Operating Instructions and Parts Manual

WS4369 and WS4469

 

 

Welding Guidelines (Continued)

Commonly Used Electrodes

1.E-6011 Deep Penetrating

The strong arc force and rapid solidification of the metal makes vertical and overhead welding easier with this rod.

Where time does not permit rust, scale or paint removal, this rod penetrates rapidly and easily.

Acceptable for AC or DC welding current (reverse polarity).

2.E-6013 General Purpose

All position, smooth deposit rod with low spatter.

For all mild steel and general purpose work.

Acceptable for AC or DC welding current (straight or reverse polarity).

3.E-7014 Iron Powder

A general purpose "drag" rod for all positions.

Ideal for situations where fit between metal pieces is poor.

The iron powder in the flux coating combines with the filler rod to make a smooth deposit with very little spatter.

Ideal for ornamental work.

Acceptable for AC or DC welding current (reverse polarity).

4.E-7018 Low Hydrogen

An all position high strength electrode designed to produce low hydrogen content combined with excellent mechanical properties.

Acceptable for AC or DC welding current (reverse polarity).

Current

The correct current involves the adjustment of the welding machine to the required amperage setting. Current represents the actual flow of electricity and is regulated by a knob on the welder. The current used depends on the size (diameter) and type of electrode used, position of the weld, and the thickness of the work piece.

Consult specifications listed on the electrode package or generalized chart in the Operation section. Excessive current burns through light metals, and the weld bead is flat and porous or the bead undercuts the work piece (See Figure 8). The bead appears high and irregular if the current is too low.

Weld Angle

Weld angle is the angle at which the electrode is held during the welding process. Using the correct angle ensures proper penetration and bead formation. As different welding positions and weld joints become necessary, electrode angle becomes an increasingly important factor in obtaining a satisfactory weld. Electrode angle involves two positions - travel angle and work angle (See Figure 7).

5º - 45º

TravelAngle

WorkWorkAngleAngle

Figure 7 - Weld Angle

Travel angle is the angle in the line of welding and may vary from 5º to 45º from the vertical, depending on welding conditions.

Work angle is the angle from horizontal, measured at right angles to the line of welding.

For most applications, a 45º travel angle and 45º work angle is sufficient. For specific applications, consult an arc welding handbook.

Note: Right handed welders should weld from left to right. Left handed

welders should weld from right to left. The electrode should always point into the weld puddle as shown.

Arc Length

Arc length is the distance from the work piece to the tip of the electrode, the distance which the arc must travel. A proper arc length is essential to generate the heat needed for welding (See Figure 8). An arc that is too long produces an unstable arc, reduces penetration, increases spatter, and causes flat and wide beads. Too short an arc does not create enough heat to melt the work piece, the electrode has a tendency to stick, penetration will be poor, and uneven beads with irregular ripples result. A proper arc should be no longer then the diameter of the rod. The sound of a proper arc is a steady, crisp sizzle, similar to bacon frying.

Travel Speed

The travel speed is the rate at which the electrode is moved across the weld area. Factors such as diameter and type of electrode, amperage, position, and work piece material thickness all effect the speed of travel necessary for completing a good weld (See Figure 8). When the speed is too fast, the bead is narrow and bead ripples are pointed as shown. When the speed is to slow, the weld metal piles up and the bead is high and wide.

Slag Removal

Wear ANSI approved safety glasses (ANSI Standard Z87.1) and protective clothing

when removing slag. Hot, flying debris can cause personal injury to anyone in the area.

After completing the weld, wait for the welded sections to cool. A protective coating called slag now covers the weld bead which prevents contaminants in the air from reacting with the molten metal. Once the weld cools to the point that it is no longer glowing red, the slag can be removed. Removal is done with a chipping hammer. Lightly tap the slag with the hammer and break it loose from the weld bead. The final clean-up is done with a wire brush. When making multiple weld passes, remove the slag before each pass.

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