STICK WELDING 101: Getting Started With SMAW

Summary

This instructional video script delves into the basics of stick welding, focusing on shielded metal arc welding. It explains the setup process, the importance of electrode selection, and the impact of polarity on welding performance. The presenter demonstrates techniques for using different rods, including E6010, E6011, E6012, and 7018, highlighting their unique characteristics, amperage settings, and ideal applications. The script emphasizes correct rod angle, arc length, and amperage for effective welding, providing a foundational guide for beginners in the field.

Takeaways

• 🔧 Shielded Metal Arc Welding (SMAW), also known as stick welding, is a simple process with few variables, primarily focused on the electrode rod.
• 🌐 The setup for stick welding involves connecting the ground or work cable to the negative side of the machine and the electrode holder to the positive terminal.
• 🔋 Polarity can be switched on some machines, or physically moved for DCEN or DCEP, with some machines also offering AC output for different welding positions.
• 👨‍🔧 Electrodes, such as E6010, have a numbering system indicating tensile strength, position capability, and flux makeup, affecting welding characteristics.
• ⚒ E6010 rods are designed for DCEP only and offer a violent, digging, fast freeze weld pool suitable for various positions but not for vertical up or down welding.
• 🔥 The technique for stick welding involves maintaining a proper angle, not using extreme angles, and directing the arc into the material with a slight rocking motion.
• 🌟 E6010 produces a fair amount of spatter and a light crystally flux that is hard to remove, requiring cooling and gentle scraping or brushing.
• 🔄 E6011 rods are similar to E6010 but can also run on alternating current, offering versatility in welding conditions.
• 🛠 E6012 rods have a soft arc, dense slag that peels off easily, and can be used with any polarity, making them suitable for various welding applications.
• 🏞 E7018 rods are versatile for all positions but are best for vertical uphill welding due to the low hydrogen flux that prevents porosity and offers good mechanical properties.
• 📚 The script emphasizes the importance of understanding rod characteristics, amperage settings, and welding techniques for effective and safe stick welding.

Q & A

What is shielded metal arc welding commonly referred to as?

Shielded metal arc welding is commonly referred to as stick welding.

What are the main components connected to the machine during stick welding setup?

During stick welding setup, the ground or work cable is connected to the negative lead or lug on the machine, and the electrode holder, also known as the stinger, is connected to the positive terminal.

What are the three types of polarities mentioned for stick welding machines?

The three types of polarities mentioned for stick welding machines are alternating current (AC), DC electrode positive (DCEP), and DC electrode negative (DCEN).

What does the number '6010' in the electrode classification indicate?

In the electrode classification '6010', the first two numbers '60' indicate the tensile strength of 60,000 pounds, the third digit '1' indicates it can be used in all positions, and the last digit '0' refers to the flux makeup and characteristics.

Why is the E6010 rod designed to run only on DCEP?

The E6010 rod is designed to run only on DCEP due to its flux makeup and electrical characteristics, which provide a violent, digging, fast freeze type of weld pool suitable for gouging and welding in all positions except vertical down.

What is the difference between E6010 and E6011 electrodes?

The main difference between E6010 and E6011 electrodes is that E6011 can run on both alternating current and DCEP, unlike E6010 which is limited to DCEP only.

What technique is demonstrated with the E6010 rod to create a weld bead?

A technique demonstrated with the E6010 rod to create a weld bead is using a very slight rocking motion while maintaining a short arc length and a gentle pitch.

Why should one avoid using extreme angles when stick welding?

Using extreme angles when stick welding can lead to improper penetration and uneven weld beads. It's important to direct the arc down into the material with a slight angle for effective welding.

What is the slag produced by the E6010 rod like, and how should it be removed?

The slag produced by the E6010 rod is light and crystally, not easy to remove connected. It should be allowed to cool and then removed using a grinder with a wire wheel or a hand wire brush.

What are some of the common techniques used when stick welding with E6010 and E6011 rods?

Some common techniques used when stick welding with E6010 and E6011 rods include the whip, stitch, and a gentle rocking or dragging motion to control the weld pool and create a consistent bead.

What is the main characteristic of the E6011 rod when used with alternating current?

When used with alternating current, the E6011 rod has a soft, smooth arc with a slightly different sound compared to DCEP, and it doesn't penetrate or dig as much due to the nature of AC.

What is the purpose of the E7018 rod, and what makes it suitable for all positions welding?

The E7018 rod is designed for all positions welding due to its low hydrogen flux, which provides soft to medium penetration and good mechanical properties. It is suitable for a variety of applications, including farm and general-purpose welding.

Why should the E7018 rod not be used for vertical downhill welding?

The E7018 rod should not be used for vertical downhill welding because its slag is too fluid and can run down in front of the weld pool, leading to potential slag inclusion and poor weld quality.