Lincoln Electric Stick Electrode Welding C2.410 Manual de usuario

STICK ELECTRODE

WELDING GUIDE

Procedures and Techniques

-2-

Customer Assistance Policy

The business of The Lincoln Electric Company is manufacturing

and selling high quality welding equipment, consumables, and

cutting equipment. Our challenge is to meet the needs of our

customers and to exceed their expectations. On occasion, pur-

chasers may ask Lincoln Electric for advice or information about

their use of our products. We respond to our customers based on

the best information in our possession at that time. Lincoln

Electric is not in a position to warrant or guarantee such advice,

and assumes no liability, with respect to such information or

advice. We expressly disclaim any warranty of any kind, includ-

ing any warranty of fitness for any customer’s particular purpose,

with respect to such information or advice. As a matter of practi-

cal consideration, we also cannot assume any responsibility for

updating or correcting any such information or advice once it has

been given, nor does the provision of information or advice cre-

ate, expand or alter any warranty with respect to the sale of our

products.

Lincoln Electric is a responsive manufacturer, but the selection

and use of specific products sold by Lincoln Electric is solely with-

in the control of, and remains the sole responsibility of the cus-

tomer. Many variables beyond the control of Lincoln Electric

affect the results obtained in applying this type of fabrication

methods and service requirements.

Subject to Change – This information is accurate to the best of

our knowledge at the time of printing. Please refer to

www.lincolnelectric.com for any updated information.

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Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

Out-of-Position Welding

(Vertical and Overhead) . . . . . . . . . . . . . . . . . . . . . .4-7

High Deposition Welding . . . . . . . . . . . . . . . . . . . .8-15

Welding Inclined Plates . . . . . . . . . . . . . . . . . . . .16-17

High Speed Welding (Sheet Metal) . . . . . . . . . . .18-23

Low Hydrogen Welding . . . . . . . . . . . . . . . . . . . .24-34

Minimum Preheat and Interpass Temperatures . . . .35

Stick Electrode Selection Guide . . . . . . . . . . . . . . . . .36-38

Welding Safety Precautions . . . . . . . . . . . . . . . . . . . .39-48

Table of Contents

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WELDING PROCEDURES

Out-Of-Position Welding (Vertical and Overhead)

When welding out-of-position, the molten metal tends to spill out

of the joint. To offset this tendency, an electrode with a fast

freezing deposit is needed.

Welding made with out-of-position electrodes is slow, relatively

expensive and require a high degree of operator skill. Therefore,

whenever possible, work should be positioned for downhand

welding using High-Deposition electrodes – see pages 8-15.

Procedures

Vertical Up Groove Welds . . . . . . . . . . . . . . . page 6

Vertical Down Welds . . . . . . . . . . . . . . . . . . . page 6

Vertical Up Fillet Welds . . . . . . . . . . . . . . . . . . page 7

Overhead Fillet Welds . . . . . . . . . . . . . . . . . . page 7

For vertical up and vertical down pipe welding technique,

request Lincoln bulletin C2.420, Welding Pressure Pipelines.

Alternate Electrodes

Vertical, overhead, and horizontal groove welds on plate thicker

than 1/2” are most economically done with low hydrogen

electrodes – see pages 24-34.

Vertical Up vs. Vertical Down

Vertical down is recommended for fastest welding of 18 gauge

to 3/16” thick steel. A description of the recommended drag

technique along with sheet metal procedures are given in the

section High-Speed Welding on pages 18-23.

Vertical up techniques provide deeper penetration and lower

overall welding costs on plate over 3/16” thick.

Electrode, Current and Polarity

The vertical up and overhead procedures in this section

recommend 3/16” and smaller Fleetweld 5P or 5P+ (E6010)

electrode using electrode positive and currents in the lower

portion of the electrode’s range. When only AC otuput is

available, use Fleetweld 35 or Fleetweld 180 (E6011) electrode at

about 10% higher current.

-5-

Vertical Up Techniques for Fillet and Groove Welds

1. Make first pass root beads with a whipping technique. Whip

the electrode tip out of the molten crater and up for a short

time to let the crater cool before returning the electrode tip to

the crater area to add more weld metal.

2. Root pass beads, particularly when made with a

whipping technique, tend to be humped in the middle.

Therefore, a box weave is often needed for the second pass

to assure good fusion along the edge of the first bead. The

box weave is similar to the straight weave except a slight

upward motion is made at both sides of the weld. Maintain a

short arc with no whipping.

3. Employ a straight weave for the final passes. Simply move

the electrode tip back and forth across the surface of the

weld pausing slightly at both edges to insure penetration and

wash-in without undercut.

Overhead Techniques

Weld overhead as a series of root beads using a slight

circulation motion in the crater sometimes accompanied by a

whip. Weave beads are too fluid and will spill.

Whip

first pass

Box weave

second pass

Straight weave

Vertical Up Groove Welds

Vertical Down Welds

Weld thicker plate with vertical up techniques.

-6-

Groove Fillet

Plate Size – T (in.) 3/16 —

Leg Size – L (in.) —5/32

No. of Passes 1-2 1

Electrode/AWS Class Fleetweld 5P, Fleetweld 5P+ E6010

Diameter (in.) 5/32

Current (Amps) 120

Polarity DC+

Arc Speed In./Min.(1) 10-11

Ft. of Weld/Hr. (2) 26 55

Lbs. of Elec./Ft. of Weld .168 .071

Table A

Plate Thickness-T 1/2” 5/8” 3/4” 1”

No. of Passes 3 4 6 10

Ft. of Weld/Hr.(2) 6.6 4.4 3.1 1.8

Lbs. of Elec/Ft. .990 1.48 2.08 3.56

1/8"

1/2” and thicker plates are more economically welded

with low hydrogen electrodes.

Plate Size – T (in.) 1/4 5/16 3/8 1/2-1

No. of Passes 1-2 1-2 1-2 All

Electrode/AWS Class Fleetweld 5P, Fleetweld 5P+ /E6010

Diameter (in.) 5/32 5/32 3/16 3/16

Current (Amps) 110 120 150 160

Polarity DC+ DC+ DC+ DC+

Arc Speed In./Min.(1) 5-1/2 4 5 4

Ft. of Weld/Hr.(2) 11 8.5 10 See

Lbs. of Elec./Ft. of Weld .323 .440 .586 Table A

3/32" gap

3/16"

(1) First pass only. On later passes adjust arc speed to obtain proper bead size.

(2) Total for all passes. 100% operating factor.

No. of Passes 1 1 1 1 1-2 1-3 1-4

Leg Size – L (in.) 3/16 1/4 5/16 3/8 1/2 5/8 3/4

Electrode/AWS Class Fleetweld 5P, Fleetweld 5P+(1)/ E6010

Diameter (in.) 3/16 3/16 3/16 3/16 3/16 3/16 3/16

Current (Amps) 150 155 155 155 160 160 160

Polarity DC+ DC+ DC+ DC+ DC+ DC+ DC+

Arc Speed In./Min.(2) 85324-1/2 4-1/2 4-1/2

Ft. of Weld/Hr.(3) 40 25 15 10 6.8 4.4 3.0

Lbs. of Elec./Ft. of .137 .211 .346 .514 .850 1.31 1.93

Weld

-7-

Vertical Up Fillet Welds

Overhead Fillet Welds

After first bead, the sequence

of bead placements starts on

vertical plate for each layer.

No. of Passes 1 1 1 1-2 1-3 1-6 1-10 1-15

Leg Size – L 5/32 3/16 1/4 5/16 3/8 1/2 5/8 3/4

Electrode/AWS Class Fleetweld 5P, Fleetweld 5P+ /E6010

Diameter (in.) 5/32 5/32 5/32 5/32 3/16 3/16 3/16 3/16

Current (Amps) 130 170 170 170 170 170 170 170

Polarity DC+ DC+ DC+ DC+ DC+ DC+ DC+ DC+

Arc Speed In./Min.(2) 7-1/2 9 5 7 7 7 7 7

Ft. of Weld/Hr.(3) 38 45 25 18 12 6.9 4.4 3.1

Lbs. of Elec./Ft. of .100 .145 .253 .369 .532 .945 1.48 2.13

Weld

(1) 5/32” electrode can be used to allow better control.

(2) First pass only. On later passes adjust arc speed to obtain proper bead size.

(3) Total for all passes. 100% operating factor.

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High-Deposition Welding

High deposition applications includes groove, fillet, lap and

corner welds in 3/16” and thicker plate welded with the work

level or slightly downhill. These joints are capable of holding a

large molten pool of weld metal as it freezes.

These welds are made with Jetweld electrodes because the high

iron powder content in the coating produces high deposit rates

to fill joints in the shortest time for economical welding.

Procedures

Lap welds . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11

Corner Welds . . . . . . . . . . . . . . . . . . . . . . . . . page 11

Groove Welds . . . . . . . . . . . . . . . . . . . . . . . . page 12

Flat Fillet Welds . . . . . . . . . . . . . . . . . . . . . . . page 14

Horizontal Fillet Welds . . . . . . . . . . . . . . . . . . page 15

Alternate Electrodes

When desired, the following alternate electrodes can be used

with similar procedures:

Recommended Alternate

Jetweld 1 (E7024-1) Jetweld 3 (E7024)

Jetweld 1 or 3 (E7024) Jetweld LH-3800 (E7028H8)

Jetweld Operating Techniques

Polarity and Current – Use AC for fast welding speeds, high

deposit rates, and good arc characteristics. DC can be used but

the resulting arc blow may complicate control of the molten

puddle.

Optimum current for most jobs is 5-10 amps above the center of

the electrodes range. Do not exceed the center of the range for

x-ray quality deposits.

Use a Drag Technique – Tip the electrode 10 to 30° in the direc-

tion of travel and make stringer beads. Weld with the electrode

end lightly dragging on the work to force the molten metal out

from under the electrode tip allowing adequate penetration. The

smooth welds look almost like automatic welds.

-9-

Travel fast, but not too fast for good slag coverage. Stay about

1/4” to 3/8” ahead of the molten slag. If travel speed is too slow,

a small ball of molten slag may form and roll ahead of the arc

causing erratic bead shape, spatter, and poor penetration.

Deep Groove Groove Welds – To hold the large pool of molten

weld metal from Jetweld electrodes, either a weld backing plate

or a root pass made with deep penetrating electrode (usually

E6010 or E6011) is required. Deposit Jetweld beads with a

stringer technique or a slight weave to obtain fusion to both

plates. Split weave welds are better than a wide weave near the

top of deep grooves. Size the second to last layer so the last

layer will not exceed a 1/16” buildup.

1/8" root gap between

electrode coating and plate

Slow travel

Fused metal Plate

WRONG

Fast Travel

Fused metal

Electrode coating

touches plate lightly

Plate

RIGHT

60 to 80°

Slag

-10-

Fillet and Lap Welds – The ideal fillet or lap weld has equal legs

and a flat or slightly convex bead. Excess convexity wastes weld

metal. A concave bead is susceptible to shrinkage cracks.

Flat fillet and lap welds are made with the same general

techniques as groove welds.

Weld single pass fillets using a drag technique with the tip of the

electrode touching both plates. Usually weld with the electrode

at a 45° angle (end view) from the horizontal plate. However,

adjust this angle from as little as 30° to as much as 60° when

required to maintain equal leg sizes on both plates.

When two passes are needed, deposit the first bead mostly on

the bottom plate. To weld the second pass hold the electrode at

about 45° angle fusing into the vertical plate and the first bead.

Make multiple pass horizontal fillets as shown in the sketch. Put

the first bead in the corner with fairly high current even though

there may be slight undercut, succeeding passes will burn it out.

Deposit the second bead on the horizontal plate fusing into the

first bead. Hold the electrode angle needed to deposit the filter

beads as shown, putting the final bead against the vertical plate.

End view Side view

45°60°

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