Shielded Metal Arc Welding: Mild Steel I (E7018)
Shielded Metal Arc Welding: Mild Steel I (E7018)
Shielded Metal Arc Welding: Mild Steel I (E7018)
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Index
Course Information
3-5
7-8
9-11
Science on Science
12-19
20
Welding Projects
21-35
Final Exam
36-39
40
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Introductory Statement
Weld 112, Shielded Metal Arc Welding: Mild Steel I (E7018) is an intermediate welding course offered
at Portland Community College. This class will assist the student in developing the techniques needed
when using low hydrogen electrodes. This course utilizes a lecture/lab format includes classroom
discussions and lab demonstrations. Student will develop knowledge and manipulative skills in the use
of E7018 mild steel electrodes when performing various welds in the flat, horizontal and vertical
positions. Topics covered will include safety, uses, nomenclature, equipment operation and set-up and
shutdown procedures for oxy-acetylene cutting and shielded metal arc welding.
This is an outcome-based course that will allow the student to work at his/her own pace. The student will
be required to follow all safety regulations and complete common cutting and welding projects in
accordance with industry standards. The student is expected to complete all the exercises within this
training packet to receive a grade for this course. Please read the packet and pertaining materials
thoroughly and enjoy the course.
Operate oxyacetylene portable and track cutting systems in accordance with industry standards
Demonstrate correct setup and shutdown procedures for the hand cutting and track cutting
systems.
Perform oxyacetylene cutting with guided practice.
Interpret drawing and symbols to accurately layout, prepare and assemble weld joints
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Weld common joints with the E-7018 electrode to code quality standards in the flat, horizontal and
vertical positions.
Course Assignments
Reading
Welding Principles and Applications, Jeffus, Larry.
Chapter 3, Shielded Metal Arc Equipment, Setup, and Operation
Chapter 4, Shielded Metal Arc Welding of Plate
Chapter 20, Welding Joint Design and Welding Symbols
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Math
Practical Problems in Mathematics, Robert Chasan
Chapter 5, Introduction to Common Fractions
Chapter 6, Measuring Instruments: The Tape Measure, Calipers, and Micrometer
Chapter 7, Addition of Common Fractions
Chapter 8, Subtraction of Common Fractions
Recommended assignments
Complete review question following each assigned chapter
Cutting Projects
Complete Bill of Materials
Welding Projects
E7018 Bead Plate (Surfacing)
E7018 Corner Joint (1F)
E7018 T-Joint (2F)
E7018 Single V Grove Weld (2G)
E7018 T-Joint (3F)
Final Exam
Part One (Closed Book Exam)
Part Two (Practical Exam)
Reference List
IPTs Metal Trades Handbook, Garby, Ronald and Ashton, Bruce.
Time Line:
Open-entry, open-exit instructional format allows the student to work at his/her own pace. Its the
students responsibility for completing all assignments in a timely manner within your pre-scheduled
time. See your instructor for assistance.
Outcome Assessment Policy:
The student will be assessed on his/her ability to demonstrate the achievement of course outcomes. The
methods of assessment may include one or more of the following: oral or written examinations, quizzes,
written assignments, visual inspection techniques, welding test, safe work habits, task performance and
work relations.
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Accessing the Interactive ebook for Principles and Applications and Practical
Problems in Mathematics
Here is a link to the publishers website that goes over some getting started procedures
with CourseMate.
http://www.cengage.com/tlconnect/client/product/fcis.do?productId=535
For New Students
Your book bundle will contain an access code for both your Principles and Applications
book and the Practical Problems in Mathematics.
For Returning Students
If you have the Seventh Edition of the Principles and Applications book you should have
an access code. If not see your instructor. For the math book you will have to go to this
site http://www.cengagebrain.com/shop/isbn/9781111313593 and rent the ebook for either a six
month or one year option.
Your math quizzes will be accessible through Desire 2 Learn. Your Instructor will assist you in
accessing this.
Course Key There will be a master course key containing all of the courses available on CourseMate.
You will find the course you are currently taking and enter the corresponding number in the appropriate
area in CourseMate.
Note For each class there will be separate Access code and course key for Principles and
Applications and Practical Problems in Mathematics
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Blueprint
Reading
Basics
for
Welders
Note: your text book has a chapter dedicated to print reading. Make sure
you review that too.
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Definitions of Lines
Lines are the basic communication tool used in blueprints. Listed below are examples of the most
common lines used in blueprints today. Take the time to memorize each type of line and know its uses.
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Helpful Hints
Arc Length E7018
Due to the nature of low hydrogen electrodes it is critical to maintain a short and consistent
arc length. This will maximize the shielding gas coverage for the weld puddle. Arc length
can be determined by sight and sound.
1st If the arc is to long you will see the globular transfer.
2nd
If it is too short you will see slag wanting to explode from the puddle and youll
hear an electrical humming sound.
3rd
The correct arc length will be between those two indicators.
Remember: The recommended Arc Length is equal to electrode diameter. It should not
exceed the diameter of the electrode at any time. If you remember this youll never have
trouble with porosity.
Starting/Restarting Technique
When starting or restarting the arc it is important to obtain a sound weld.
Therefore, the following technique should be employed.
1st Locate where you want to start. This is important so that you do not have arc
strikes all over the parent material.
2nd Utilize the tap or scratch method to initiate the arc.
3rd Start the arc directly ahead of the crater.
Once arc is started establish a long arc with an upward stroke initiation. It
is here where an extra quick movement is necessary because the E7018
has a high likelihood of sticking, you will need to pull the electrode away
quickly but yet maintain a short enough arc to keep it going. This balance
is difficult at first, but will come with time.
The purpose of this is as follows:
A. Preheats the parent metal
B. Allows gaseous shield to be established
C. Allows the amperage to flow so the heat will build up
D. Gives off light to find the crater
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4th Precede back to the crater. Once there, drop the electrode into its normal arc length
and circle in the crater and then start to travel with the normal travel speed.
By circling in the crater you accomplish two things:
A. Its a timing device used to fill the crater flush with the weld
bead.
B. It will help drive out any slag/porosity that may of other wise it
becomes entrapped.
The E7018 is easier to initiate with a new rod than a used rod. However, when restarting a
used rod, it is important to note that the flux surpasses the core wire. The core wire also tends
to have a slag covering on it as well. These two items make it more difficult to initiate the
arc. Hence, if you scrap the end of the rod off before striking it will light up easier. Take care
not to break away any excessive coatings off the end of the rod. The flux coatings helps
stabilize the arc without the flux it will make arc initiation troublesome.
Quick flick technique when terminating your arc will allow a globular ball to fly off the end of
the electrode. This glob will take the slag off the end of the rod. Thus allowing an easier
restart.
5th
REMEMBER:
The quality of welds produced depends largely upon the skill of the welder.
Developing the necessary skill level requires Practice. However, practicing the
welds repeatedly without changing techniques will not aid in developing the
required skills. Each time a weld is completed it should be evaluated, and then
a change should be made in the technique to improve the next weld.
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Science
on
Steel
The Welding Fabrication Industry needs qualified welder fabricators who can deal with a variety of
situations on the job. This portion of the training packet explores science as it relates to industry
requirements.
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Other sources of hydrogen contamination, which are avoidable with good workmanship practices,
include: oil, grease, paint, dirt, moisture-absorbing rust and other hydrogen-containing materials.
Oil and grease are hydrogen-carbons, which dissociate into free hydrogen and carbon dioxide during
welding. Although hydrogen does not impair arc stability, it does cause serious cracking in the heataffected zones of welds deposited on thick and/or high strength steels.
Hydrogen is the smallest atom in the universe and is an interstitial (a crystalline lattice containing
smaller atoms of a different element within its interstices, voids or holes between the atoms and the
lattice) in iron, so hydrogen can diffuse in steel rapidly even at and below room temperature.
Interstitial atoms like hydrogen are so small compared to iron that they can diffuse between the iron
atoms. That is, the iron atoms do not move while the hydrogen atoms diffuse between the iron atoms.
Because the flux coating can absorb moisture from the air, E7018 electrodes that have been removed
from their hermetically sealed, moisture/water tight containers must be stored in a baking oven. The
electrode exposure to the atmosphere shall not exceed: Four (4) hours maximum. (Table 5.1. AWS
D1.1. The oven is set at a temperature recommended by the manufacturer, which is within the
temperature range specified by the welding code of interest. For example, the D1.5 Bridge Welding
Code specifies baking temperature for E7018 in the range from 250F to 500F. Generally, the
manufactures recommendation will fall within this range. The reason for baking the electrodes is to
effectively evaporate all traces of water or moisture from the flux coating.
Advantages of E7018 Electrode for SMAW
The E7018 electrode for SMAW is often called lime electrode, basic electrode and lowhydrogen electrode. The three primary functions of E7018 electrodes are to provide (1) all-position
capability, (2) weld metal with low hydrogen content for greatest cracking resistance, and (3) Charpy
impact toughness typically required for all code work. Outstanding features of E7018 electrode
include:
All-position welding
Low hydrogen weld deposits
Tough weld metal (having high Charpy V-notch (CVN) impact toughness)
Iron powder addition for improved deposition rate
Required for all welding codes to join thick steel and high strength steels to
prevent hydrogen-assisted cracking
Sound weld deposits (X-ray quality)
Reduced preheating requirements
Either DCEP (reverse polarity) of AC can be used
Moderately heavy slag which is easy to remove
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E7018 Composition
of Weld Metal (wt %)
AWS A5.1
C: not specified
S:
not specified
P:
not specified
Ni: not specified
Mn: 1.60 max
Si: 0.75 max
Cr: 0.20 max
Mo: 0.30 max
Typical
C: 0.05
S: 0.009
P:
0.015
Mn: 1.40
Si: 0.45
Cr: 0.05
Ni
0.05
Mo: 0.03
Mechanical Properties
of Weld Metal
Tensile Strength:
72ksi (500MPa) min
Yield Strength:
60ksi (420MPa) min
% Elongation: 22% min
CVN Toughness:
20ft-lbs @ -20F min
Tensile Strength:
84 ksi (MPa)
Yield Strength:
70 ksi (MPa)
% Elongation: 30%
CVN Toughness:
120ft-lbs @ -20 F
Radiographic Soundness
per AWS A5.1
Diffusible Hydrogen
H4 (4 ml/100g max)
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3 ml/100g
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Arc Blow
The welding current flowing through a plate or any residual magnetic fields in the plate will result
in uneven flux lines. These uneven flux lines can, in turn, cause an arc to move during a weld.
This movement of the arc is called arc blow. Arc blow makes the arc drift as a string would drift
in the wind Arc blow is more noticeable in corners, at the ends of plates and when the work lead
is connected to only one side of a plate. If arc blow is a problem, it can be controlled by
connecting the work lead to the end of the weld joint and making the weld in the direction toward
the work lead. Another way of controlling arc blow is to use two work leads, on each side of the
weld. The best way to eliminate arc blow is to use alternating current. A very short arc length can
help control arc blow.
Arc blow is a phenomenon encountered in DC arc welding when the arc stream does not follow
the shortest path between the electrode and the work-piece but is deflected forward or backward
from the direction of travel or, less frequently, to one side. Unless the arc blow is controlled arc
blow can cause the welder some difficulties in controlling the weld pool and slag. You will have
excessive spatter, possibly cause lack of fusion, slower welding speed, excessive undercut and
will cause weld pool to boil out and leave a large mound of weld in the center of your weld bead
or drip down leaving an ice cycle below your crater.
When electrons flow they create lines of magnetic force that circle around the line of flow. Lines
of magnetic force are referred to as magnetic flux lines. These lines space themselves evenly
along a current-carrying wire. If the wire is bent, the flux lines on one side are compressed
together, and those on the other side are stretched out. The unevenly spaced flux lines try to
straighten the wire so that the lines can be evenly spaced once again. The force that they place on
the wire or cable is usually small. However, when welding with very high amperages, 600 amps
or more, the force may cause the wire or cable to move.
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Reduce the welding current which may require you to slower travel speed
2.
Change angle of electrode with the work opposite the direction of arc blow
3.
Weld away from the ground to reduce back blow weld toward the ground to reduce
forward blow
4.
Wrap ground cable around the work piece and pass ground current through it in such a
direction the magnetic field causing the arc blow
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Cover Pass
Flush to 1/8
1/32 deep
Smooth Transition
None Allowed
None Allowed
None Allowed
See Specification on Print
None Allowed
21
Project #1
Technique
Employ a straight stringer bead technique holding a tight arc length. Allow the puddle to obtain
a 3/8 to 1/2 width and adjust travel speed to keep puddle size consistent. See info sheet on
Striking Arc for helpful hints.
Welding Sequence: Alternate direction of welding for each pass. Weld full length of plate.
Alternate
direction
with each
pass
VT Criteria
Reinforcement (0 1/8)
Undercut (1/32)
Weld Bead Contour
Penetration
Cracks (none)
Arc Strikes (none)
Fusion (complete)
Porosity (none)
Student Assessment
Instructor Assessment
Grade
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Date
22
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Corner Joint 1F
Best of Two
Project #2
Technique:
Use a stringer bead with tight arc. Center the weld in the first pass (root pass) so that it is equally
distributed on to each piece of metal. This is accomplished by adjusting the work angle so that
the bead centers itself. The additional passes should then be laid down to allow the weld
deposits to flow equally on the previous passes and to the parent material. Desired outcome is to
make each individual pass tie into the previous pass(es) and/or parent metal so that a convex
weld is achieved.
Welding Sequence
Alternate directions of welding for each pass.
VT Criteria
Project #1
Project #2
Reinforcement (0
1/8)
Undercut (1/32)
Weld Bead Contour
Penetration
Cracks (none)
Arc Strikes (none)
Fusion (complete)
Porosity (none)
Grade
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Date
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Grade
Date
24
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E7018 T-Joint 2F
Best of Two
Project #3
Technique:
Use a string bead technique with a tight arc length. When running the first pass (root weld) it is
important to center the weld so that it has equal distribution onto each piece of metal. This is
accomplished by adjusting the work angle so that the bead centers itself. Additional passes
should then be laid down to allow the weld deposits to flow equally on the previous passes and to
the parent material. The key is to make each individual pass tie into the previous pass(es) and or
parent metal so that a flat to convex surface is obtained.
When welding any of the passes in the T-joint it is critical to not let any of the slag float ahead of
the electrode. This will cause slag inclusions because the arc is not forceful enough to remove
the slag (see helpful hints section for technique in dealing with this problem). Corners must be
wrapped.
Welding Sequence
Weld the root pass on all four sides of the joint. Rotate the work so that all the welding is
completed in the horizontal position. Notice bead placement starting at the bottom and stair
stepping towards top of parent metal.
Stair Stepping
Project #1
Project #2
Reinforcement (0 1/8)
Undercut (1/32)
Weld Bead Contour
Penetration
Cracks (none)
Arc Strikes (none)
Fusion (complete)
Porosity (none)
Grade
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Date
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Grade
Date
26
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Project #4
Welding Sequence
When running the first pass (root weld) it is important to center the weld so that it has equal
distribution into each piece of metal. This is accomplished by adjusting the work angle so that
the bead centers itself. It is important to drop the angle enough to prevent undercut from
happening on the top toe of the weld bead. Additional passes should then be laid down to allow
the weld deposits to flow equally on the previous passes and to the parent material. Start with
the bottom pass first and use the previous pass as a shelf. This approach is much like walking up
a set of stairs-start at the bottom first. The key is to make each individual pass tie into the
previous pass(es) and or parent metal so that a flat to convex surface is obtained. Dont let your
welds develop cold lap because this can cause slag to be trapped. .
VT Criteria
Reinforcement (0 1/8)
Undercut (1/32)
Weld Bead Contour
Penetration
Cracks (none)
Arc Strikes (none)
Fusion (complete)
Porosity (none)
Student Assessment
Instructor Assessment
Grade
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Date
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Project #5
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WARNING:
If the torch handle and hoses are already connected to the regulators, the system MUST
be evacuated (drained) after every shut-down. Open the oxygen valve turn. Allow the
gas to flow ten seconds for tips up to size 3 and 5 seconds for sizes 4 and larger for each
25 feet of hose in the system. Close the oxygen valve. Evacuate the fuel system in the
same manner.
12. If system is leak free, repeat set-up procedure and prepare to light the torch.
13. Open the fuel valve on the torch handle approximately 1/8 turn. Ignite the gas with a
spark lighter. Be sure the spark lighter is away from the tip and not obstructing the
gas flow.
WARNING:
Wear protective clothing. Use goggles to shield the eyes from bright light.
14. Continue to increase the fuel supply at the torch handle until the flame stops smoking.
15. Slowly open the preheat oxygen control valve and adjust to a neutral flame
16. Since squeezing the cutting oxygen lever changes the gas ratios, further adjustment of
the preheat oxygen may be needed to achieve a neutral flame, with the oxygen lever
depressed.
WARNING:
Inspect the areas where molten metal and sparks will fall. Serious fires and explosions
are caused by careless torch operations. Take all possible precautions. Have fire
extinguishers available. Remove or protect flammable substances, including oxygen and
fuel hoses, before starting to work.
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Step 1
Hold the cutting attachment or torch handle comfortably in both hands. Stabilize the
torch with one hand. Position cutting tip preheat flames approximately 1/8 from the base
metal (this is known as coupling distance or stand off). The other hand is free to depress
the cutting oxygen lever.
Step 2
Direct the preheat flame on the spot where you want to start the flushing. Before the
cutting action can start, preheat the base metal to a bright cherry red. When the red spot
appears, squeeze the oxygen cutting lever slowly and completely.
Start flushing with a slow up and down or rocking motion on back strap down to within
1/8 of an inch of base material to prevent gouging into base material.
Tip pointing up
then rock down
or lower tip to
bottom of back
strap.
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Step 3
While rocking your torch up and down slowly move forward removing about 1/8 to of
an inch of the material stopping about 1/8 of an inch above base metal you are flushing.
You want to travel slow enough to allow molten material to be blown away while
depressing the oxygen lever. You should try to avoid leaving grooves in the base metal,
which could lead to damage
Step forward slightly
Back Strap
Base Metal
1/8 inch of
material left above
base metal
remaining material
must be removed
by grinding.
Slag
VT Criteria
Reinforcement (0 1/8)
Student Assessment
Instructor Assessment
Grade
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Date
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Best of Two
Project #6
Welding Sequence
Vertical up welding requires special attention to heat control. See Vertical Up Info Sheet for
helpful hints.
For multi pass welds first deposit a fillet weld bead by using a slight weave continue up over the
top for a wrap. Deposit additional layers with a slight side to side weave hesitating at the sides
long enough to minimize undercut. When weaving, do not spend time in the middle of the
puddle. It takes care of itself. Do not use a whip technique or take the electrode out of the
molten pool. Travel slowly enough to maintain the shelf without causing metal to spill. Use
currents in the lower portion of the range. You can use a weave or a straight stringer bead.
VT Criteria
Project #1
Project #2
Reinforcement (0 1/8)
Undercut (1/32)
Weld Bead Contour
Penetration
Cracks (none)
Arc Strikes (none)
Fusion (complete)
Porosity (none)
Grade
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Date
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Grade
Date
35
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Final Exam
This portion of the final exam is a closed book test. You may use the review questions you
completed at the end of the assigned chapters as a cheat sheet. Consult with your instructor to
determine items that you may need to review. Once you determine that you are ready for the
exam, see your instructor.
Study Guide
Safety
Oxyacetylene safety
SMAW safety
Hand Tool Safety
SMAW and OAC Processes
Power source specifics
o Electricity
Volts, Amps, Ohms, WATTS
Transformers/rectifiers etc.
o Polarity
DCSP, DCRP, Max penetration
o Current out put
o Amperage settings and bead profiles (for different size electrodes too)
o Arc blow
o Duty Cycle
AWS electrode classification
OAC
o Theory of cutting
o Flame types
o Safety
Welding Symbols and Blueprints
Orthographic views
Isometric views
Welding symbol
o Weld symbols
o Reference line
o Tail
Math and Math conversions
Adding and subtracting fractions
Reading a tape measure
Metric conversions
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Part Two
This portion of the exam is a practical test where you will fabricate and weld a weldment from a
blue print. The evaluation of this portion of the exam will be based on the Traveler.
2nd step
3rd step
4th step
Weld Quality
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Date______________________
Instructors
Evaluation
10 points
10 points
15 points
35 points
Weld Quality
Subtract 1 point for each weld discontinuity,
incorrect weld size and incorrect spacing sequence.
Minimum points acceptable. This equates to the
minimum AWS D1.1 Code requirements.
Total Points
/40
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