SMAW SKILL

PRESENTED BY: HARDISH TRIVEDI 1

 Welding process in brief

• Welding is a process of joining two metals

permanently with or without heat, with or
without filler metal.
• Heat sources:
- Electric Arc,
- Electrical resistance
- Friction
- Oxy - Fuel Flame
PRESENTED BY: HARDISH TRIVEDI 2
 Welding processes

• Gas welding
- OXYFUELwelding
• Arc welding
- SMAW,GTAW,SAW,GMAW,FCAW
- EBW,LBW, PAW
• Resistance welding

PRESENTED BY: HARDISH TRIVEDI 3

 Arc welding processes

• Heat source
- Arc generated between electrode
and base metals
• Shielding of liquid metal
- Flux-slag system
- Inert or non-reactive gas shielding
- Mixture of above two
PRESENTED BY: HARDISH TRIVEDI 4
PRESENTED BY: HARDISH TRIVEDI 5
 Machine & accessories

• Machine must be calibrated

• Meters must be in working condition.
• Cable should be crimped by machine.
• Earthing lugs should be properly fitted.
• Earthing cable to be attached to job directly.

PRESENTED BY: HARDISH TRIVEDI 6

 Advantages of SMAW

• All position welding

• welding in areas of restricted access
• Wide variety of materials
• Any thickness above 3 mm can be welded
• Simpler & lighter equipment
• Low-investment

PRESENTED BY: HARDISH TRIVEDI 7

 Limitations of SMAW

• Slow process-low productivity

• Electrodes not available for few materials
• No scope for mechanization
• Flux coatings have limited life
• Difficult to weld open root with single side full
penetration joint.
PRESENTED BY: HARDISH TRIVEDI 8
 Quality of SMAW
• Welder skill in position & technique
• Welding procedure (current,voltage,bead length
per electrode,weaving,arc length)
• Preheat,post heating,post weld heat treatment
• Proper condition of flux coating,baking of
electrode
• Base metal & interpass cleaning

PRESENTED BY: HARDISH TRIVEDI 9

 Welding parameters

• Polarity
(A) DCEP (DC Electrode positive )
Reverse Polarity
(B) DCEN (DC Electrode negative)
Straight Polarity

PRESENTED BY: HARDISH TRIVEDI 10

 Preheat
• Requirement of preheat
- Preheat min.1 inch on either side of joint
- Use only LPG / Electrical heating
- Carry out uniform preheat
- Use temperature stick to check preheat
• Advantages
- To remove oil moisture
- Prevent Fast cooling (reduce rate of
cooling.
- Minimise cracking tendency
PRESENTED BY: HARDISH TRIVEDI 11
 Preheat
MATERIAL THICKNESS PREHEAT TEMPERATURE
( mm ) ( Deg. C )
(A) CARBON STEEL UP TO 25 10
SA 516 GR60 / 70 26 - 50 75
SA 106 GRB 51 - 75 100
SA 537 CL1 76 - 100 125
100 AND ABOVE 150
(B) LOW ALLOY STEEL UP TO 25 100
( P3 GR1,2 ) 26 - 50 125
SA 335 P1 51 - 75 150
SA 182 F1 76 - 100 175
SA 204 GRB 100 AND ABOVE 200
(C) LOW ALLOY STEEL UP TO 25 125
( P4 GR1 ) 26 - 50 150
SA 182 GRF11 51 - 75 175
SA 335 P11 76 - 100 200
SA 387GR12 CL2 100 AND ABOVE 225
(D) LOW ALLOY STEEL UP TO 25 150
( P5A GR1 ) 26 - 50 175
SA 182 GRF22 51 - 75 200
SA 213 T22 75 AND ABOVE 225
SA 387GR22 CL2
SA 335 P22
PRESENTED BY: HARDISH TRIVEDI 12
REFER SHOP WELDING PLAN / WPS FOR ACTUAL PREHEAT
 Interpass temperature

The temperature of previously laid bead,

just prior to striking the next bead on it.
• Interpass temperature - always with Upper limit
- Controls Heat input
- Impact properties
- Chemical composition of Weld metal
- To be checked with Temp. Stick only.

PRESENTED BY: HARDISH TRIVEDI 13

 Post heating
Raising the preheat temp. to a higher range and
maintained it for specific duration before preheat
temp. cools down to room temp.

• Ex . : Heating at 300- 3500c, for minimum 3 and

maximum 4 hrs. before allowing weld to cool to
room temperature from preheat temp.
• After post heating cover the joint with asbestos
cloth to control rate of cooling.
• Advantage
- To avoid crack, minimise hardness of
weld metalPRESENTED BY: HARDISH TRIVEDI 14
 Cleanliness
• Weld joint must be cleaned 25mm on both
side of WEP before welding
• Oil, grease, dust, paint etc..should be
removed
(If not properly cleaned, welding will be
defective - Porosity )

PRESENTED BY: HARDISH TRIVEDI 15

 Angle

• Electrode angle depends on welding

position.
• Improper angle may result in poor bead
placement.

PRESENTED BY: HARDISH TRIVEDI 16

 Arc length

• Gap between e tip of the electrode & the

surface of the molten weld pool.
• Proper arc length result sound weld metal.

• Generally arc length should be equal or

shorter than core diameter of electrode.
PRESENTED BY: HARDISH TRIVEDI 17
 Selection of electrode

• Types of electrodes
- Chemical composition of base metal
- Mechanical properties of base metal
• Dia.of electrode
- Base metal thickness
- Position of welding
- WEP
PRESENTED BY: HARDISH TRIVEDI 18
 Electrode dia.-current

• Generally electrode - dia. current is as below :

Dia. (mm) L (mm) Current (amp)
2.50 350 70-90
3.15 450 100-130
4.00 450 140-170
5.00 450 170-240
6.30 450 270-340

PRESENTED BY: HARDISH TRIVEDI 19

 Baking of electrode

• Baking is done to remove hydrogen from

the electrode which may be in electrode
due to moisture

• If not done which may result in repairs like

porosity & crack

PRESENTED BY: HARDISH TRIVEDI 20

 Tacking & its importance

• Tack should be welded by qualified welder

- Use WPS
-Tack should be of approx.of 2 inch. length
• Tack should be uniformly staggered
- Put min.2-3 layers
• Importance
- To hold s/u, To avoid cracking in LAS
PRESENTED BY: HARDISH TRIVEDI 21
 Bead placement
• Sequence of passes to achieve required size of weld
and reinforcement. Joint may be Grooved or Fillet.

Improper bead placement may result in….

• Lack of fusion
• Merge & re-shoot in RT (RT rework)
• Poor bead finish
PRESENTED BY: HARDISH TRIVEDI 22
 Bead length / welding speed

• Bead length/welding speed is also important factor

in case of welding. It depends on welding position
& diameter, length of electrode .
• Min.bead length per electrode is as below:
Dia. Length min.bead length/Electrode
2.5 350 50mm
3.2 450 75mm
4.0 450 125mm
5.0 450 275mm
PRESENTED BY: HARDISH TRIVEDI 23
 Weaving techniques
• Weaving permitted is max. 3 times of core dia. of
electrode
• Excessive weaving may result in ….. 1. Excessive
heat input
2. Poor mechanical properties
3. Loss of chemical ingredients
4. Excessive distortion

PRESENTED BY: HARDISH TRIVEDI 24

 Annealing bead welding

• Annealing bead welding is the last bead to

be welded & which shall not touch base
metal.
ANNEALING BEAD

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 Bead finish & interpretation of RT

• Ensure good bead overlap (bead placement)

• Use stringer bead
• Avoid valleys & ridges
• Avoid undercuts
• Ensure uniform grinding
• Remove spatters

PRESENTED BY: HARDISH TRIVEDI 26

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 WELDING DEFECTS

• STRAY ARCING

• LAMELLAR TEARS IN PLATES

• CRATER CRACKS

PRESENTED BY: HARDISH TRIVEDI 28

 WELDING DEFECTS
POROSITIES:

• SET-UP MORE THAN 24HRS OLD ( PIPE # PIPE JOINT )

• RAINY WEATHER- DRY OFF MOISTURE

• ARC BLOW DUE TO RESIDUAL MAGNETISM

PRESENTED BY: HARDISH TRIVEDI 29

 WELDING DEFECTS
POROSITIES:

WELD JOINT NOT CLEAN

LOWER PREHEAT TEMPERATURE

• STRONG WIND FLOW ON ARC

PRESENTED BY: HARDISH TRIVEDI 30

 WELDING DEFECTS
POROSITIES:

- SMAW :
DAMAGED ELECTRODE TIP

E7018

• UNBAKED- COLD ELECTRODE

PRESENTED BY: HARDISH TRIVEDI 31

 WELDING DEFECTS
POROSITIES:

• USE OF EXCESS CURRENT IN OUT OF POSITION WELD OR

USE OF LOWER CURRENT

• FAULTY RESTART TECHNIQUE

START
PRESENTED BY: HARDISH TRIVEDI 32
 WELDING DEFECTS

CRACKS

UNBAKED ELECTRODES / FLUXES

LOW PREHEAT
INSUFFICIENT POST HEATING
UNCLEAN WELD JOINTS

PRESENTED BY: HARDISH TRIVEDI 33

 WELDING DEFECTS

CRACKS

• HEAVY RESTRAINT- WELD TACKS WITH HIGHER CROSS

SECTION
• EXCESSIVE LOCAL HEATING - USE OF RING BURNERS
( NOZZLE# SHELL/ D.END JOINTS )
• USE OF WRONG ELECTRODE / FLUX
• FAULTY CONS. QUALITY / SELECTION
PRESENTED BY: HARDISH TRIVEDI 34
 WELDING DEFECTS

CRACKS

HANDLING OF COMPONENTS BEFORE ISR / SR IN LAS

EXCESSIVE DILUTION IN BARRIER LAYER OF SS O/L
EXCESS CURRENT / INTERPASS TEMP DURING SS WELDING

PRESENTED BY: HARDISH TRIVEDI 35

 WELDING DEFECTS

SLAG INCLUSIONS:

IMPROPER INTERPASS CLEANING

POOR BEAD FINISH- ROUGH, LUMPY BEADS NOT DRESSED
BEFORE WELDING
FAULTY RESTART - LUMP AT STARING POINT - TO BE
GROUND
WELDING PARAMETERS (I,V, T.S) NOT AS PER WPS
WRONG BEAD PLACEMENT
PRESENTED BY: HARDISH TRIVEDI 36
 WELDING DEFECTS

SLAG INCLUSIONS:

• EXCESSIVE WEAVING

• LESS INCLUDED ANGLE

• INSUFFICIENT CHIPBACK DEPTH
• IMPROPER EARTHING / FEED BACK WIRE
CONNECTION
• JERKY MOTION OF CIRC. SEAM DUE TO TANK
ROTATOR / DRIFT/ LONG. SEAM REINFORCEMENT
PRESENTED BY: HARDISH TRIVEDI 37
 WELDING DEFECTS
LACK OF FUSION / PENETRATION

LF
LP

LOWER CURRENT

• POOR WEP / SET-UP - LOW ROOT GAP,

HIGH ROOT FACE, LOWER INCLUDED ANGLE

• RUST / PAINT ON WEP

PRESENTED BY: HARDISH TRIVEDI 38
 WELDING DEFECTS
LACK OF FUSION / PENETRATION

LF
LP

• BEAD SHAPE AND BEAD PLACEMENT

• EXCESSIVE WEAVING
• HIGHER VOLTAGE IN SAW / FCAW

PRESENTED BY: HARDISH TRIVEDI 39

 GOOD
ENGINEERING
PRACTICES

PRESENTED BY: HARDISH TRIVEDI 40

 IMPORTANT CODE REQUIREMENT AND
PRACTICES RELATED TO WELDING

( A ) BEFORE STARTING WELDING

1. For specific seam :

Refer shop weld plan, WPS and test
plan.

2. Check the seam number on the job.

PRESENTED BY: HARDISH TRIVEDI 41

 IMPORTANT CODE REQUIREMENT AND
PRACTICES RELATED TO WELDING
3. Check identification marks of welding consumables.

Supercito E 7018

E7018

4. Process Quantity (max. )

SMAW 15 Electrodes
SAW/FCAW 1 Wire Spool
SAW Flux 10 Kg
ESSC Flux 25 Kg
CALIBRATION
DUE ON:
5. Check calibrations of welding
31.10.99
machine and carry out trial
where required. PRESENTED BY: HARDISH TRIVEDI 42
 IMPORTANT CODE REQUIREMENT AND
PRACTICES RELATED TO WELDING

6. Check cable connections and earthing.

. Clean WEP+25 mm on either side. Remove rust , paint, oil etc

25 mm 25 mm

25 mm 25 mm

8. Provide run - in, run - out plates for L - seams.

PRESENTED BY: HARDISH TRIVEDI 43

 IMPORTANT CODE REQUIREMENT AND
PRACTICES RELATED TO WELDING

. Get temperature sticks for preheat & interpass.

Temperature > Preheat
< Interpass

25 mm 25 mm

10. Check preheat at least 25 mm

away from WEP on both sides.

BURNER

1. Use SS wire brush /wire wheel for SS, Inconels , Monels and
Cupro-nickels. Do not useBY:
PRESENTED grinding wheels used on CS.
HARDISH TRIVEDI 44
 IMPORTANT CODE REQUIREMENT AND
PRACTICES RELATED TO WELDING

( B ) WHILE WELDING

1. Tacks and temporary cleats

- Use specified electrodes and preheats
- Qualified Welder
- No hammering

2. Weaving < 3 x Electrode diameter.

3. No stray arcing on job.

PRESENTED BY: HARDISH TRIVEDI

4. SMAW Electrode left over after 4 hrs - return to stores. 45
 IMPORTANT CODE REQUIREMENT AND
PRACTICES RELATED TO WELDING

( C ) AFTER WELDING

1. Welder stamp to be stamped on seams - max. 3 feet apart.

Max. 3 feet

2. Return unused consumable to shop stores.

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 GOOD PRACTICES FOR WELDING

( A ) GENERAL
1. Use correct shade of welding glass.

2. Keep your head out of welding fumes.

WRONG RIGHT

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 GOOD PRACTICES FOR WELDING

3. Do not direct fan air on welding arc .

PRESENTED BY: HARDISH TRIVEDI 48

 GOOD PRACTICES FOR WELDING

4. When working in confined space ensure adequate

ventilation / exhaust.

CONFINED SPACE

WELDING

BLOWER
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 GOOD PRACTICES FOR WELDING

5. Eliminate mix-up of electrode / filler wire / flux.

6. Never over weld fillets ---

- 6 CFW to 8 CFW - 78 % extra weld .
- Loss of man hours + consumable
- Distortion.

140 Gms / mt 250 Gms / mt

6 8

6 8
PRESENTED BY: HARDISH TRIVEDI 50
 GOOD PRACTICES FOR WELDING

7. Give minimum root gaps for fillet joints - 3 mm gap

on
6 CFW increases weld metal by 125 %.

125% WELD METAL

6 6

6 6

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 GOOD PRACTICES FOR WELDING

8. Do not give excessive reinforcements.

. Weld bead restart - end : return arc on crater to fill up the crater
and to avoid crater cracks - porosity

CRATER CRACK
END

- restart ahead of end crater so that end crater gets melted and
filled - up. PRESENTED BY: HARDISH TRIVEDI 52
 GOOD PRACTICES FOR WELDING

0. Burn complete electrode - max. stub end should be 50 mm.

E7018
E7018

> 50mm
< 50mm

11. For NG - SAW and ESSC follow instructions from welding Engg.

PRESENTED BY: HARDISH TRIVEDI 53

 GOOD PRACTICES FOR WELDING
( B ) WELD OVERLAY
1. Use only specified voltage / current / travel speed to avoid higher
dilution.

2. Higher dilution may result in cracking : weld with

correct
parameters .

3. End craters of SS, Inconel, Nickel, Monel overlay show

crack if
current is high, arc length is longer and cleanliness is not
maintained. Crater must be filled up.
4. Bead overlap must be minimum 50 %.

PRESENTED BY: HARDISH TRIVEDI 54

 GOOD PRACTICES FOR WELDING

5. Minimum bead length per electrode must be achieved.

6. Clad stripping must remove complete SS material, check with

CuSo4 solution.

CS

SS
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 GOOD PRACTICES FOR WELDING

( C ) PIPE # PIPE BUTT JOINTS

1. Set up should be done after cleaning I.D.

weld as soon as possible after set up

2. Thin pipes ( up to 4mm thk ) - weld using two passes

( GTAW )
-do not end both passes on same location stagger the ends.

3. Root set up must be accurate - or problem of lack of

penetration
( less root gap, thick root face ) - will occur.

( D ) NOZZLE # SHELL / D’JOINTS ON THICK VESSELS

1. These are highly restrained joints - and tacks may cracks.

Weld thick tacks 4 - 6 passes.

2. Ensure higher preheat ( +25° C ) on nozzle forging.

PRESENTED BY: HARDISH TRIVEDI 56
PRESENTED BY: HARDISH TRIVEDI 57