEST

Module I. ASME or AWS Groove Weld Tests

Milestone B, 'V' Groove with Backing Strip in the Vertical


Posi'ion
Project 2; Time: 18 hours

INTRODUCTION
The student will make a 'V' groove weld with backing strip in
the vertical position, using 5/32 inch E6010 electrodes. The
beads will be deposited as follows: first pass, penetration;
second pass, single bead; third pass, two beads; fourth pass,
two bead cover. The finished weld must be of test quality to
be used for qualifying the welder's skill.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs,, safety
equipment, and shaper.

MATERIAL NEEDED
i pieces 3/8 x 4 x 8 inch steel plate, beveled on one side to
30°, 1 piece 1/8 x 1 x 9 inch for backing strip, 5/32 E6010
electrodes.

PROCEDURE
1 thru 6. Repeat equipment & safety procedures.
7. Tack weld the back side of the plates to the backing
strip with a root opening of 3/16 inches.
8. Place this assembly in position for vertical welding.
9. Establish an arc, raise electrode slightly, move to the
starting point.
10. Close the arc gap to the proper dimension.
11. Place the first pass using an up and down motion in small
increments.
12. After each pass is completed, chip and wire brush the
weld so that the bead is completely clean of slag.
13. Place the succeeding beads as directed by your instructor.
Concentrate the arc on the edges of the previous bead.
14. Place the cover beads so that the total reinforcement does
not exceed the plate thickness by more than 1/8 inch above
the plate thickness, nor wider than 1/16 inch at each side
of the groove.
15. Repeat this procedure until a weld is produced to the
specification.
16. Show work to your instructor for a discussion of results.
17. Prepare for testing; remove all metal at the face and
root of the weld down to plate thickness. Cut out 1-1/2
inch coupons for the bend test.

121
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titiok, A. OVERHEAD POSITION


"B"

B. WELD SEQUENCE

NAME MILESTONE C MODULE NO. I


ASME-AWS GROOVE WELD TESTS "V" GROOVE WELD W/BACK UP
IN THE OVERHEAD POSITION FIGURE NO. 3

ELECTRODE SIZE 5_ TYPE


32 DIA. DC /RP AWS- E 6010
MATERIAL STEEL SPE . AM T SIZE 1 X4X8
LD
MOLD 2 8
STEEL MILD I X 1 X9

122
SHIELDED METAL-ARC WELDING

CERTIFICATION TEST

Module I. ASME or AWS Groove Weld Tests

Milestone C, 'V' Groove with Backing Strip in the Overhead


Position

Project 3; Time: 9 hours

INTRODUCTION
The student will make a 'V' groove weld with backing strip in
the overhead position, using 5/32 inch E6010 electrodes. The
beads will be deposited as follows: first pass, penetration;
second pass, single bead; third pass, two beads; fourth pass,
three bead cover. The finished weld must be of test quality
to be used for qualifying the welder's skill.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs, safety
equipment, positioner, and shaper.
MATERIAL NEEDED
2 pieces 3/8 x 4 x 8 inch steel plate, beveled on one side to
30°, 1 piece 1/8 x 1 x 9 inch for the backing strip, 5/32 inch
E6010 electrodes.

PROCEDURE
1 thru 6. Repeat equipment & safety procedures.
7. Tack weld the back side of the plates to the backing strip
with a root opening of 3/16 inches.
8. Place this assembly in the positioner for overhead welding.
9. Establish an arc, raise electrode slightly, move to the
starting point.
10. Close the arc gap to the proper dimension.
11. Place first pass using a forward and back motion in small
increments.
12. After each pass is completed, chip and wire brush the
weld so that it is completely clean of slag.
13. Place the succeeding beads as directed by your instructor.
14. Concentrate the arc on the edges of the previous weld.
15. Place cover beads so that the total reinforcement will not
exceed the plate thickness by more than 1/8 inch, nor be
wider than 1/16 inch at each side of the groove.
16. Repeat this procedure until a weld is produced to the
specification.
17. Show work to your instructor for a discussion of results.
18. Prepare for testing; remove all metal at the face and root
of the weld down to plate thickness. Cut out 1-1/2 inch
coupons for the bend test.

123
1

SHIELDED METAL-ARC WELDING

CERTIFICATION

PHASE III PART B OBJECTIVE

Following the completion of shielded metal-arc welding

certification in Part A of this program, the trainee

is given the opportunity to participate in Part B. This

module uses the construction code tests of city or state

inspection agencies where the student will have residence.


I

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A. HORIZONTAL POSITION

8. WELD SEQUENCE

NAME MILESTONE A MODULE NO. I


CITY OF LOS ANGELES "V" GROOVE W /BACK UP
SHOP AND FIELD CERTIFICATION IN THE HORIZONTAL POSITION FIGURE NO. 4
ELECTRODE SIZE 5 TYPE
32
DIA. DC/ RP AWS- E 6010
MATERIAL
STEEL SPEC. AMT.. SIZE I X 4 X 8
MILD 2 8
STEEL MILD I X I X9

126
SHIELDED METAL-ARC WELDING

CERTIFICATION TEST

Module II. City of Los Angeles Shop and Field Certification

Milestone A, 'V' Groove with Backing Strip in the Horizontal


Position

Project 4; Time: 12 hours

INTRODUCTION
The student will make a 'V' groove weld with backing strip in
the horizontal position, using E6010 electrodes. The beads
to be deposited in the following manner: first pass, pene-
tration; second pass, single bead; third pass, three beads;
fourth pass, three bead cover. The finished weld must be
of test quality to be used for qualifying the welder's skill.

EQUIPMENT REQUIRE
DC welding machine, slag hammer, wire brush, tongs, safety
equipment, and shaper. Al,:o the use of a positioner.-

MATERIAL NEEDED
2 pieces 3/8 x 4 x 8 inch steel plate, beveled on one site to
30°, 1 piece 1/8 x 1 x 9 inch steel for backing strip, S/32
inch E6010 electrodes.

PROCEDURE
1 thru 6. Repeat equipment & safety procedures.
7. Tack weld the back side of the plates to the backing strip
to form a butt weld with a root opening of 3ilb inch's.
8. Place this assembly in the positioner for welding in the
horizontal position.
9. Establish the arc, raise the electrode slightly, move to
the starting point.
10. Lower electrode to proper arc length.
11. Place the first pass using a forward and back motion in
small increments.
12. After each pass is completed, chip and wire brush the
weld so that is is completely clean of slag.
13. Place succeeding beads as directed by your instructor.
14. Concentrate the arc on the edges of the previous bead.
15. Place cover beads so that the total reinforcement will
not exceed the plate thickness by more than 1/8 inch
above the plate thickness.

127
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oriaA. VERTICAL POSITION


413111E0
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B. WELD SEQUENCE

NAME MILESTONE B MODULE NO. If


CITY OF LOS ANGELES "V" GROOVE W/ BA :K UP
SHOP AND FIELD CERTIFICATION IN THE VER'ICAL POSIT:ON FIGURE NO. 5

ELECTRODE SIZE 5 TYPE


32 DIA. DC/RP AWS E 6010
MATERIAL SPEC. AMT. SIZE _Ir
STEEL MILD X4X8
STEEL MILD I 8XI X9
. .

128
SHIELDED METAL-ARC WELDING

CERTIFICATION TEST

Module II. City of Los Angeles Shop and Field Certification

Milestone B, 'V' Groove with Backing Strip in the Vertical


Position

Project 5; Time: 18 hours

INTRODUCTION
The student will make a 'V' groove weld with backing strip in
the vertical position, using E6010 electrodes. The beads to
be deposited in t e following manner: First pass, penetration;
second pass, single bead; third pass, two beads; fourth pass,
two bead cover. The finished weld must be of test quality to
be used for qualifying the welder's skill.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs, safety
equipment, and shaper.

MATERIAL NEEDED
2 pieces 3/8 x 4 x 8 inch steel plate, beveled on one side to
30 , 1 piece 1/8 x 1 x 9 inch steel for backing strip, 5/32
inch E6010 electrodes.

PROCEDURE
1 thru 6. Repeat equipment & safety procedures.
7. Tack weld the back side of the plates to the backing strip
to form a butt weld with a root opening of 3/16 inches.
8. Place this assembly in position for vertical welding.
9. Establish the arc, raise the electrode slightly, move to
the starting point.
10. Lower electrode to proper arc length.
11. Place the first pass using an up and down motion in small
increments.
12. After each pass is completed, chip and wire brush the weld
so that it is completely clean of slag.
13. Place succeeding beads as directed by your instructor.
14. Concentrate the arc on the edges of the previous bead.
15. Place cover beads so that the total reinforcement will not
exceed the plate thickness by more than 1/8 inch, nor more
than 1/8 wider than the groove.
16. Repeat this procedure until a weld is produced to the
specification.
17. Show work to your instructor for a discussion of results.
18. Prepare for testing; remove all metal at the face and
root of the weld down to plate thickness. Cut out 1-1/2
inch coupons for the bend test.

129
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1311

B. WELD SEQUENCE

NAME MILESTONE C MODULE NO. II


CITY OF LOS ANGELES "V " GROOVE W/ BACK UP
SHOP AND FIELD CERTIFICATION IN THE OVERHEAD POSITION FIGURE NO. 6
ELECTRODE SIZE 5 DIA. DC /RP TYPE
32 AWS-E- 6010
MATERIAL STEEL SPEC. AMT SIZE 3 X4X8
MILD 2 8
STEEL MILD I X 1 X 9
8
SHIELDED METAL-ARC WELDING

CERTIFICATION TEST

Module II. City of Los Angeles Shop and Field Certification

Milestone C, 'V' Groove with Backing Strip in the Overhead


Position
Project 6; Time: 9 hours

INTRODUCTION
The student will make a 'V' groove weld with backing strip in
the overhead position, using E6010 electrodes. The beads to
be deposited in the following manner: first pass, penetration;
second pass, single bead; third pass, two beads; fourth pass,
three bead cover. The finished weld must be of test quality
to be used for qualifying the welder's skill.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs, safety
equipment, positioner, and shaper.
MATERIAL NEEDED
2 pieces 3/8 x 4 x 8 inch steel plate, beveled on one side to
30 , 1 piece 1/8 x 1 x 9 inch steel for backing strip, 5/32
inch E6010 electrodes.

PROCEDURE
1 thru 6. Repeat equipment & safety procedures.
7. Tack weld the plates to the backing strip on the back side
to form a butt weld with a root opening of 3/16 inches.
8. Place this assembly in the positioner for overhead welding.
9. Establish the arc, drop the electrode slightly, move to
starting point.
10. Raise electrode to the proper arc length.
11. Place the first pass using a forward and back motion in
small increments.
12. After each pass is completed, chip and wire brush the weld
so that it is completely clean of slag.
13. Place succeeding beads as directed by your instructor.
14. Concentrate the arc on the edges of the previous bead.
15. Place the cover beads so that the total reinforcement will
not exceed the plate thickness by more than 1/8 inch, nor
more than 1/16 inch at each side of the groove.
16. Repeat this procedure until a weld is produced to the
specification.
17. Show work to your instructor for a discussion of results.
18 Prepare for testing; remove all metal at the face and root
of the weld down to plate thickness. Cut out 1-1/2 inch
coupons for the bend test.

131
1

AWS-E- 7018
AI
Mil
11111=111111

AWS-E- 7024

A. AWS-E- 7018 FILLET WELD


VERTICAL POSITION.

B. AWS- E-7Q24 GROOVE WELD


OPTIONAL POSITION.

L. 2 J
NAME MILESTONE 0 MODULE NO. X
CITY OF LOS ANGELES WELD SOUNDNESS TEST
SHOP AND FIELD CERTIFICATION IN THE VERTICAL POSITION FIGURE NO. 7
ELECTRODE SIZE TYPE
AWS-E-70I8 / AWS-E-7024
1
--a- DIA. D 17/RP
MATERIAL SPEC. AMT SIZE 3
STEEL MILD I 8 X 2 X 10
STEEL MILD 2
if3 X 32- X 8
1

132
SHIELDED METAL-ARC WELDING

CERTIFICATION TEST

Module II. City of Los Angeles Shop and Field Certification

Milestone D, Weld Soundness Test in the Vertical Position


Project 7; Time: 9 hours

INTRODUCTION
The student will make a weld soundness test in the vertical
positon. This will be made with a backing strip, using both
E7018 and E7024 electrodes. The square cut plates are tack
welded to the backing strip so that the first beads are fillet
welds in the vertical position with the E7018 electrodes, The
assembly is then placed for welding in a flat position;
the remaining groove is filled using the E7024 electrodes.
The finished weld must be of test quality to be used for quali-
fying the welder's skill.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs, safety
equipment, positioner, and shaper.

MATERIAL NEEDED
2 pieces 3/8 x 3-1/2 x 8 inch steel plate, squart cut, 1 piece
3/8 x 2 x 10 inch steel for the backing strip, 1/8 inch E7018
and 1/8 inch E7024 electrodes.

PROCEDURE
1 thru 6. Repeat equipment & safety procedures.
7. Tack weld the back side of the plates to the backing strip
to form a butt weld with an opening of 15/16 inches.
8. Place this assembly in the positioner for vertical welding.
9. Establish the arc, raise the electrode slightly, move to
the starting point, using the E7018 electrodes for these
fillets.
10. Lower the electrode to proper arc length.
11. Place the fillets using a small weave motion. Concentrate
the arc in the corners for good penetration.
12. Chip and wire brush the beads after each pass.
13. Place the weldment in the flat position and continue to
fill the groove with the E7024 electrodes. Make overlapping
stringer beads without manipulation.
14. Repeat these procedures until a consistent, sound weld is
produced.
15. Prepare for testing; remove the backing strip and face
reinforcement to the plate thickness. Cut out 1-1/2 inch
coupons for the bend test.

133
i
1.1111114.0

IMP

A-13
or

AWS- E -7018
3-i-

WWI
WWI
1
1 MB
0 AWS- E - 7024

co A. AWS-E-70I8 FILLET WELD


OVERHEAD POSITION

ztt,
t4t B. AWS-E- 7024 GROOVE WELD
t t OPTIONAL POSITION

NAME MILESTONE E MODULE NO. 11


CITY OF LOS ANGELES WELD SOUNDNESS TEST
SHOP AND FIELD CERTIFICATION IN THE OVERHEAD POSITION FIGURE NO. 8
ELECTRODE SIZE b DIA. DC/RP TYPE AWS-E- 7018/ AWS-E-7024
MATERIAL
STEEL SPEC. A2MT. SIZE
r
3
X4X8
STEEL MILD I - I T x ix 9
1

134
SHIELDED METAL-ARC WELDING

CERTIFICATION TEST

Module II. City of Los Angeles Shop and Field Certification

Milestone E, Weld Soundness Test in the Overhead Position


Project 8; Time: 3 hours

INTRODUCTION
The student will make a weld soundness test in the overhead
position. This will be made with a backing strip, using both
E7018 and E7024 electrodes. The square cut plates are tack
welded to the baking strip so that the first beads are fillet
welds made in the overhead position using the E701R electrodes.
The assembly is then placed for welding in a flat position;
the remaining groove is filled using the E7024 electrodes. The
finished weld must be of test quality to be used for qualifying
the welder's skill.

EQUIPMENT REQUIRED
DC welding machine, slag hammer, wire brush, tongs, safety
equipment, positioner, and shaper.

MATERIAL NEEDED
2 pieces 3/8 x 4 x 8 inch steel plate, square cut, 1 piece
1/8 x 1 x 9 inch steel for the backing strip, 1/8 inch E7018
and E7025 electrodes.

PROCEDURE
1 thru 6 Repeat equipment & safety procedures.
7.' Tack weld the back side of the
plates to the backing strip
to form a butt weld with an opening of 15/16 inches.
8. Place this assembly in the positioner for overhead welding.
9. Establish the arc, lower the electrode slightly, move to
the starting point, using the 1/8 inch E7018 electrodes
for these fillets.
10. Raise the electrode to the proper arc length.
11. Place the fillets using a small "C" motion. Concentrate
the arc in the corners for good penetration.
12. Chip and wire brush the beads after each pass.
13. Place the weldment in the flat position and continue to
fill the groove with the 1/8 inch E7024 electrodes. Make
overlapping stringer beads without manipulation.
14. Repeat these procedures until a consistent, sound weld is
produced.
15. Prepare for testing; remove the backing strip and face
reinforcement to the plate thickness. Cut out 1-1/2 inch
coupons for the bend test.

135
1

OXYACETYLENE WELDING AND CUTTING

PHASE IV OBJECTIVE

By taking part in the practice of oxyacetylene

welding and cutting the student will learn how

to assemble and use this equipment, while famil-

iarizing himself with the processes.

A second objective in learning oxyacetylene welding

is to prepare the student for use of the gas tung-

sten-arc torch. Each system uses a hand held torch


while filler metal is hand fed.

I 137

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co PENETRATION
co

_ e I

A. FLAT POSITION

B. FLAME NEUTRAL 4.1-

C. DO NOT PENETRATE (THREE EACH)

D. DO NOT PENETRATE (THREE EACH)

E. PENETRATE (THREE EACH)

,
NAME MILESTONE A MODULE NO. I
PROCESS FAMILIARIZATION RUNNING STRINGER BEADS
AND EQUIPMENT USE WITHOUT FILLER RODS FIGURE NO. i
ELECTRODE SIZE TYPE
N/A N/A
MATERIAL SPEC. AMT SIZE
STEEL MILD I 18 GA.X 24 X 6
I
OXYACETYLENE WELDING

Module I. Process Familiarization and Equipment Use

Milestone A, Running Stringer Beads Without Filler Rod


Project 1; Time: 3 hours

INTRODUCTION
The student will make weld beads across a piece of 18 gage
steel. The purpose for this exercise is to learn torch
control, flame adjustment, and rate of travel. There will
be three sets of three beads, the first bead should be
straight and narrow with a fine ripple. The second should
be twice the width of the first, with the same appearance.
The third bead should be the same size as the second, but
will have uniform penetration on the back side.

EQUIPMENT REQUIRED
Oxyacetylene torch, tips, regulators, flint lighter, wrench,
tongs, goggles, vise grip-pliers.

MATERIAL NEEDED
1 piece of 18 gage steel 2-1/2 x 6 inches.

PROCEDURE
1. Inspect hose and fittings to see that they are servicable.
2. Attach hose to torch, use wrench for a leak tight union.
3. Select proper tip size for the metal thickness being
welded; attach to torch barrel, finger tight.
4. Close torch valves.
5. Turn regulator adjustment screws counterclockwise until
tension is released.
6. Open oxygen and acetylene source valves.
7. Turn regulator adjustment screws clockwise until the
specified pressure is raised.
8. Close oxygen and acetylene source valves; watch for any
pressure drop at regulators. Correct for any leaks.
9. Clean work and put on goggles.
18. Open torch valves about one quarter turn; light with
flint lighter.
11. Adjust flame to a neutral condition with a cone length
as directed.
12. Hold torch as a pencil, the flame pointed with a 45°
leading angle, the tip of cone 1/8 inch from metal
surface.
13. Hold at metal edge until melting starts, then move this
puddle slowly across.
14. For beads 2 and 3 use some torch side motion to increase
puddle, and bead width.
15. Practice this procedure until the desired results are
produced.
16. Secure equipment.

139
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32
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12 GAAL 3 ..1

A. FLAT POSITION

B. FLAME NEUTRAL

C. WELD ALL FOUR EDGES

D UNIFORM RIPPLE

NAME MILESTONE B MODULE NO. I


PROCESS FAMILIARIZATION
EDGE WELD W1THOVT FILLER ROD FIGURE NO. 2
AND EQUIPMENT USE
ELECTRODE SIZE TYPE
N/A N/A
MATERIAL
STEEL
SP. AM T SIZE 12 GA. 12.1 X3
ILD
MEC 2

140
OXYACETYLENE WELDING

Module I. Process Familiarization and Equipment Use'


Milestone B, Edge Welds Without Filler Rod

Project 2; Time: 3 hours

INTRODUCTION
The student will clamp together two pieces of 12 gage steel
to form an edge joint. This assembly will be positioned for
flat position welding. The edges will be fused without the
use of filler rod. The weld should have a fine and uniform
ripple and a convex face.

EQUIPMENT REQUIRED
Oxyacetylene torch, tips, regulators, flint lighter, wrench,
tongs, goggles, vise grip-pliers.

MATERIAL NEEDED
2 pieces 12 gage steel 1-1/2 x 3 inches.

PROCEDURE
1 - 8. Repeat equipment & safety procedures.
9. Clamp the metal pieces together with vise grip-pliers,
the edges aligned. Position for flat welding.
10. Open torch valves about one quarter turn; light with
flint lighter.
11. Adjust flame to a neutral condition with a cone length
as directed.
12. Hold torch as a pencil, the flame pointed with a 45°
leading angle, the tip of cone 1/8 inch from metal
surface.
13. Hold flame steady at edge of joint until fusion starts;
move from right to left with a steady motion, melting
down the edges consistently. Join all four edges.
14. Repeat this procedure until the desired results are
produced.
15. Secure equipment.

141
A. FLAT POSITION

B. FLAME NEUTRAL

C. PENETRATE

zr
OAW
32 A-B-C
120.
..) 3
1

12 GA.s.,s/4 ...- 12 GA.

REINFORCEMENT

PENETRATION

ROOT GAP
32

NAME MILESTONE A MODULE NO. Z


GROOVE WELD CORNER WELD
!N THE FLAT POSITION FIGURE NO. .3
ELECTRODE SIZE
16 DIA. TYPE COPPER COATED AWS-ASTM CLASS 1 TYPE C
MATERIAL SPEC.
STEEL A2 MT. SIZE12
MILD X3

142
I

OXYACETYLENE WELDING

Module II. Groove Weld

Milestone A, Corner Weld in the Flat Position

Project 3; Time: 6 hours

INTRODUCTION
A corner weld will be made by joining two pieces of steel at
;Ly
60°. This joint will be welded in the flat position with
full penetration. Use filler rod and one pass. The weld
face will have uniform ripple and convex face.

EQUIPMENT REQUIRED
Oxyacetylene torch, tips, regulators, flint lighter, wrench,
tong:, goggles, vise grip-pliers.

MATERIAL NEEDED
2 pieces 12 gage steel, 1-1/2 x 3 inches, 1/16 inch steel
filler rod.

PROCEDURE
1 8. Repeat equipment & safety procedures.
9. Clamp two pieces of steel together to form a corner
joint of 60° with a root opening of 1/32 inch. Position
for flat welding.
10. Open torch valves about one quarter turn; light with
flint lighter.
11. Adjust flame to a neutral condition with a cone length
as directed.
12. Hold torch as a pencil, the flame pointed with a 45°
leading angle, the tip of cone 1/8 inch from metal
surface.
13. Hold on metal edge until melting starts, then move this
puddle slowly across.
14. Add filler metal in center of puddle to fill out bead
size.
15. Travel from right to left at a rate resulting in a
uniform bead in height and width.
16. Secure equipment.

143
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A

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LC(LICIffillil/C31111fitideSo

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2
-11.

A. FLAME NEUTRAL

NAME MILESTONE A MODULE NO. III


FILLET WELD LAP WELD
FIGURE NO. 4
ELECTRODE SIZE I i Y PE
16 DIA. COPPER COATED /WS -ASTM CLASS I TYPE C
MATERIAL STEEL SPEC. AMT SIZE
MILD 2 12 GA. If X 3

144
---
I

OXYACETYLENE WELDING
1

Module III. Fillet Weld


i

1 Milestone A, Lap Weld

IProject 4; Time: 6 hours

INTRODUCTION
The student will overlap two pieces of steel to form fillet
weld joints. These two joints will be welded, using filler
wire. They should have a flat face, no undercut and without
excessive deposit above the upper piece of steel.

EQUIPMENT REQUIRED
Oxyacetylene torch, tips, regulators, flint lighter, wrench,
tongs, goggles, vise grip-pliers.

MATERIAL NEEDED
2 pieces 12 gage steel, 1-1/2 x 3 inches, 1/16 inch steel
filler.

PROCEDURE
1 - 8. Repeat equipment 4 safety procedures.
9. Overlap two pieces of steel 1/2 inch and clamp with the
vise grip-pliers. Place for welding in the flat position.
10. Open torch valves about one quarter turn; light with
flint lighter.
11. Adjust flame to a neutral condition with a cone length
as directed.
12. Hold torch as a pencil; the flame pointed with a 450
leading angle, the tip of cone 1/8 inch from metal
surface.
13. Hold flame in joint so that top and bottom pieces are
fused; add filler metal as required to form a uniform
fillet.
14. Move along joint at a uniform rate to form a fillet with
a flat face and even ripple.
15. Repeat this procedure until the desired results are
produced.
16. Secure equipment.

..-....---->

I
145
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A-B-C
D-E §
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z A. FLAT POSITION
C1

B. FLAME NEUTRAL

C.32
32
ROOT OPENING

D. 30° BEVEL

)
alkE. FOREHAND TECHNIQUE

L REINFORCEMENT
PENETRATION
ROOT GAP

NAME MILESTONE B MODULE NO. II


GROOVE WELD 'IV" GROOVE WELD
IN THE FLAT POSITION FIGURE NO. 5
ELECTRODE SIZE rel
DIA. TYPE COPPER COATED AWS -ASTM CLASS I TYPE C
MATERIAL SPMILD
EC. ANT SIZE
STEEL I2 GA. X12 X 3
2

146
OXYACETYLENE WELDING

Module II. Groove Weld

Milestone B, 'V' Groove Weld in the Flat Position


Project 5; Time: 6 hours

INTRODUCTION
The student will make a single pass forehand butt weld with
a 1/32 inch root opening for full penetration. The bead
should have a uniform build-up and ripple.

EQUIPMENT REQUIRED
Oxyacetylene torch, tips, regulators, flint lighter, wrench,
tongs, goggles, vise grip-pliers.

MATERIAL NEEDED
2 pieces 12 gage steel 1-1/2 x 3 inches, 1/16 inch steel
filler wire.

PROCEDURE
1 8. Repeat equipment & safety procedures.
9. Lay pieces of steel flat with parallel edges and a gap
of 1/32 inch; tack weld at each end.
10. Hold flame at beginning of weld with filler wire close.
When fusion starts this must be quickly added.
11. Move along the joint, watching for melt through at root,
then adding filler to the amount that gives the proper
build-up.
12. Continue this procedure until the required weld is
produced.
13. Secure equipment.

147
Ns 2 I Fi 3
1---
4 1

60.

R
4

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NAME MILESTONE A MODULE NO. Tir


OXYACETYLENE CUTTING HAND CUTTING / OXYACETYLENE TORCH
FIGURE NO. 6
ELECTRODE SIZE TYPE
N/ A N/A
MATERIAL SPEC. AMT. SIZE

STEEL MILD I -- X 8 X 10

148
OXYACETYLENE WELDING

Module IV. Oxyacetylene Cutting

Milestone A, Learning to Use the Hand Cutting Oxyacetylene


Torch

Project 6; Time: 3 hours

INTRODUCTION
The student will demonstrate his ability to assemble and
use the manual oxyacetylene cutting torch. He will layout
simple patterns on steel plate, then cut to these lines.
The cuts should be square edged, have a smooth surface with
a minimum amount of slag.

EQUIPMENT REQUIRED
Cutting torch and hose, tips, flint lighter, wrench, tongs,
goggles, gloves, scale, dividers, center punch, scribe.
MATERIAL NEEDED
Steel plate with a surface suitable-for layout work. Refer
to drawing #6.

PROCEDURE
1 - 8. Repeat equipment &_safety procedures.
9. Clean plate with wire brush; layout shapes according to
the drawing; place on the burning table.
10. Open torch valves about one quarter turn; light with
flint lighter.
11. Adjust flame to a neutral condition with preheat flame
of the proper length, as directed.
12. Hold flame at edge of plate on the guide line; when
color changes to red slowly open cutting oxygen valve,
depress fully.
13. Immediately move along the guide line. Move at a
constant rate determined by the condition of the cut.
Too fast will lose the cut, and too slow will fill the
kerf with slag.
14. Repeat this procedure until the desired cuts can be
made.
15. Secure equipment.

149
8

I/ 1
0
v.

Mir

-1
1 I

NOTE:
A. CUT INTO 81. SO

NAME MILESTONE 8 MODULE NO. 17


OXYACETYLENE CUTTING MACHINE CUTTING/
AUTOMATIC CUTTING MACHINE FIGURE NO. 7
ELECTRODE SIZE TYPE
N/A N /A
MATERIAL
STEEL SPEC. MAT. SIZE i X 8 X 40
MILD

- 150
OXYACETYLENE WELDING
T
Module IV. Oxyacetylene Cutting

Milestone B, Learning to Use the Automatic Cutting Machine


Project 7; Time: 3 hours

INTRODUCTION
The student will demonstrate his ability to assemble and
use the automatic cutting torch. He will cut several
square pieces from steel plate.

EQUIPMENT REQUIRED
Cutting torch for automatic use, tractor, track, tips, flint
lighter, wrench, electric cable, pressure regulators, hose,
wire brush, scale, straight edge, square, tongs, goggles,
and gloves.

MATERIAL NEEDED
Steel plate. Refer to drawing #7.

PROCEDURE
1. Place steel plate on the cutting table, clean with wire
brush, put track on the plate 12 inches in from and
parallel to its edge.
2. Place tractor on track, engage clutch to lock in place,
put motor switch to off, then plug in cable to current
outlet.
3 8. Repeat equipment & safety procedures. Select, attach
appropriate sized cutting tip.
9. Move tractor to one end of the cut and adjust torch to
8-1/16 inches in from the plate edge.
10. Lift the torch about one inch above the plate and trace
out the cut.
11. Return to the starting edge of the cut, lower torch to
1/4 inch above plate, put on goggles.
12. Open oxygen and acetylene torch valves one quarter turn;
light torch with flint lighter; adjust to a neutral
condition, with preheat flames of the proper length as
directed.
13. Heat the plate edge to a red spot, slowly open cutting
oxygen valve to full, and immediately close the tractor
switch to on.
14. Watch the condition of the cut; hold one hand on the speed
regulator; change faster or slower when indicated.
15. Watch for any change in the flame clearance and make
adjustment to maintain at about 1/8 inch above plate.
16. Repeat this procedure to produce five steel squares of
8 inches each.
17. Secure equipment.

151
,°//1°/°°°°°"

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A. HORIZONTAL POSITION

Oa
Tillil- 'IIIIIIIIIIIIP'
B. FLAME NEUTRAL

C. WELD BOTH SIDES

PENETRATION

NAME MILESTONE B MODULE NO. 1TE


l'ILLET WELD FILLET WELDS
IN THE HORIZONTAL POSITION FIGURE NO. 8
ELECTRODE SIZE I DIA.
16 TYPE COPPER COATED AWS ASTM CLASS 1 TYPE C
MATERIAL SPEC. AMT
STEEL SIZE 12
GA. X lf X 3
MILD 2
1

I OXYACETYLENE WELDING

Module III. Fillet Weld

Milestone B, Fillet Welds in the Horizontal Position


Project 8; Time: 12 hours

INTRODUCTION
1 The student will make a fillet weld by joining two pieces
of steel in a "T" joint. This will be welded on each side
in one pass. There will be full penetration, flat face,
equal leg length, and no undercut.

EQUIPMENT REQUIRED
Oxyacetylene torch, tips, regulators, flint lighter, wrench,
1 tongs, goggles, vise grip-pliers.

MATERIAL NEEDED
2 pieces 12 gage steel 1-1/2 x 3 inches, 1/16 steel welding
rod.

PROCEDURE
1
1 - 8. Repeat equipment & safety procedures.
9. Hold steel pieces with tongs and tack weld at 90° in a
"T" form; place for horizontal welding.
I 10. Direct flame into root of joint so that full penetration
is obtained.
11. Move across weld slowly with a slight forward and back
motion; add filler on back motion.
12. Completed fillet must have a flat face and equal leg
length.
13. Repeat this procedure until the desired weld is produced.
I 14. Secure equipment.

153

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REINFORCEMENT B. FLAME NEUTRAL
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C. R ROOT OPENING

WV' D. 30 BEVEL

E. BACKHAND SCALE
TECHNIQUE
I
32 \--- PENETRATION

ROOT OPENING

NAME
GROOVE WELD
MILESTONE C
"V" GROOVE WELD
MODULE NO. r
IN THE FLAT POSITION FIGURE NO. 9
ELECTRODE SIZE rgi TYPE
DIA . COPPER COATED AWS -ASTM CLASS I TYPE C
MATERIAL SPEC. AM T. SIZEI2
STEEL MILD 2 GA. X If X 3

154
9XYACETYLENE WELDING

Module II. Groove Weld

Milestone C, 'V' Groove Welds in the Flat Position

Project 9; Time: 6 hours

INTRODUCTION
The student wil) make a two pass backhand butt weld with
full penetraion on 12 gage steel plate. The bead surface
must be convex and uniform in appearance.

EQUIPMENT REQUIRED
Oxyacetylene torch, tips, regulators, flint lighter, wrench,
tongs, goggles, vise grip-pliers.

MATERIAL NEEDED
2 pieces 12 gage steel 1-1/2 x 3 inches, 1/16 steel welding
rod.

PROCEDURE
1 - 8. Repeat equipment & safety procedures.
9. Tack weld pieces in a butt joint without gapping; place
for flat position welding.
10. Orym torch valves about one quarter turn; light with
flint lighter.
11. Adjust flame to a neutral condition with a cone length
as directed.
12. Hold torch with a dragging angle of about 45° at the
left end of joint; hold tip of cone clear of steel by
1/8 inch.
13. Move to the right cone of flame directed backward into
puddle.
14. Add filler material to make a full bead.
15. Follow technique as demonstrated.
16. Repeat this procedure until the desired weld is produced.
17. Secure equipment.

155
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REINFORCEMENT

A. VERTICAL POSITION
Ah..11111".

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a FLAME NEUTRAL

C. PENETRATE

ROOT OPENING k

NAME MILESTONE D MODULE NO. .T1


GROOVE WELD CORNER WELD
IN THE VERTICAL POSITION FIGURE NO. ID

ELECTRODE SIZE 1 1 YPE


re DIA. COPPER COATED AWS -ASTM CLASS I TYPE C
MATERIAL SPEC. AMT. SIZE 12 GA.
STEEL M ILD 2 1 X3

156
OXYACETYLENE WELDING

Module II. Groove Weld

Milestone D, Corner Weld in the Vertical Position


Project 10; Time: 3 hours

INTRODUCTION
The studert will make a vertical -up corner weld joint by
joining two pieces of 12 gage steel at 60°. This is a one
pass weld with full penetration. Bead surface should be
convex and uniform in appearance.

EQUIPMENT REQUIRED
Oxyacetylene torch, tips, regulators, flint lighter, wrench,
tongs, goggles, vise grip-pliers.

MATERIAL NEEDED
2 pieces 12 gage steel 1-1/2 x 3 inches, 1/16 steel welding
rod.

PROCEDURE
1 - 8. Repeat equipment & safety procedures.
9. Clamp steel pieces together at 60° to form a corner
joint; with a 1/32 inch root gap. Position for vertical
welding.
10. Open torch valves about one quarter turn; light with
flint lighter.
11. Adjust flame to a neutral condition with a cone length
as directed.
12. Hold torch as a pencil, the flame pointed with a 45°
leading angle, the tip of cone 1/8 inch from metal
surface, puddle slowly across.
13. Hold tor;11 steady at base of the joint until fusion
starts.
14. Add filler in puddle as torch is moved upward.
15. Repeat this procedure until desired result is obtained.
16. Secure equipment.

157
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or-- PENETRATION

NAME MILESTONE C MODULE NO. mr


FILLET WELD FILLET WELDS
IN THE VERTICAL POSITION FIGURE NO. II
.
ELECTRODE SIZE I_ TYPE
COPPER COATED AWS-ASTM CLASS I TYPE C
16 " _
MATERIAL SPEC. AMT. SIZE
STEEL MILD 2 12 GA. X 1-- X 3
1

158
OXYACETYLENE WELDING

Module III. Fillet Weld

Milestone C, Fillet Welds in the Vertical Position

Project 11; Time: 6 hours

INTRODUCTION
The student will make a 'T' joint to be welded in the vertical
position. This is a one pass fillet; there should not be any
voids at the root. It will have a flat face and equal leg
length.

EQUIPMENT REQUIRED
Oxyacetylene torch, tips, regulators, flint lighter, wrench,
tongs, goggles, vise grip-pliers.

MATERIAL NEEDED
2 pieces 12 gage steel 1-1/2 x 3 inches, 1/16 steel welding
rod.

PROCEDURE
1 8. Repeat equipment & safety procedures.
9. Hold steel pieces with tongs and tack weld at 90° in a
'T' form; place"for vertical-up welding.
10. Open torch valves about one quarter turn; light with
flight lighter.
11. Adjust flame to a neutral condition with a cone length
as directed.
12. Hold torch as a pencil, the flame pointed with a 45°
leading angle, the tip of cone 1/8 inch from metal
surface.
13. Hold torch steady at base of the joint until fusion
starts.
14. Add filler in puddle as torch is moved upward.
15. Repeat this procedure until desired result is obtained.
16. Secure equipment.

159
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REINFORCEMENT

ROOT OPENING

NAME MILESTONE A MODULE NO. 3t


BRAZE WELD "V" GROOVE WELD
IN THE FLAT POSITION FIGURE NO. 12

ELECTRODE SIZE TYPE


1
DIA. GAS BRAZING ROD
MATERIAL
STEEL SPECMIL. AMT. SIZE12 lit X
D 2

160
416
OXYACETYLENE WELDING

Module V. Braze Welds

Milestone A,- 'V' Groove Weld in the Flat Position

Project 12; Time: 3 hours

INTRODUCTION
The student will form a groove butt joint with 2 pieces of
12 gage steel having a root gap of 1/32 inch. These pieces
will be jointed by braze welding, using brass filler with
flux. There should be full penetration with uniform rein-
forcement at face and root.

EQUIPMENT REQUIRED
Oxyacetylene torch, tips, regulators, flint lighter, wrench,
tongs, goggles, vise grip-pliers.

MATERIAL NEEDED
2 pieces 12 gage steel 1-1/2 x 3 inch, 1/8 inch brazing rod,
brazing flux.

PROCEDURE
1 - 8. Repeat equipment & safety procedures.
9. Tack weld pieces to form a butt joint with a 1/32 inch
root gap.
10. Open torch valves about one quarter turn; light w.
flint lighter.
11. Adjust flame to a neutral condition with a cone length
as directed.
12. Hold torch as a pencil, the flame pointed with a 45°
leading angle, the tip of cone 1/8 inch from metal
surface'.
13. Heat the brass rod, dip into flux for a -2 to 3 inch
coating.
14. Heat joint end to the melting point of the brass, 1651°F.
There will be little color change of the steel, and no
melting of the steel.
15. Move along joint with torch motion back and forth or
circular, deposit brass on back motion. Do not allow
bead to flow away from the joint over the steel surface.
16. Repeat this procedure until the desired weld is produced.
17. Secure equipment.

161
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12 GA. -_J L 3

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C. WELD BOTH _SIDES .

PENETRATION

NAME MILESTONE B MODULE NO. IIZ


BRAZE WELD FILLET WELDS
IN THE HORIZONTAL POSITION FIGURE NO. 13

ELECTRODE SIZE TYPE


8
DIA. GAS BRAZING ROD
MATERIAL SPEC. AMT. SIZE
STEEL 12 GA. X If X 3
MILD 2

162
OXYACETYLENE WELDING

Module V. Braze Welds

Milestone B, Fillet Welds in the Horizontal Position


Project 13; Time: 3 hours

INTRODUCTION
The student will make a 'T' joint to be braze welded in the
horizontal position. This is a single pass weld with a flat
face and equal leg length.

EQUIPMENT REQUIRED
Oxyacetylene torch, tips, regulators, flint lighter, wrench,
tongs, goggles, vise grip-pliers.

MATERIAL NEEDED
2 pieces 12 gage steel 1-1/2 x 3 inch, 1/8 inch brazing rod,
brazing flux.

PROCEDURE
1 8. Repeat equipment & safety procedures.
9. Tack weld steel plate pieces to for a 'T' fillet joint.
10. Open torch valves about one quarter turn; light with
flint lighter.
11. Adjust flame to a neutral condition with a cone length
as directed.
12. Hold torch as a pencil, the flame pointed with a 45°
leading angle, the tip of cone 1/8 inch from metal
surface.
13. Heat the brass rod, dip into flux for a 2 to 3 inch
coating.
14. Heat joint end to the melting point of the brass, 1651°F.
There will be little color change of the steel, and no
melting.
15. Move along joint with torch motion back and forth or
circular, deposit brass on back motion. Do not allow
bead to flow away from the joint over the steel surface.
16. Repeat this procedure until the desired weld is produced.
17. Secure equipment.

163
A. VERTICAL POSITION

OAK> B. HORIZONTAL POSITION


A

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B A OAW
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1 2 IN VERTICAL POSITION

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NAME MILESTONE A MODULE NO. V/


PRESSURE VESSEL OXYACETYLENE WELDING
FIN, L TEST FIGURE NO. 14

ELECTRODE SIZE I TYPE


T-6 DIA. COPPER COATED ASW ASTM CLASS I TYPE C
MATERIAL SPEC. AMT. SIZE
STEEL
MILD 8 12 GA. Ii X 3
STEEL MILD I 12 GA. 4 X 6
STEEL MILD I 12 GA. 4 X 4
STEEL MILD I 12 Gi 4. 24- X 2

164
1

OXYACETYLENE WELDING

Module VI. Pressure Vessel

Milestone A, Final Test - Oxyacetylene Welding

Project 14; Time: 12 hours

INTRODUCTION
The student will make a pressure vessel from lap welded
projects. These pieces will be joined by corner welds to
form a cube on a base. This can be given a pressure test.
EQUIPMEf REQUIRED
Oxyacetylene torch, tips, regulators, flint lighter, wrench,
tongs, goggles, vise grip-pliers.

MATERIAL NEEDED
8 pieces 12 gage steel 1-1/2 x 3 inch, 1 piece 4 x 4 inch,
1 piece 4 x 6 inch, 1 piece 2-1/4 x 2-1/4 inch.

PROCEDURE
1 - 8. Repeat equipment & safety procedures.
9. Make 4 lap welds to join 8 pieces of 1-1/2 inch steel.
Overlap 1/2 inch, weld in the horizontal position.
10. Join these pieces to form a square; make 2 corner welds
in flat and 2 in the vertical position.
11. Make a base plate by centering the 4 x 4 inch piece on
the 4 x 6 inch piece. Join with 2 edge welds and 2
fillets.
12. Center the square box on this base and join with 2 fillet
welds in the horizontal and 2 in the vertical position.
13. Close the box by welding the 2-1/4 x 2-1/4 inch piece at
the top. Make 2 corner welds in the horizontal and 2 in
the vertical position.
14. Repeat these operations until all welds are properly
mace. It may be an advantage to tack weld the entire
structure together before making any one weld. This
will reduce distortion and loss of dimension.
15. This vessel may be pressure tested by melting an opening
in the top to receive a small pipe nipple. Connect this
to a water supp.: source, not air, inspect for leaks.

165
1

GAS TUNGSTEN-ARC WELDING (TIG)

PHASE V, PART A OBJECTIVE

In this course the student will learn the character-

istics of the gas tungsten-arc welding system and

how to use it. He will become familiar with air


cooled and water cooled torches. He will weld tLin
gage ferrous and non-ferrous metals.

The skill developed through this experience will make

the student employable as a welder using gas tungsten-

arc welding equipment except for that work covered by


codes or demanding advanced experience.

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PENETRATION

A." FLAT POSITION

B. WELD BOTH SIDES

NOTE, REFERS TO BEAD WIDTH


NAME MILESTONE A MODULE NO. I
FAMILIARIZATION WITH THE PROCESS STRINGER BEADS
IN THE FLAT POSITION FIGURE NO. 4-1
ELECTRODE SIZE 1 TYPE
-8- DIA. AC/HF ALUM. 1100 0
MATERIAL SPEC. AMT SIZE

ALUM. PLATE 1100 0 I 1


4
X4X4

168
GAS TUNGSTEN-ARC WELDING (TIG)

Module I. Familiarization with the Process


Milestone A, Stringer Beads

Project 1; Time: 6 hours


J INTRODUCTION
With TIG equipment and aluminum plate the student will as-
semble the torch, set proper argon gas pressure and flow
rate. Using filler wire he will hand feed this to weld
beads on both sides of the aluminum plate. These beads
must be consistent in width, be straight and have uniform
width and rippling.

REQUIRED EQUIPMENT
Alternate-direct current welding machine with high fre-
quency current, foot control, pressure regulator, flow
meter, TIG torch complete, tongs, and safety equipment.
MATERIAL NEEDED
Aluminum plate 1/4 x 4 x 4 inches, type 1100-0 filler wire.

PROCEDURE
1. Clean plate surface with steel wool, pull the filler wire
through the steel wool to remove oxide.
2. Set current controls: amperage, high frequency intensity,
polarity and remote control as required.
3. Open argon gas valve, set pressure and flow rate as
required.
4. Open cooling water valve.
5. Assemble torch with the proper sized tungsten, collet and
collet body, cup. The electrode may require grindinb to
a tapered end.
6. Start welding machine.
7. Put on face shield and gloves..
8. 'Hold torch as though it is a pencil, drop face shield.
9. Depress foot switch to start arcing on copper backing.
10. Move arc to the plate, hold until melting starts.
11. Start across plate, adding filler material, establish
rate of travel by maintaining uniform puddle width.
12. Move from right to left, with a forward and back motion
in small increments, add filler back movement.
13. Stop arc by pressing on foot control with heel, do not
lift torch until arc is extinguished.
14. Repeat this procedure until uniform beads are produced.
15. Inspect beads, discuss their quality with your instructor.
16. Secure equipment.

169
0
0 6

17 Ififf1(11011;qiflidt .10

A. HORIZONTAL POSITION

B. WELD BOTH SIDES

NAME MILESTONE A MODULE NO. 1E


FILLET WELD LAP WELDS
IN THE HORIZONTAL POSITION FIGURE NO. A-2
ELECTRODE SIZE TYPE
DIA. ALUM. 1100 0
MATERIAL SPEC. AMT. SIZE

ALUM. SHEET 1100 -0 2 .060 X 6 X 1

170
GAS TUNGSTEN-ARC WELDING (TIG)

Module II. Fillet Weld

Milestone A, Lap Welds in the Horizontal Position

Project 2; Time: 12 hours

INTRODUCTION
The student will make a lap weld set by overlapping two pieces
of sheet aluminum 1/2 inch. He will make a fillet weld on
each side of this assembly. These welds must have equal leg
length and a flat face.

EQUIPMENT REQUiRED
AC-DC welding machine with high frequency current, foot control,
pressure regulator, flow meter, TIG torch complete, tongs, vise
grip pliers, welding jig and $,ifety equipment.

MATERIAL NEEDED
2 pieces .060 x 1-1/2 x 6 inch sheet aluminum, type 1100-0
1/8 inch diameter filler wire.

PROCEDURE
1 - 6. Repeat equipment safety procedures.
7. Put on face shield and gloves.
8. Clamp the aluminum pieces in the vise grip with a 1/2 inch
overlap. Drop face shield.
9. Hold torch as though it is a pencil, depress foot control
to start the arc on the aluminum, hold uhtil melting starts.
10. Arc should be directed against the bottom piece, in the
corner of the fillet. Move forward and back with constant
arc length. Control heat with foot.
11. Dip filler wire in puddle on back stroke of torch.
12. Avoid melting the top edge too deeply.
13. Rate of travel will control size of the weld.

,
14. Repeat these procedures until the specified weld is produced.
15. Secure equipment

171
w

GTAW
A El
060 g
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A. HORIZONTAL POSITION

B. WELD BOTH SIDES

-...
NAME MILESTONE B MODULE NO.11.
FILLET WELD FILLET WELDS
IN THE HORIZONTAL POSITION FIGURE NO. A-3

ELECTRODE SIZE I TYPE


8 DIA. AC/HF ALUMINUM 1100 - 0
MATERIAL SPEC. AMT. SIZE

ALUMINUM SHEET 1100-0 2 .060 X I- X 6

172
GAS TUNGSTEN-ARC WELDING (TIG)

Module II. Fillet Weld

Milestone B, Fillet Welds in the Horizontal Position


Project 3; Time: 12 hours

INTRODUCTION
The student will make a fillet weld set with two pieces of
aluminum, tack welding them in a 'T' form. The two welds
will be made i. the flat position and must have equal leg
lengths and flat faces. This type of joint does not allow
for penetration through the vertical member.

EQUIPMENT REQUIRED
AC welding machine with high frequency current, foot control,
pressure regulator, flow meter, TIG torch complete, tongs,
welding jig and safety equipment, vise grip pliers.

MATERIAL NEEDED
2 pieces .060 x 1-1/2 x 6 inch sheet aluminum, 1/8 inc type
1100-0 aluminum filler wire.
PROCEDURE
1 6. eat equipment & safety procedures.
7. Put on face shield and gloves.
8. Form a 'T' joint by supporting the vertical piece with,
the vise grip pliers at the center of the base piece.
Drcp face shield.
9. Depress foot control to initiate the arc to the copper
grounding plate.
10. Move arc to the joint and tack weld each end.
11. Make the fillet welds; direct the arc in the corner with
the greate'st amount of heat against the base plate. Move
forward and back in small increments, deposit filler on
back stroke.
12: Welds must be equal in leg dimension, have flat face
without undercut.
13. Repeat this procedure until welds are to specification.
14. Secure equipment.

173
I ....
1

1
w
1
1

1 1

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A El
90
REINFORCEMENT

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A\11P

.060

.060
\i PENETRATION
LAP .003

A. FLAT POSITION

B. JIG WITH BACK UP

NAME MILESTONE A MODULE NO. MI


GROOVE WELD CORNER WELD
FIGURE NO. 4-41

- ELECTRODE SIZE DIA. AC/HF TYPE ALUM. 1100 0


8
MATERIAL SPEC. AMT. SIZE

ALUMINUM SHEET 1100 -0 2 .060 X li X 6

174
GAS TUNGSTEN-ARC WELDING (TIG)

Module III. Groove Weld

Milestone A, Corner Weld in the Flat Position


Project 4; Time: 6 hours

INTRODUCTION
The student will tack weld tliJ pieces of sheet aluminum to
form a corner weld. Welding will be done in the flat position
in one pass. The weld should fully penetrate the joint, have
a slight convex surface with even ripple.

EQUIPMENT REQUIRED
AC-DC welding machine with high frequency current, foot control,
pressure regulator, flow meter, TIG torch complete, tongs,
welding jig and safety equipment.

MATERIAL NEEDED
2 pieces .060 x 1-1/2 x 6 inch aluminum sheet, 1/8 filler
wire type 1100-0.

PROCEDURE
1 - 6. Repeat equipment & safety procedures.
7. Place pieces in the welding jig to form a corner joint.
8. Put on face shield and gloves.
9. Hold torch as though it is a pencil, drop face shield.
10. Depress the foot control to initiate the arc to the jig
backing.
11. Move the arc to the joint, make the weld with a forward
and back motion in small increments; add filler wire on
the back stroke.
12. Repeat this procedure until the desired weld is produced.
13. Secure equipment.

175
1 co
. ..7.:_,

N14.'rc.4'14444,.

I i
G TAW
.060 A-B REINFORCEMENT

0
co
0

. fi

1-21 --01

3
PENETRATION

A. FLAT POSITION

B. JIG WITH GAS BACK UP

NAME MILESTONE 9 MODULE NO. iEr


GROOVE WELD SQUARE BUTT WELDS
IN THE FLAT POSITION FIGURE NO. A-5

ELECTRODE SIZE
a
1
I.
DA A C/ HF
TYPE
ALUM. 1100-0 -0

MATERIAL SPEC. AMT. SIZE

ALUMINUM SHEET 1100-0 2 .060 X li X 6


it

GAS TUNGSTEN-ARC WELDING (TIG)

Module III. Groove Weld

Milestone B, Square Butt Weld in the Flat Position


Project 5; Time: 6 hours

INTRODUCTION
The student will make a single pass butt weld with full
penetration. The weld will have a convex face with even
ripple. There should be no undercut.

EQUIPMENT REQUIRED
AC-DC welding machine with high frequency current, foot control,
pressure regulator, flow meter, TIG torch complete, tongs,
welding jig, and safety equipment.

MATERIAL NEEDED
2 pieces .060 x 1-1/2 x 6 inch aluminum sheet, 1/8 inch
filler wire type 1100.0.

PROCEDURE
1 6. Repeat equipment & safety procedures.
7. Place pieces in the welding jig to form a tight butt joint.
8. Put on face shield and gloves.
9. Hold torch at though it is a pencil, drop face shield.
10. Depress foot control to initiate the arc to the jig backing.
11. Move the arc to the joint, make the weld with a forward and
back motion in small increments; add filler wire on the
back stroke
12. Repeat this rocedure until the desired weld is produced.
13. Secure equipment.

177
.0601' GTAW
.060 l B

to
N.
v.
. .

..,

GTAW, "
B .06011

337
r; GTAW
060 B
3.25 90
GTAW
Tg A
.
1
cv
GTAW
.060pr A

0 o
to 4 co
O q
6 A. HORIZONTAL POSITION
-

B. FLAT POSITION

NAME MILESTONE A MODULE NO. II'


PRESSURE VESSEL ALUMINUM PRESSURE VES :L
FIGURE NO. A-6
ELECTRODE SIZE TYPE
8 DIA. AC/HF ALUM. 1100-0
MATERIAL SPEC. AMT SIZE
ALUMINUM SHEET 1100-0 .060 X 4.75 X 4
I
ALUMINUM SHEET 1100 -0 I .060 X 4.75 X 6
ALUMINUM SHEET 1100 -0 I .060 X 3.25 D.
ALUMINUM SHEET 1100 -0 I .060 X 10.25 X 2
178
GAS TUNGSTEN-ARC WELDING (TIG)

Module IV. Pressure Vessel

Milestone A, Aluminum Pressure Vessel

Project 6; Time: 3 hours,

INTRODUCTION
Follow the instructions in the drawing to construct a vessel
using the prepared materials. This structure will be joined
by 1 butt, 1 corner, 2 lap, 2 edge, and 1 fillet weld. This
is the final project of this module; the vessel may be pres-
sure tested.

EQUIPMENT REQUIRED
AC-DC welding machine, with high frequency current, foot control,
pressure regulator, flow meter, TIG for .1 complete, tongs,
welding jig, and safety equipment.

MATERIAL NEEDED.
Pre-cut aluminum pieces listed and shown on drawing A-6.
PROCEDURE
Use the drawing to determine the assembly and welding routine.
Duplicate all operations shown.

179
I

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.., ,....,
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-...
.....,
--::'--:"14, ..,..
......,.,
_
......,.,
....,...
........
.......-

4 i
--.

4' GTAW
REINFORCEMENT AB

= .urAstimmmi
fro
PENETRATION

A. FLAT POSITION

WELD BOTH SIDES


B. WELD
4

NOTE: REFERS TO BEAD WIDTH


NAME MILESTONE 8 MODULI_

FAMILIARIZATION WITH ThE PROCESS STRINGER BEADS


IN THE FLAT POSIT ION FIGURE NO. A-7

ELECTRODE SIZE i_ DC/ SP


TYPE
S. S. 308
/6 DIA.
MATERIAL SPEC. AMT. SIZE

STAINLESS STEEL PLATE 308 1 X4X4


, A

180
GAc TUNGSTEN -ARC WELDING (TIG)

Module I. Familiarization of Process


I
Milestone B, Stringer Beads in the Flat Position

Project 7; Time: 6 hours

INTRODUCTION
The student will make stringer beads to form a pad covering
both sides of a stainless steel plate. The beads, made with
1/16 inch filler wire, must be uniform in width, straight,
and have a 25S overlap on each bead.

EQUIPMENT REQUIRED
AC-DC welding machine with high frequency current, foot control,
pressure regulator, flow meter, torch assembly, tongs, and
safety equipment.

MATERIAL NEEDED
1 piece 1/8 x 4 x 4 inch stainless steel plate, 1/16 inch
filler wire of a type that will match the base metal.

PROCEDURE
1 - 6. Repeat equipment & safety procedures.
7. Hold the torch as though it were a pencil, drop face shield.
8. Depress foot control to initiate the arc to the copper
backing, move the arc to the plate and hold until melting
starts.
9. Move at a constant rate with forward and back motion in
small increments.
10. Add filler metal on the back motion of the torch.
11. Control fate of travel by keeping a constant bead width.
12. When a bead is completed, raise face shield to evaluate
results.
13. Repeat this procedure until an acceptable bead is produced.
14. Secure equipment.
,...,.....

A. HORIZONTAL POSITION

B. WELD BOTH SIDES

NAME MILESTONE C MODULE NO. IL'


FIL LET WELD LAP WELDS
IN THE HORIZONTAL POSITION FIGURE NO. A-8
ELECTRODE SIZE Ft1_ TYPE
DIA . DC/SP STAINLESS STEEL 308
MATERIAL SPEC. AMT SIZE

STAINLESS STEEL 308 2 .060 X IiI X 3

182
GAS TUNGSTEN-ARC WELDING (TIG)

Module II. Fillet Weld

Milestone C, Lap Welds in the Horizontal Position


Project 8; Time: 12 hours

INTRODUCTION
The student will overlap two pieces of stainless steel by
1/2 inch. He will weld both sides of this lap joint with
two single pass fillet welds. These must have a flat face
and legs of equal dimension.

EQUIPMENT REQUIRED
AC-DC welding machine with high frequency current, foot control,
pressure regulator, flow meter, torch assembly, vise grip pliers,
tongs, and safety equipment.

MATERIAL NEEDED
2 pieces .960 x 1-1/2 x 3 inch stainless steel, 1/10 inch
filler wire of a type matching the base metal.

PROCEDURE
1 - 6. Repeat equipment & safety procedures.
7. Set amperage, high frequency start only, and remote control
as directed.
8. Hold the torch as though it is a pencil, drop face shield,
9. Depress foot control to initiate the arc to the copper
backing, move arc to the joint and hold until melting
starts. Direct the arc into the corner of the joint with
the major heat against the bottom plate.
10. Move at a constant rate with forward anC back motion in
small increments.
11. Add filler metal on the back motion of the torch.
12. Control the rate of travel by keeping a constant bead
width.
13. Repeat this procedure until the desired well is produced.
14. Secure equipment.

183
o.'

Pi)
tk' °

.060
I GTAW
A FT"

IT....,
. .' CV 0
co
O

ilk WWWWW®

I-21

A. HORIZONTAL POSITION

B. WELD BOTH SIDES

. .

NAME MILESTONE 0 it MODULE NO. IC


FILLET WELD FILLET WELDS
IN THE HORIZONTAL POSITION FIGURE NO. i. -9

ELECTRODE SIZE I DC/ SP


TYPE
STAINLESS STEEL 308
DIA .
16
MATERIAL SPEC. AMT SIZE

ST4INLESS STEEL SHEET 308 2 .060 X If X 3


,ss

GAS TUNGSTEN-ARC WELDING GIG)

Module II. Fillet Weld

Milestone D, Fillet Welds in the Horizontal Position


Project 9; Time: 12 hours

INTRODUCTION
The c*tudent will make a 'T' joint and weld the fillets in
the flat/horizontal position. These will be made in one
pass, must have a flat face and equal leg length. They
must not have undercut, or penetration through the vertical
plate.

REQUIRED EQUIPMENT
AC-DC ,elding machine with high frequency current, pressure
regulator, flow metcr, torch assembly, vise grip pliers,
tongs, and safety equipment.

MATERIAL NEEDED
2 pieces .060 x 1-1/2 x 3 inch stainless steel, 1/16 inch
filler wire of a type to match. the base metal.

PROCEDURE
1 - 6. Repeat equipment & safety procedures.
7. Put on face shield and glov^s.
8. Form a 'T' joint by supporting vertical piece with vise
rip pliers at the center of the base plate.
9. Drop face shield.
10. Depress foot control to initiate C.e a:(.. to the copper
grounding plate.
11. Move arc to the joint and tack weld each end.
12. Make tile fillet welds; direct the arc in the corner
with the greatest amount of heat against the base plate. r
Move forward and back in small increments, deposit filler
on back stroke.
13. Welds must be equal in leg length, dimension, have a flat
face without undercut.
14. Repeat this procedure until welds are to specifications.
15. Secure equipment.

185
I

I
I

I
ro

I
A\
0
/\
. 060
GTAW
. A- B
90
REINFORCEMENT

41,
\e( PENETRATION
LAP .003
.060

A. FLAT POSITION

B. JIG WITH BACK UP

NAME MILESTONE c MODULE NOTIC


GROOVE WELD CORNER WELDS
IN THE FLAT POSITION FIGURE NO. A -10

ELECTRODE SIZE I DIA. DC/ SP TYPE STAINLESS STEEL 308


; ig
MATERIAL SPEC. AMT. SIZE
r

; STAINLESS STEEL SHEET 308 2 .060 X 17 X 31

186
GAS TUNGSTEN-ARC WELDING (TIG)

Module III. Groove Weld

Milestone C, Corner Weld in the Flat Position


Project 10; Time: 6 hours

INTRODUCTION
The student will make a corner weld set by tack welding two
pieces of stainless steel at an angle of 90 °. This joint
will be welded in the flat position. Make a full penetration
bead in one pass. Weld face should be slightly convex and
have even ripple.

EQUIPMENT REQUIRED
AC-DC welding machine with high frequency current, pressure
regulator, flow meter, torch assembly, tongs, and safety
equipment, welding jig.

MATERIAL NEEDED
2 pieces .C60 x 1-1/2 x 3 inch stainless steel, 1/16 inch
filler of a type to match the base metal.
PROCEDURE
1 6. Repeat equipment & safety procedures.
7. Place pieces in jig to form a corner joint.
8. Put on face shield and gloves.
9. Hold torch as though it is a pencil, drop face shield.
10. Depress foot control to start arcing to the jig, move
to the joint.
11. Direct arc so that edges of metal fuse. Add filler when
torch is moved back in the forward and back procedure.
12. Repeat this procedure until a satisfactory weld is produced.
13. Secure equipment.

187
t

114.11111114.4°'4..

GTAW
.060 A_B REINFORCEMENT

0
c)
°.

i_____IIIIIMIL
f

3
PENETRATION

A. FLAT POSITION

B. JIG WITH GAS BACK UP

NAME MILESTONE D MODULE NO. XL


GROOVE WELD SQUARE BUTT WELDS
IN THE FLAT POSITION FIGURE NO. AII
ELECTRODE SIZE I TYPE
Th- DIA. DC/ SP S. S. 308
MATERIAL . SPEC. AMT. SIZE

STAINLESS STEEL SHEET . 308 2 .060 X I X3

188
GAS TUNGSTEN-ARC WELDING (TIG)

Module III. Groove Weld

Milestone D, Square Butt Weld in the Flat Position


Project 11; Time: 6 hours

I INTRODUCTION
The student will make a single pass butt weld with full
penetration. The finished weld should be convex, of uniform
width and shope. There should be no undercut.
I
EQUIPMENT REQUIRED
AC-DC welding machine with high frequency current, pressure
regulator, flow meter, torch assembly, tongs, welding jig,
and safety equipment.
7" MATERIAL NEEDED
2 pieces .060 x 1-1/2 x 3 inch stainless steel, 1/16 inch
filler wire of a.type matching the base metal.
PROCEDURE
1 - 6. Repeat equipment & safety procedures.
7. Place the pieces in a jig so that edges are flush and
touching.
8. Put on face shield and gloves.
9. Hold torch as though it is a pencil, drop face shield.
10. Depress foot control to start arcing to the jig, move
to the start of the joint.
11. Hold torch so that both edges fuse. Add filler metal
when torch is moved back, in the forward and back
1- procedure.
12. Repeat this procedure until a satisfactory weld is produced.
13. Secure equipment.

189
.060
GTAW
.060 8
6'

III
N
1 .

GTAW
8 .060 400 '.1_,....._.......4

el
. o
.
:
:

3.37 t.0
0: TAW
GTAW
8
3.25

r. GTAW
A
t
tti
GTAW
060 A

0
to
0
to
0 0
al- 6 A. HORIZONTAL POSITION

c
B. FLAT POSITION

NAME MILESTONE e MODULE. NO. 1Z


PRESSURE VESSEL PRESSURE VESSEL
IN A MULTIPLE POSITION FIGURE NO. A-12

ELECTRODE SIZE
16
DIA. DC/ SP S. S. 308
MATERIAL SPEC. AMT. SIZE
STAINLESS STEEL SHEET 308 I .060 X 4.75 X 4
STAINLESS STEEL. SHEET .308 I .060 X 4.75 X 6
STAINLESS STEEL SHEET 308 I .060 X 3.25 D.
STAINLESS STEEL SHEET 308 I .060 X 10.25 X 2
190
GAS TUNGSTEN-ARC WELDING (TIG)

Module IV. Pressure Vessel

Milestone B, Pressure Vessel in a Multiple Position


Project 12; Time: 3 hours

INTRODUCTION
The student will construct a vessel. to the specifications
shown in the drawing. Use the precut and rolled material
provided. This assembly will contain 1 butt, 1 corner, 2
lap, 2 edge, and 1 fillet weld. This vessel is the final
project of this module, kt....pay be pressure tested.

EQUIPMENT REQUIRED
AC-DC welding machine with high frequency current, foot control,
pressure regulator, flow meter, tongs, welding jig, and TIG
torch, safety equipment.

MATERIAL NEEDED
Prepared stainless steel pieces shown in the drawing, 1/16
inch filler metal of a type matching the base metal.
PROCEDURE
Use the drawing to determine the assembly and welding routine.
Duplicate all operations shown.

191
GAS METAL-ARC WELDING (MIG)

PHASE V, PART B OBJECTIVE

In this section of phase V the student will learn

to use the semi-automatic equipment of the gas

metal-arc process. He will become familiar with


the different methods of metal transfer, as in

spray, short circuiting, and flux cored electrode


welding.

The skill developed through this experience will

make the student employable as a welder using gas

metal-arc welding equiPMent except for that work


covered by codes or demanding advanced experience.

.J193
1

00g
,*-4.-
.17.---"
-

.._
..;.-- ,..z__-_-

W. ..'
4...- --
t.-.--, ,_

G MAW
ABCD 4 r PENETRATION -

.. .,

#
WELD SEQUENCE
4

A. FLAT POSITION C. SPRAY ARC

B. M.1. G. PROCESS D. WELD ALL SIDES

NAME MILESTONE A MODULE NO. I


FILLET WELD FILLET WIFLDS
IN THE FLAT POSITION FIGURE NO. B-1

ELECTRODE SIZE TYPE


.035 DIA. DC/CP WIRE SPOOL MO -1313 STEEL
MATERIAL
STEEL SPEC.
MILD
AMT.
I
SIZE
-4 X 2 X 24
1

STEEL MILD 2 -X I X 24

194
GAS METAL-ARC WELDING (MIG)

Module I. Fillet Weld

Milestone A, Fillet Welds in the Flat Position


Project 1; Time: 2 hours

INTRODUCTION
The student will make a fillet weld set of steel plate that
will contain four 3/4 inch fillet welds 24 inches long. He
will use the spray method of metal transfer, depositing the
number of passes that will Make a fillet of the desired
depth. Weld will be made in the flat position.

EQUIPMENT REQUIRED
DC constant potential welding machine, wire feeder with gun,
gas mixing manifold, tongs, wire brush and safety equipment.
MATERIAL NEEDED
1 piece 1/4 x 2 x 24 and 2 pieces 1/4 x 1 x 24 inch steel
plate.

PROCEDURE
1. Clean the plate as required.
2. Select the proper size and type of fil- wire, wire
guides drive rolls, contact tube, and ga. cup.
3. Thread wire through the system with 1 inch of stick out
below the contact tube.
4. Select the proper shielding gas mixture and set pressures
and flow rates.
5. Set proper amperage, voltage, slope, and wire feed rate.
6. Start welding machine.
7. Open cooling water valve.
8. Put on face shield and gloves.
9. Hold gun, drop face shield, and tack weld the pieces to
form a cross.
10. Direct the gun so that the wire points to the corner of
the joint.
11. Close contactor switch, move gun along the joint.
12. Use a leading angle and a small weave motion.
13. On thin gage material do not use weaving, and hold gun
with a drag angle.
14. Make the required width of bead by controlling the rate
of travel.
15. Repeat this procedure until a uniform weld is produced.
16. Secure equipment.

195
1

4..

4
/ St
WELD SEQUENCE
\
GM A W
A-8- C-D
PENETRATION

...."--- ....?"

7-Na0
7
----; I .- 1--

.- 7: :::
I I Op I
16
li 4
1
1
07
it
0A
W
-1ILIAF O

A. VERTICAL DOWN POSITION

13. MI.G PROCESS

C. SHORT ARC

D. WELD ALL SIDES

NAME MILESTONE 8 MODULE NO. 1


FILLET WELD FILLET WELDS
IN THE VERTICAL DOWN POSITION FIGURE NO. 0-2
ELECTRODE SIZE TYPE
.035 DIA. DC/CP WIRESPOOI MO -1313 STEEL
MATERIAL
STEEL
SPEC, AMT SIZE j_ X 2 X 24
MILD 1 4
I
STEEL MILD 2 X 1 X 24
..

196
GAS METAL-ARC WELDING (MIG)

Module I. Fillet Weld

Milestone B, Fillet Welds in the Vertical Down Position


Project 2; Time: 2 hours

INTRODUCTION
The student will make a fillet weld set with steel plate
to hold four S/8 x 24 inch fillet welds. He will use the
short circuiting arc method of metal transfer, making the
number of passes that will produce the desired depth of
weld. This is made in the vertical down position.
EQUIPMENT REQUIRED
DC welding machine with constant potential, wire feeder
with gun assembly, ,gas mixing manifold, tongs, wire brush,
and safety equipment.

MATERIAL NEEDED
I piece 1/4 x 2 x 24 and 2 pieces 1/4 x 1 x 24 inches
steel plate.
I

PROCEDURE
1 - 8. Repeat equipment & safety procedures.
9. Hold pieces with tongs, drop face shield, tack weld
plate to form a cross for the four fillet welds.
10. Place this assembly in the positioner for vertical
welding.
11. Drop face shield, point gun so that wire is at top
center of the joint.
12. Close contactor switch, pull or drag gun down with a
slight weave pattern. Move at a uniform rate to form
the bead of the desired width.
13. Repeat this procedure until a uniform weld is produced.
14..Secure equipment.

197
III

I
1111111

II
,
t V C"
g-,

I
I

I 1

\
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6 MAW .

ABCD 7 Pr PENETRATION

\ ;
\ 2
\/ i
2
16
lr 3
4-

ill WELD SEQUENCE

A. FLAT POSITION C. SPRAY ARC

B. M. I. G. PROCESS D. WELD ALL SIDES

NAME MILESTONE C MODULE NO. I


FILLET WELD FILLET WELDS
IN THE FLAT POSITION FIGURE NO. 8-3
ELECTRODE SIZE I TYPE
g DIA. DC/CP WIRESPOOL 4043 ALUM.
MATERIAL
ALUMINUM PLATE SPEC.
4043
AMT.
1
SIZE I
4- X
,c 24 24
I
ALUMINUM PLATE 4045 2 wX I X 24

!98
GAS METAL-ARC WELDING (MIG)

Module I. Fillet Weld

Milestone C, Fillet Welds in the Flat Position


Project 3; Time: 2 hours

INTRODUCTION
The student will make a fillet on aluminum by making a
set to contain four 3/4 x 24 inch welds. The spray metal
transfer method will be used to. deposit the needed filler
metal to make the required depth of deposit. This will be
done in the flat position.

EQUIPMENT REQUIRED
DC welding machine with constant potential, wire feeder
with gun assembly, pressure regulator and flow meter,
tongs, and safety equipment.

MATERIAL NEEDED
1 piece 1/4 x 2 x 24, 2 pieces 1/4 A 1 x 24 inch aluminum
plate.

PROCEDURE
1 - 9. Repeat equipment & safety procedures.
10. Hold pieces with tongs, drop face shield, tack weld
plates to form a cross for the four fillet welds.
11. Point the gun so that wire is directed to the corner
and starting point of the fillet.
12. Close contactor switch, push gun along with a slight
lead angle, use a small weave motion.
13. Move at a uniform speed that will deposit the desired
amount of filler metal.
14. Repeat this procedure until a uniform weld is produced.
15. Secure equipment

199
2

1141\1111k
N400116 4"
WELD SEQUENCE

r GMAW
A-B-C-D
PENETRATION

. . - - ,....
,- ...,
,,,-.4....
....

ea
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i ^ If
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it
A. VERTICAL DOWN POSITION

B. M.I.G. PROCESS

C. SHC"T ARC

D. WELD ALL SIDES

NAME MILESTONE to FILLET WELDS MODULE NO. I


FILLET WELD IN THE VERTICAL DOWN POSITION
W/ SHORTCIRCUITING METAL TRANSFER FIGURE NO. 8-4
ELECTRODE SIZE I TYPE
16 DIA. DC/CP WIRESPOOL 4043 ALUM.
MATERIAL
ALUMINUM PLATE SC,
PE AMT. SIZE -iI f X 2 X 24
4043 I

ALUMINUM PLATE 4043 2 1X I X 24

200
I

GAS METAL-ARC WELDING (MIG)

Module I. Fillet Weld

1 Milestone D, Vertical Down Welding with Short Circuiting


I
Metal Transfer
Project 4;- Time: 2 hours

INTRODUCTION
The student will make a fillet weld set of aluminum to
contain four 5/8 inch welds. The short circuiting metal
transfer method will be used, welding in the vertical down
position. Deposit the number of beads needed to complete
the weld to dimension. Equal leg length and a flat face
should be produced.

EQUIPMENT REQUIRED
1
DC constant potential welding machine, wire feeder, with
1
gun complete, pressure regulator, flow meter, tongs, and
safety equipment.

MATERIAL NEEDED
1 piece 1/4 x 2 x 24 inch, 2 pieces 1/4 x 1 x 24 inch
aluminum plate, filler wire type 4043.
PROCEDURE
1 8. Repeat equipment & safety procedures.
9. Hold gun, drop face shield and tack weld plate in the
form of a cross for fillet welds.
10. Place this assembly in the positioner for vertical
welding.
11. Point the gun at the top of the joint with a slight
drag angle.
12. Use a small weave motion, move down at a rate to form
the proper sized bead.
13. Continue' welding until the 5/8 inch dimension is
reached; overlap and fuse each bead added.
14. Repeat this procedure until the desired weld can be
produced.
15. Secure equipment.

201
i

I
N
cm O ga,,.
sAc_l?--
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re).

illiktg`:
;Z
--:1 rA
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....-ate-
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60°

REINFORCEMENT
GMAW
A-B-C
32
60°
ROOT FACE MC= 1161,
%I
_ iiim1 Ir
3
32
L 2
PENETRATION

ROOT GAP A. FLAT POSITION

B. M.I.G PROCESS

C. SUBSTITUTE STEEL PIPE


IF AVAILABLE

NAME MILESTONE A MODULE NO. IC


GROOVE WELD "V" GROOVE BUTT WE LDS
IN THE FLAT POSITION FIGURE NO. B-5

ELECTRODE SIZE TYPE


.035 DIA. DC/CP WIRESPOOL MO-1313 STEEL
MATERIAL SPEC. AMT. SIZE

I
STEEL MILD 2 2 X 2 X 24

202
GAS METAL-ARC WELDING (MIG)

Module II. Groove Weld

Milestone A, 'V' Groove Butt Weld in the Flat Position


(when available, substitute pipe)
Project 5; Time: 2 hours

INTRODUCTION
The student will make a butt weld on steel plate in the
flat position: This weld can be made with either four
weave passes or seven stringer beads. The reinforcement
should be slightly convex, uniform in width but without
undercut or pinholes. Penetration should be complete.
EQUIPMENT REQUIRED
DC constant potential welding machine, wire feeder with
gun complete, gas mixer manifold, tongs, and safety
equipment.

MATERIAL NEEDED
2 pieces 1/2 x 2 x 24 inch steel plate beveled to 30°.

PROCEDURE
1 - 7. Repeat equipment & safety procedures.
8. Place the plate in the jig for butt weld with a root
opening of about 1/8 inch.
9. Point the gun at the centerline of the joint, drop face
shield.
10. Close trigger switch, push gun along the joint at about
15° from vertical in the direction of travel.
11. Use either the weave or stringer procedure.
12. Move at a uniform rate and-repeat until the groove is
filled.
13. Reinforcement should not exceed plate thickness by more
than 1/8 inch; it should be uniform in appearance.
14. Repeat the procedure until an acceptable weld is produced.
15. Secure equipment.

203
3
52 2 ROOT FACE
PENETRATION

-IN IIIIIIVA
"M.
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G MAW
A-B-C 2
60°
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REINFORCEMENT

60°

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14:1 WI'
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,
15'

O ":;

4.

A. VERTICAL DOWN POSITION

B. M. I.G. PROCESS

C. SUBSTITUTE STEEL PIPE


IF AVAILABLE .

NAME MILESTONE B MODULE NO. Zr


GROOVE WELD "V" GROOVE BUTT WELDS
IN THE VERTICAL DOWN POSITION FIGURE NO. B-6

ELECTRODE SIZE .035 DIA. DC/CP WIRESPOOL TYPE MO-13I3


STEEL
MATERIAL SPEC. AMT. SIZE

STEEL MILD 2 -L X 2 X 24

204
GAS METAL-ARC WELDING (MIG)

Module II. Groove Weld

Milestone B, 'V' Groove Butt Weld in the Vertical Down


Position (when available, substitute pipe)
Project 6; Time: 2 hours

INTRODUCTION
The student will make a butt weld on steel plate in the
vertical down position. This weld can be made using
short circuiting arc method of metal transfer, making
the number of passes that will produce the desired weld
size. The reinforcement should be slightly convex, uni-
form in width,but without undercut or pinholes. Pene-
tration should be complete.

EQUIPMENT REQUIRED
DC constant poi..c.ntial welding machine, wire feeder with
gun complete, gas mixer manifold, tongs, and safety
equipment.

MATERIAL NEEDED
2 pieces 1/2 x 2 x 24 inch steel plate beveled on one side
to 30°.

PROCEDURE
1 - 7. Repeat equipment $ safety procedures.
8. Place the plate in the jig for a butt weld with a root
opening of about 1/8 inch.
9. Position this assembly for vertical welding.
10. Point the gun at the center line of the joint, hold a
slight dragging angle down. Drop the face shield.
11. Close trigger switch, move downward with a small weave
motion, or hold steady to make stringer beads.
12. Move at a uniform rate and repeat until the groove is
filled.
13. The reinforcement should not exceed plate thickness by
more than 1/8 inch; it should be uniform in appearance.
14. Repeat this procedure until an acceptable weld is produced.
15. Secure equipment.

205
it
Al
.,

1 ''
C
6S-;
t.L

REINFORCEMENT
G) '1W
kE- 1
2
i
ROOT FACE

\1P, f
A 71.- 2
PENETRATION

LROOT GAP A. FLAT POSITION

a M.I.G. PROCESS

C. SPRAY ARC

D. SUBSTITUTE STEEL PIPE


IF AVAILABLE

NAME MILESTONE G MODULE NO. II


GROOVE WELD uVu GROOVE BUTT WELD
IN THE FLAT POSITION FIGURE NO. 8-7
ELECTRODE SIZE I
m DIA. DC/CP WIRESPOOL TYPE 4043 ALUM.
MATERIAL SPEC. AMT. SIZE

ALUMINUM PLATE 4043 2 y X 2 X 24

206
GAS METAL-ARC WELDING (MIG)

Module II. Groove Weld

Milestone C, 'V' Groove Butt Weld in the Flat Position


(when available, substitute pipe)
Project 7; Time: 2 hours

INTRODUCTION
The student will make a butt weld on aluminum plate in the
flat position. This weld can be made using spray method
of metal transfer, making the number of passes that will
produce the desired weld size. The reinforcement should
be slightly convex, uniform in width, but without undercut.
Penetration should be complete.

EQUIPMENT REQUIRED
DC constant potential welding machine, wire feeder with gun
complete pressure regulator, flow meter, tongs, and safety
equipment.

MATERIAL NEEDED
2 pieces 1/2 x 2 x 24 inch aluminum plate beveled on one
side to 30°; spool of type 4043 filler wire.

PROCEDURE
1 - 7. Repeat equipment & safety procedures.
8. Place the plate in the jig for butt joint witil a root
opening of about 1/8 inch. Place for flat position
welding.
9. Put on face shield and gloves.
10. Point the gun at the centerline of the joint, drop face
shield.
11. Close the trigger switch, push gun along the joint at
about 15° from the vertical in the direction of travel.
12. Use either weaving or stringer procedure.
13. Move at a uniform rate and repeat until groove is filled.
14. Reinforcement should not exceed plate thickness by more
than 1/8 inch; it should be uniform in appearance.
15. Repeat this procedure until an acceptable weld is produced.
16. Secure equipment.

207

1
3
32 2 ROOT FACE
PENETRATION

En lira
1111
41110
GMAW
A-B-C-D r 32
60 REINFORCEMENT

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. 7

a,
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14
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V:I

i
A. VERTICAL DOWN POSITION
1:?..

B. M. I. G. PROCESS I

C. SHORT ARC

D. SUBSTITUTE STEEL PIPE


IF AVAILABLE

NAME MILESTONE D MOOULE NO. Z


GROOVE WELD "V" GROOVE BUTT WELDS
IN THE VERTICAL DOWN POSITION FIGURE NO. B-8
ELECTRODE SIZE J_ DIA. DC/CP WIRESPOOL TYPE
16 4043 ALUM.
MATERIAL SPEC. AMT. SIZE

ALUMINUM PLATE 4043 2 -2I X 2 X 24

208
GAS METAL-ARC WELDING (MIG)

Module II. Groove Weld

Milestone D, 'V' Groove Butt Weld in the Vertical Down


Position (when available, substitute pipe)
Project 8; Time: 2 hours

INTRODUCTION
The student will make a butt weld on aluminum plate in the
vertical down position. This weld can be made using short
circuiting arc method of metal transfer making the number
of passes that will produce the desired weld size. The
reinforcement should be slightly convex, uniform in width,
but without undercut or pinholes. Penetration should be
complete.

EQUIPMENT REQUIRED
DC constant potential welding machine, wire feeder with gun
complete, pressure regulator, flow meter, tongs, and safety
equipment.

MATERIAL NEEDED
2 pieces 1/2 x 2 x 24 inch aluminum plate, beveled on one
side to 30°; type 4043 filler wire.

PROCEDURE
1 - 7. Repeat equipment 4 safety procedures.
8. Place the plate in the jig for a butt joint with a root
opening of about 1/8 inch. Position for vertical welding.
9. Put on face shield and gloves.
10. Point gun at the centerline of the joint, drop face
shield.
11. Close trigger switch, move downward with a slight drag
angle.
12. Use either weaving or stringer welding procedure.
13. Move at uniform rate and repeat until the groove is filled.
14. Reinforcement should not exceed plate thickness by more
than 1/8 inch; it should be uniform in appearance.
1S. Repeat this procedure until an acceptable weld is produced.
16. Secure equipment.

209
l

0, ,e: CZ:.
i.k 14"
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--f. z:.-- -V,.#
,:-." s-;,. ;
;..

GMAW
ABCD PENETRATION

I /
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.

WELD SEQUENCE

A. FLAT POSITION C. FLUX CORE

B. M. I.G. PROCESS D. WELD ALL SIDES

NAME MILESTONE A MODULE NO..IIL


FLUX CORED ELECTRODE WELDING FILLET WELDS
IN THE FLAT POSION FIGURE NO. B-9

ELECTRODE SIZE
.045 DIA. DC/CP WIRESPOOLYPE AWS A5 20 69
MATEMAL
STEEL SPEC. AMT. SIZE I X 2 X 24
MILD I 4
STEEL MILD 2 -X I X 24

210
MIMM1Di.,=....

GAS METAL-ARC WELDING (MIG)

Module III. Flux Cored Electrode Welding

Milestone A, Fillet Welds in the Fiat Position


Project 9; Time: 2 hours

INTRODUCTION
The student will make a fillet weld set of steel plate for
welding in the flat position. Four fillet welds will be
made with 3/4 inch leg dimension. Flux cored electrode
equipment will be used to deposit the metal needed to fill
the fillets to the required depth. These should have a flat
face .and equal leg length.

EQUIPMENT REQUIRED
DC constant potential welding machine, wire feeder with gun
complete, gas mixing manifold, tongs, and safety equipment.
MATERIAL NEEDED
1 piece 1/4 x 2 x 24 inch and 2 pieces 1/4 x 1 x 24 inch
steel plate.

PROCEDURE
1 - 8. Repeat equipment 4 safety procedures.
9. Hold gun, drop face shield and tack weld the pieces to
form a cross.
10. Direct the gun so that the wire points to the corner of
the joint. .

11. Close contactor switch, move gun along the joint.


12. Use a leading angle and a small weaving motion.
13. Make the required width of bead by controlling the rate
of travel.
14. Repeat this procedure until a uniform bead is produced.
15. Secure equipment.

211
I
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45

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itt
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ir
00

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GMAW
REINFORCEMENT (---
A-B-C
60
T.L. law
-4. meraffils
I 1 PENETRATION
1r

OOT GAP A. FLAT POSITION

B. M.LG. PROCESS

C. FLUX CORE

. D. SUBSTITUTE STEEL PIPE


IF AVAILABLE

NAME MILESTONE 0 MODULE NO. Si


FLUX CORED ELECTRODE WELDING "Vn GROOVE
GROO BUTT WELD W/BACK UP
IN THE FLAT POSITION FIGURE NO. EI-10

ELECTRe:E SIZE
.045 DIA. DC/CP WIRESPOOL TYPE AWS A-5 20 - 69
MATERIAL
STEEL SPEC. ANT. SIZE i X 2 X 24
MIL D
I
STEEL MILD I iT X I X 25

21
GAS METAL-ARC WELDING (MIG)

Module III. Flux Core Electrode Welding

Milestone B, 'V' Groove Butt Weld in the Flat Position


with Backing Plate
Project 10; Time: 2 hours

INTRODUCTION
The student will make a butt weld with backing strip on
steel plate with a beveled edge. Two or three passes will
be needed to complete this weld, depending on the size of
the wire used. The reinforcement should be slightly convex,
with uniform ripple. Fusion with the backing strip should
be complete. There should not be any undercut or pinholes.

EQUIPMENT REQUIRED
DC constant potential welding machine, wire feeder with gun
complete, gas mixing manifold, tongs, and safety equipment.

MATERIAL NEEDED
2 pieces 1/2 x 2 x 24 inch steel plate with one side beveled
to an angle of 300; 1 piece of 1/4 x 1 x 25 inch steel bar.
I PROCEDURE
1 7. Repeat equipment & safety procedures.
8. Place the plates in welding jig to form a butt weld with
the backing strip. The root opening should be about
3/16 inches.
9. Put on face shield and gloves.
10. Hold gun with wire pointed at the root of the joint.
11. Drop face shield, close contactor switch, move along
the root of the joint. Use a small weave motion so
that all three members of the joint are fused.
12. Clean each pass as it is completed, continue depositing
beads until the groove is filled.
13. The reinforcement should be uniform, have a slightly
convex surface without undercut or pinholes.
14. Repeat this procedure until the desired weld is produced.
15. Secure equipment.

213

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