PRACTICES SMAW 01

PRACTICE NAME ASSEMBLE ANGLE T JOINT

PROCESS SMAW GMAW GTAW
POSITION ALL
FILLER ALL
MACHINE SETTINGS SET FOR ELECTRODE AND POSITION

Technique: assemble and tack weld two pieces of 1 ¼ angle six inches long as shown
above and run welds in the position of the practice until the angle is completely full of
weld on all sides.

PRACTICES SMAW 02
PRACTICE NAME FILLET WELD
PROCESS SMAW
POSITION FLAT
FILLER E-7018 1/8 ELECTRODES
MACHINE SETTINGS DCRP 130-150 AMPS

Technique: Set the Amperage on DCRP 130 to 150 and using E-7018 Electrodes place a
weld between the joint. Hold the Electrode 90 degrees to the joint as shown above.
Change angle of Electrode slightly to overlap next weld beads evenly until the joint is full
of weld.

Once the arc is struck the electrode may lightly touch the metal or a slight arc length may
be maintained.

Slag each weld bead before applying the next.

Travel from left to right on all weld beads first, and then practice alternating direction.

FOR ALL SMAW PRACTICES

BURN ALL ELECTRODES DOWN AS LOW AS POSSIBLE

PRACTICES SMAW 03

PRACTICE NAME HORIZONTAL T JOINT

PROCESS SMAW
POSITION HORIZONTAL
FILLER E-7018
MACHINE SETTINGS DCRP 150-160 AMPS
Technique: set the Amperage and weld the first bead using the angles shown above.
Adjust the angle slightly to overlap the first bead with the second and third weld beads.

Continue to weld beads from the bottom up overlapping each bead in half until the joint
is filled.

Watch for the weld puddle to split the center of the bead under it to keep it straight and
for proper placement.

PRACTICES SMAW 04

PRACTICE NAME FILLET WELD

PROCESS SMAW
POSITION FLAT
FILLER E-6010
MACHINE SETTINGS 90-110

Technique: Set the Amperage on DCRP 90 to 110 and using E-6010 Electrodes place a
weld between the joint. Hold the Electrode 90 degrees to the joint as shown above.
Change angle of Electrode slightly to overlap next weld beads evenly until the joint is full
of weld.

Once the arc is struck the electrode may lightly touch the metal or a slight arc length may
be maintained.

Slag each weld bead before applying the next.

Travel from left to right on all weld beads first, and then practice alternating direction.

Notice the difference in the appearance between the E-7018 Electrode and the E6010
Electrode. While the 7018 produces a thicker smoother weld bead with a heavy slag and
medium penetration, the 6010 produces a flatter weld bead with pronounced ripples
thinner slag and deep penetration.

PRACTICES SMAW 05

PRACTICE NAME HORIZONTAL T JOINT

PROCESS SMAW
POSITION HORIZONTAL
FILLER E-6010
MACHINE SETTINGS DCRP 90-110 AMPS

Technique: set the Amperage and weld the first bead using the angles shown above.
Adjust the angle slightly to overlap the first bead with the second and third weld beads.
Continue to weld beads from the bottom up overlapping each bead in half until the joint
is filled.

Watch for the weld puddle to split the center of the bead under it to keep it straight and
for proper placement.

The resulting weld bead is flatter with more pronounced ripples than those produced with
the E-7018 electrode. The E-7018 electrodes have iron powder added to the electrode
covering (Flux). The iron powder and metal available from the core of these electrode
accounts for the heavier, smoother weld bead.

The E-6010 electrode provides a hotter arc that cuts through dirty, rusty, or painted
surfaces and produces a weld with a flatter profile, lighter slag covering and deep
penetration.

PRACTICES SMAW O6

PRACTICE NAME VERTICAL TEE JOINT 03

PROCESS SMAW
POSITION VERTICAL DOWNWARD
FILLER E-6010
MACHINE SETTINGS DCRP 100-110 AMPS
Technique: Set the welding Amperage on DCRP 100-110 and starting at the top of the
joint, hold the correct travel angle, start the arc, and weld down the joint.

There should be no side to side or weave technique used and the weld bead should be
about the size of the electrode including the flux.

Change the angle slightly to overlap a series of weld beads from one side of the joint to
the other. Completely fill each side of the angle assembly.

PRACTICES SMAW 07

PRACTICE NAME FILLET WELD T JOINT

PROCESS SMAW
POSITION VERTICAL UP WEAVE
FILLER E-6010
MACHINE SETTINGS DCRP 90-110 AMPS

Technique: set the welding machine for DCRP at 90-110 amps and weld vertical upwards
from the bottom of the joint to the top using the weave technique.

The vertical up weave is similar to the vertical up stringers except each pass is weaved
from side to side and completely covers the prior weld bead.

The initial amperage (or heat) setting may need to be increased slightly when weaving
wider than the first three passes.

Pause in each corner to allow proper filling and weld formation. The weld appearance
will be flat with a pronounced ripples.
 PRACTICES SMAW 08

PRACTICE NAME VERTICAL UP T JOINT

PROCESS SMAW
POSITION VERTICAL: UPWARD STRINGERS
FILLER E-6010
MACHINE SETTINGS DCRP 90-110 AMPS

Technique: Set the correct amperage on the machine and weld from the bottom of the T
joint to the top.

Use a slight weave from side to side as you move up the joint. The closer the weave
pattern the better.

The weld bead width should be approximately 1 ½ times the diameter of the electrode.

Place the second and third weld beads as shown above, keeping them the same size and
allowing them to overlap half of the prior weld bead.
The side to side weave shown should be quick enough to produce a bead of the proper
width, without being too high in the center. Pause slightly in each corner of the weave
pattern similar to the motion of a windshield wiper.

Fill each side of the angle assembly flush with weld beads.

PRACTICES SMAW 09

PRACTICE NAME FILLET WELD T JOINT

PROCESS SMAW
POSITION VERTICAL UP WEAVE
FILLER E-7018
MACHINE SETTINGS DCRP 125-150 AMPS
Technique: set the welding machine for DCRP at 125-150 amps and weld vertical
upwards from the bottom of the joint to the top using the weave technique.

The vertical up weave is similar to the vertical up stringers except each pass is weaved
from side to side and completely covers the prior weld bead.

The initial amperage (or heat) setting may need to be increased slightly when weaving
wider than the first three passes.

Pause in each corner to allow proper filling and weld formation. The weld appearance
will be flat to slightly round with a smooth appearance.

PRACTICES SMAW 10

PRACTICE NAME OVERHEAD T JOINT

PROCESS SMAW
POSITION OVERHEAD
FILLER E-6010
MACHINE SETTINGS DCRP E-6010 90-110 AMPS
Technique: Set the welding machine on DCRP 90-100 amps for E-6010 electrodes. Weld
the assembled angle joint in the overhead position using E-6010 Electrodes. Hold the
electrode as indicated and weld from one end of the joint to the other. A slight push or
drag method may be used.

In the Overhead position maintain travel speeds that result in a weld bead that is flat and
well formed. Slow travel speeds result in a large bead being deposited at is difficult to
overlap and blend in. Travel speeds that are too fast result in a thin stringy bead with little
penetration.

Continue to run stringer beads until the entire angle is filled with weld.

PRACTICES SMAW 11

PRACTICE NAME OVERHEAD T JOINT

PROCESS SMAW
POSITION OVERHEAD
FILLER E-7018
MACHINE SETTINGS E-7018 125-150 AMPS

Technique: Set the welding machine on DCRP 125-150 amps for E-7018 electrodes.
Weld the assembled angle joint in the overhead position using E-7018 Electrodes. Hold
the electrode as indicated and weld from one end of the joint to the other. A slight push or
drag method may be used.

In the Overhead position maintain travel speeds that result in a weld bead that is flat and
well formed. Slow travel speeds result in a large bead being deposited at is difficult to
overlap and blend in. Travel speeds that are too fast result in a thin stringy bead with little
penetration.

Continue to run stringer beads until the entire angle is filled with weld.
 PRACTICES SMAW 12

PRACTICE NAME ASSEMBLE GROOVE WELDS

PROCESS SMAW
POSITION FLAT HORIZONTAL VERTICAL OVERHEAD
FILLER E-7018
MACHINE SETTINGS DCRP 150 – 165 AMPS
Technique: The Instructor will use the track burner to cut beveled plates then cut a
backing bar for assembling the groove.

The student will remove burning slag and grind the groove face for welding.

The instructor will assist you in aligning and assembling the groove joint and setting it in
the welding position.

Remember: we add two more beveled pieces to make 3 welded joints before discarding

PRACTICES SMAW 13

PRACTICE NAME FLAT POSITION VEE GROOVE

PROCESS SMAW
POSITION FLAT 1G
FILLER E-7018
MACHINE SETTINGS DCRP 130-165 AMPS
Technique: Place the groove in the flat position and weld the root pass against the
backing bar, then continue welding stringers until the joint is filled. The cover passes
should not exceed 1/8 inch high or be more than 1/8 over each side of the groove.

PRACTICES SMAW 14
 PRACTICE NAME HORIZONTAL POSITION VEE GROOVE
PROCESS SMAW
POSITION HORIZONTAL 2G
FILLER E-7018
MACHINE SETTINGS DCRP 130-165 AMPS

Technique: Place the groove in the Horizontal position and weld the root pass against the
backing bar, then continue welding stringers until the joint is filled. The cover passes
should not exceed 1/8 inch high or be more than 1/8 over each side of the groove.
 PRACTICES SMAW 15

PRACTICE NAME VERTICAL POSITION VEE GROOVE 3G

PROCESS SMAW
POSITION 3G VERTICAL UPWARD
FILLER E-7018
MACHINE SETTINGS DCRP 130-165 AMPS
Technique: Place the groove weld in the Vertical up position and weld the first pass
against the backing strip using the side to side weave motion. Slag and continue weld
passes until joint is filled flush. The final cover pass should not be more than 1/8 inch
high and not more than 1/8 inch over the edge of the groove.

PRACTICES SMAW 16

PRACTICE NAME OVERHEAD POSITION VEE GROOVE

PROCESS SMAW
POSITION OVERHEAD 4G
FILLER E-7018
MACHINE SETTINGS DCRP 130-165 AMPS
Technique: Place the groove in the Overhead position and weld the root pass against the
backing bar, then continue welding stringers until the joint is filled. The cover passes
should not exceed 1/8 inch high or be more than 1/8 over each side of the groove.