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Electric Welding 3 Course: Techniques of Electric Welding. Methodical Guide for Instructors............1
0. Introductory remarks...........................................................................................................................1
1. Fillet welding in the verticalup position.............................................................................................2
1.1. Welding the root pass...............................................................................................................3
1.2. Welding the cover pass.............................................................................................................6
1.3. Evaluation of the finished fillet weld..........................................................................................7
2. V type welding in the verticalup position...........................................................................................9
2.1. Welding the root pass...............................................................................................................9
2.2. Welding the inner passes........................................................................................................10
2.3. Welding the cover pass...........................................................................................................12
3. V type welding with 5 tacks...............................................................................................................13
3.1. Preparation of the specimen plates.........................................................................................13
3.2. Tacking the V type welds........................................................................................................14
3.3. Welding the tacks in the gravity position.................................................................................14
3.4. Welding the tacks in the verticalup position..........................................................................16
3.5. Evaluation of the finished tacks...............................................................................................16
4. Welding a profile joint with a root pass and two cover passes.........................................................17
4.1. Preparation of the welding specimen......................................................................................17
4.2. Tacking the specimen.............................................................................................................18
4.3. Welding the profile joint...........................................................................................................18
4.4. Welding the root pass.............................................................................................................18
4.5. Welding the first cover pass....................................................................................................20
4.6. Welding the second cover pass..............................................................................................20
4.7. Evaluation of the welded profile joint.......................................................................................21
5. Fillet welding in the semioverhead position......................................................................................22
5.1. Welding the root pass.............................................................................................................22
5.2. Welding the first cover pass....................................................................................................24
5.3. Welding the second cover pass..............................................................................................24
5.4. Evaluation of the finished fillet weld........................................................................................25
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Deutsche Gesellschaft fr
Technische Zusammenarbeit (GTZ) GmbH
Institut fr berufliche Entwicklung e.V.
Berlin
Original title:
"ESchweien 3"
Author: Dietmar Mhs
First edition IBE
Institut fr berufliche Entwicklung e.V.
Parkstrae 23
13187 Berlin
Order No.: 90320603/2
0. Introductory remarks
These methodical instructions have been elaborated in order to impart knowledge, capacities and skills in
electric welding.
It is the purpose of the methodical instructions to give aid and support to an instructor for practical vocational
training in the preparation and realization of his instructional work. What is suggested to the instructor are
possible ways to reach the goals of his pedagogical activities.
The methodical instructions are organized in such a way that the trainees are systematically informed of
fillet welding in the verticalup position,
V type welding the verticalup position,
V type tacking, 5 tacks,
welding a profile joint, root pass and two cover passes, and fillet welding in the
semioverhead position.
The preparation of the welding specimens (plates), the selection of the electrodes and the respective
electrode manipulation as well as the evaluation of the welds are the most important points to be considered.
Learning the above mentioned skills of welding and welding positions carries on the task of Parts I and II of
Electric Welding instructions. The order of succession of learning the weld types and welding positions was
determined on the basis of experience gained in the training of electric weldors. Thus mastering the weld
types and welding positions described in Parts I and II of the Electric Welding instructions is prerequisite to
learning the weld types and welding positions explained in the present instructions. Having passed the
examination, the trainees are authorized to weld
fillet welds in the verticalup position and the semioverhead position,
V type weld in the verticalup position,
V type welds with 5 tacks,
profile joints with a root pass and two cover passes on plates and profiles with a thickness
of 6 12 mm.
3.25 mm
120... 160 A
arc starting
45
45
2 cover passes
1 cover pass
4.00 mm
electrode
3.25 mm
170 A
amperage
110... 120 A
The procedure before welding the root pass is as described in the instructions for horizontal fillet welding.
Fig. 8 Weld gage (1) for measuring the fillet weld height
For verticalup fillet welds, the permissible tolerance of the weld height is + 2.0 0,5 mm
Fracture appearance
To evaluate the fracture appearance, break the fillet weld specimen in a suitable fixture.
The criteria for evaluating the fracture appearance are as follows:
Melting of the web plate edge
Slag inclusions
Porosity
Lack of fusion
Thereafter evaluate the results of work. Take concrete examples to discuss weld faults and their causes.
Evaluation of the Section "Verticalup fillet welding"
After finishing the training section of fillet welding, the trainees should have acquired the following knowledge,
capabilities and skills:
Obeying the labour safety regulations including order and cleanliness at the working place
Preparation of the welding specimen
Mattering verticalup fillet welding
Recognition of typical welding faults in fillet welds
Evaluation of their own work.
Examples of questions on the Section "Verticalup fillet welding"
1. Describe the weld buildup of a verticalup fillet weld.
2. What are the typical welding faults which occur in verticalup fillet welding?
How can these faults be avoided?
3. Explain the marking of the welding electrodes used.
4. What are the dangers the weldor is faced with in his work?
How can he protect himself from such dangers?
V type weld
Gravity position
verticalup position
electrode
type "Titan" E 43
4 RR (B) 22
red colour marking
weld
reinforcement
0, +2.5 mm
Fig. 9 Electrode manipulation for welding the inner passes and the cover pass
Mind the arc blow effect in this case, too. It is counteracted in the same way as in welding
the root pass.
According to the basical representation of the electrode manipulation, give to the trainees the following
instructions for welding the inner passes.
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Take care that the amplitude of the weaving motion is not too broad. The outer edge of the electrode
coating must not move beyond the existing bead width.
If the weaving amplitude is broader, then too large a molten bath results and the weld
metal flows down in the centre, which leads to a high reinforcement of the inner pass.
The electrode is to melt to a length of 40 mm.
After the first inner pass has been welded and cleaned from slag and spatter, the next
inner pass can be welded.
All the inner passes are welded in the same way as the first one, only the amperage can
be reduced by 20... 30 A. The electrode manipulation can be maintained without any
change.
Fig. 10 Poor and good bead ripple pattern of the cover pass
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Fig. 11 Electrode position for avoiding undercuts at the side walls of the seam
To avoid overheating of the weld, it is necessary to have a short interruption after each pass
in order to provide for the cooling required.
After finishing all the inner passes, the upper edge of the last inner pass should be 1... 1.5
mm below the plate surface.
The remaining edge allows an orientation in welding the cover pass.
The end craters of all inner passes should be filled very carefully. This is achieved by
shortening the arc.
After finishing the inner pass welding, clean the weld carefully from slag residues and spatter. Check the
uniformity of the last inner pass. Unevennesses should be smoothed out by chipping. A successful welding of
the cover pass depends critically on the appearance of the last inner pass.
12
Take care to draw the arc most quickly over the centre of the seam in order to avoid an
excessive buildup of weld metal.
When welding the cover pass, do not weld beyond the plate edge on the right and left sides
of the seam.
When the arc is restarted, this should be done in the middle of the end crater. The end
crater is filled by slow weaving. Subsequently the welding operation is continued in the usual
thythm.
Evaluation of the Section "Verticalup V type welding"
Having finished the training section on V type welding, the trainees should have acquired the following
knowledge, capabilities and skills:
Obeying the labour safety regulations including order and cleanliness at the working place
Preparation of the welding specimen
Mattering V type welding in the verticalup position
Recognition of typical faults in V type welds
Evaluation of their own work
Examples of questions on the Section "Verticalup V type welding"
1. Describe the buildup of a V type weld in the verticalup position.
2. Explain the marking and the properties in use of the welding electrode employed.
3. What are your possibilities of obtaining a uniform root formation by electrode manipulation?
A. How do you counteract the arc blow effect in verticalup welding?
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14
15
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4. Welding a profile joint with a root pass and two cover passes
The hitherto acquired skills in electric welding are prerequisite to the discussion of the following section. To
begin with, clarify and recapitulate, respectively, the concepts of a profile joint, the root, cover passes and the
horizontal position.
Let one of the trainees explain and illustrate the concepts of root and cover passes by means of a blackboard
sketch before the other trainees.
17
Fig. 15 Channel profile tacked on the base plate; the figure indicates the welding sequence
Now place the tacks No. 1, 2 and 3. Clean the tack spots from slag and the welding specimen from possible
spatter. Check the proper tacking of the welding specimen by the trainees.
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19
After root welding has been finished, clean the specimen carefully from slag residues and spatter.
Check the root weld for the central arrangement of the root pass and for possible welding faults such as
porosity, slag pockets and undercutting.
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21
1. What are the measures you take to counteract the arc blow effect in welding a profile joint?
2. What are the dangers a weldor is faced with by weld spatter?
How do you protect yourself from spatter?
3. Explain the welding sequence in welding a profile joint.
4. What is the effect of the welding amperage on the weld appearance?
Fig. 21 Fillet weld specimen clamped in a positioning fixture in the semioverhead position
Sequence of operations in fillet welding:
Adjust the amperage to appr. 140 A.
Start the arc at the left outer edge of the fillet weld.
Weld the root pass as a string bead.
In doing so, consider that at the beginning of the root welding the fillet weld specimen is still
cold and must first be preheated with a longer arc.
After one or two centimeters of the root pass, the arc can be shortened to its normal length.
Generally, use as short an arc as possible in semioverhead welding.
To obtain a symmetrical, central weld buildup, the electrode position must be such that an
angle of 70 between the electrode and the boom plate is exactly maintained.
22
Fig. 23 Electrode manipulation for minimizing the influence of the arc blow effect
Discuss the consequences of disregarding the arc blow effect with the trainees.
This may lead to welding faults such as
an interrupted seam,
slag inclusions,
heavy spattering at the side walls of the seam, etc.
For the seam length of 200 mm, an electrode change will be required.
Tell the trainees to proceed as follows:
Clean the seam end from slag and spatter. Start the arc with the new electrode in the lower part of the end
crater. A gradual preheating is absolutely required in order to melt the end crater, which is achieved by a slight
weaving motion with a long arc. Start the actual depositing of weld metal not earlier than at the moment when
the weld metal threatens to flow off. A slight overhang of the weld is better than a lack of fusion. If necessary,
remove the weld overhang by chipping.
23
Take care that the end crater of the root pass is properly filled. This is achieved by
shortening the arc.
After the root pass has been finished, the fillet weld is carefully cleaned from slag and spatter.
Slag residues and slag pockets cannot be removed by overwelding.
Check the root weld for the central position of the root pass and for possible welding faults such as porosity,
slag pockets and undercutting.
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