Lincoln Electric C2.410 User Manual

STICK ELECTRODE

WELDING GUIDE

Procedures and Techniques

Customer Assistance Policy

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying this type of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

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Table of Contents

Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

Out-of-Position Welding

(Vertical and Overhead) . . . . . . . . . . . . . . . . . . . . . .4-7

High Deposition Welding . . . . . . . . . . . . . . . . . . . .8-15

Welding Inclined Plates . . . . . . . . . . . . . . . . . . . .16-17

High Speed Welding (Sheet Metal) . . . . . . . . . . .18-23

Low Hydrogen Welding . . . . . . . . . . . . . . . . . . . .24-34

Minimum Preheat and Interpass Temperatures . . . .35

Stick Electrode Selection Guide . . . . . . . . . . . . . . . . .36-38

Welding Safety Precautions . . . . . . . . . . . . . . . . . . . .39-48

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WELDING PROCEDURES

Out-Of-Position Welding (Vertical and Overhead)

When welding out-of-position, the molten metal tends to spill out of the joint. To offset this tendency, an electrode with a fast freezing deposit is needed.

Welding made with out-of-position electrodes is slow, relatively expensive and require a high degree of operator skill. Therefore, whenever possible, work should be positioned for downhand welding using High-Deposition electrodes – see pages 8-15.

ocedures

Vertical Up Groove Welds . . . . . . . . . . . . . . . page 6

Vertical Down Welds . . . . . . . . . . . . . . . . . . . page 6

Vertical Up Fillet Welds . . . . . . . . . . . . . . . . . . page 7

Overhead Fillet Welds . . . . . . . . . . . . . . . . . . page 7

For vertical up and vertical down pipe welding technique, request Lincoln bulletin C2.420, Welding Pressure Pipelines.

nate Electrodes

Alter

Vertical, overhead, and horizontal groove welds on plate thicker than 1/2” are most economically done with low hydrogen electrodes – see pages 24-34.

ertical Up vs. Vertical Down

Vertical down is recommended for fastest welding of 18 gauge to 3/16” thick steel. A description of the recommended drag technique along with sheet metal procedures are given in the section High-Speed Welding on pages 18-23.

Vertical up techniques provide deeper penetration and lower overall welding costs on plate over 3/16” thick.

ode, Current and Polarity

Electr

The vertical up and overhead procedures in this section recommend 3/16” and smaller Fleetweld 5P or 5P+ (E6010) electrode using electrode positive and currents in the lower portion of the electrode’s range. When only AC otuput is available, use Fleetweld 35 or Fleetweld 180 (E6011) electrode at about 10% higher current.

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Vertical Up Techniques for Fillet and Groove Welds

Whip

first pass

Box weave

second pass

Straight weave

1. Make first pass root beads with a whipping technique. Whip

the electrode tip out of the molten crater and up for a short time to let the crater cool before returning the electrode tip to the crater area to add more weld metal.

2. Root pass beads, particularly when made with a

whipping technique Therefore, a box weave

, tend to be humped in the middle.

is often needed for the second pass to assure good fusion along the edge of the first bead. The box weave is similar to the straight weave except a slight upward motion is made at both sides of the weld. Maintain a short arc with no whipping.

3. Employ a straight weave

for the final passes. Simply move the electrode tip back and forth across the surface of the weld pausing slightly at both edges to insure penetration and wash-in without undercut.

Overhead Techniques

Weld overhead as a series of root beads using a slight circulation motion in the crater sometimes accompanied by a whip. Weave beads are too fluid and will spill

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Vertical Up Groove Welds

1/8"

1 2

1/8"

3/32" gap

3/16"

Plate Size – T (in.) 1/4 5/16 3/8 1/2-1 No. of Passes 1-2 1-2 1-2 All

Electrode/AWS Class Fleetweld 5P, Fleetweld 5P+ /E6010

Diameter (in.) 5/32 5/32 3/16 3/16

Current (Amps) 110 120 150 160 Polarity DC+ DC+ DC+ DC+ Arc Speed In./Min.

(1)

5-1/2 4 5 4

Ft. of Weld/Hr.

(2)

11 8.5 10 See

Lbs. of Elec./Ft. of Weld .323 .440 .586 Table A

Table A

Plate Thickness-T

1/2” 5/8” 3/4” 1”

No. of Passes 3 4 6 10

Ft. of Weld/Hr.

(2)

6.6 4.4 3.1 1.8

Lbs. of Elec/Ft. .990 1.48 2.08 3.56

1/2” and thicker plates are more economically welded with low hydrogen electrodes.

Vertical Down Welds

Weld thicker plate with vertical up techniques.

Groove Fillet

Plate Size – T (in.) 3/16 — Leg Size – L (in.)

No. of Passes 1-2 1

Electrode/AWS Class Fleetweld 5P, Fleetweld 5P+ E6010

Diameter (in.) 5/32

—

5/32

Current (Amps) 120 Polarity DC+ Arc Speed In./Min.

Ft. of Weld/Hr.

(1)

(2)

26 55

10-11

Lbs. of Elec./Ft. of Weld .168 .071

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(1) First pass only. On later passes adjust arc speed to obtain proper bead size. (2) Total for all passes. 100% operating factor.

ertical Up Fillet Welds

No. of Passes 1 1 1 1 1-2 1-3 1-4 Leg Size – L (in.) 3/16 1/4 5/16 3/8 1/2 5/8 3/4

Electrode/AWS Class Fleetweld 5P, Fleetweld 5P+

(1)

/ E6010

Diameter (in.) 3/16 3/16 3/16 3/16 3/16 3/16 3/16

Current (Amps) 150 155 155 155 160 160 160 Polarity DC+ DC+ DC+ DC+ DC+ DC+ DC+ Arc Speed In./Min.

(2)

85324-1/2 4-1/2 4-1/2

Ft. of Weld/Hr.

(3)

40 25 15 10 6.8 4.4 3.0

Lbs. of Elec./Ft. of .137 .211 .346 .514 .850 1.31 1.93

Weld

Overhead Fillet Welds

After first bead, the sequence of bead placements starts on vertical plate for each layer.

No. of Passes 1 1 1 1-2 1-3 1-6 1-10 1-15 Leg Size – L 5/32 3/16 1/4 5/16 3/8 1/2 5/8 3/4

Electrode/AWS Class Fleetweld 5P, Fleetweld 5P+ /E6010

Diameter

Current (Amps) 130 170 170 170 170 170 170 170 Polarity DC+ DC+ DC+ DC+ DC+ DC+ DC+ DC+ Arc Speed In./Min.

Ft. of Weld/Hr. Lbs. of Elec./Ft. of .100 .145 .253 .369 .532 .945 1.48 2.13

(1) 5/32” electrode can be used to allow better control. (2) First pass only. On later passes adjust arc speed to obtain proper bead size. (3) Total for all passes. 100% operating factor.

(in.)

Weld

5/32 5/32 5/32 5/32 3/16 3/16 3/16 3/16

(2)

7-1/2 9 5 7 7 7 7 7

(3)

38 45 25 18 12 6.9 4.4 3.1

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High-Deposition Welding

High deposition applications includes groove, fillet, lap and corner welds in 3/16” and thicker plate welded with the work level or slightly downhill. These joints are capable of holding a large molten pool of weld metal as it freezes.

These welds are made with Jetweld electrodes because the high iron powder content in the coating produces high deposit rates to fill joints in the shortest time for economical welding.

ocedures

Lap welds . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11

Corner Welds . . . . . . . . . . . . . . . . . . . . . . . . . page 11

Groove Welds . . . . . . . . . . . . . . . . . . . . . . . . page 12

Flat Fillet Welds . . . . . . . . . . . . . . . . . . . . . . . page 14

Horizontal Fillet Welds . . . . . . . . . . . . . . . . . . page 15

nate Electrodes

Alter

When desired, the following alternate electrodes can be used with similar procedures:

Recommended Jetweld 1 (E7024-1) Jetweld 3 (E7024) Jetweld 1 or 3 (E7024) Jetweld LH-3800 (E7028H8)

Jetweld Operating T

Polarity and Current – Use AC for fast welding speeds, high deposit rates, and good arc characteristics. DC can be used but the resulting arc blow may complicate control of the molten puddle.

Optimum current for most jobs is 5-10 amps above the center of the electrodes range. Do not exceed the center of the range for x-ray quality deposits.

Use a Drag Technique – Tip the electrode 10 to 30° in the direction of travel and make stringer beads. Weld with the electrode end lightly dragging on the work to force the molten metal out from under the electrode tip allowing adequate penetration. The smooth welds look almost like automatic welds.

echniques

Alternate

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Slow travel

WRONG

Slag

Fused metal

RIGHT

Electrode coating

touches plate lightly

Slag

Fused metal

Fast Travel

1/8" root gap between electrode coating and plate

Plate

60 to 80°

Plate

Travel fast, but not too fast for good slag coverage. Stay about 1/4” to 3/8” ahead of the molten slag. If travel speed is too slow, a small ball of molten slag may form and roll ahead of the arc causing erratic bead shape, spatter, and poor penetration.

Deep Groove Groove Welds – To hold the large pool of molten weld metal from Jetweld electrodes, either a weld backing plate or a root pass made with deep penetrating electrode (usually E6010 or E6011) is required. Deposit Jetweld beads with a stringer technique or a slight weave to obtain fusion to both plates. Split weave welds are better than a wide weave near the top of deep grooves. Size the second to last layer so the last layer will not exceed a 1/16” buildup.

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Fillet and Lap Welds – The ideal fillet or lap weld has equal legs

End view Side view

45°

60°

and a flat or slightly convex bead. Excess convexity wastes weld metal. A concave bead is susceptible to shrinkage cracks.

Flat fillet and lap welds are made with the same general techniques as groove welds.

Weld single pass fillets using a drag technique with the tip of the electrode touching both plates. Usually weld with the electrode at a 45° angle (end view) from the horizontal plate. However, adjust this angle from as little as 30° to as much as 60° when required to maintain equal leg sizes on both plates.

When two passes are needed, deposit the first bead mostly on the bottom plate. To weld the second pass hold the electrode at about 45° angle fusing into the vertical plate and the first bead.

Make multiple pass horizontal fillets as shown in the sketch. Put the first bead in the corner with fairly high current even though there may be slight undercut, succeeding passes will burn it out. Deposit the second bead on the horizontal plate fusing into the first bead. Hold the electrode angle needed to deposit the filter beads as shown, putting the final bead against the vertical plate.

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Lap Welds

L = 1/2 T

Use fillet weld procedures for laps on 3/8” and thicker plate.

Plate Size – T (in.) 3/16 1/4 5/16 Leg Size – L (in.) 3/16 1/4 5/16 No. of Passes 1 1 1

Electrode/AWS Class Jetweld 1/E7024-1

Diameter (in.) 3/16 7/32 7/32

Current (Amps) 290 360 360 Polarity AC AC AC Arc Speed In./Min. 15-1/2 15 13

Ft. of Weld/Hr.

(1)

78 75 65

Lbs. of Elec./Ft. of weld .170 .211 .253

Cor

ner Welds

Plate Size – T (in.) 3/16 1/4 5/16 3/8 1/2 Leg Size – L (in.) 3/32 1/8 5/132 3/16 1/4 Pass 1 1 1 1 1

Electrode/Class Jetweld 1/E7024-1

Size 5/32 3/16 7/32 7/32 1/4

Current – Amps 215 260 330 340 390 Polarity AC AC AC AC AC Arc Speed In./Min. 24.5 21 20.5 18 15.5

Ft. of Weld/Hr.

(1)

120 105 103 90 77

Lbs. of Elec./Ft. of weld .075 .114 .152 .175 .250

Note: Maximum strength, full size corner welds, as illustrated, can be made using the next smaller E7024 electrode, lower currents, slower arc speed and slower travel speed. Use 2 passes on 1/2” plate when making full size corner weld.

(1) 100% operating factor.

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Groove Welds

1/16" ± 1/32"

30¡

5/16"Steel backup

Do not use for code quality work

This square edge groove joint requires the deep penetration of Fleetweld 5P or 5P+.

Plate Size – T (in.) 3/16 1/4 5/16 3/8 No. of Passes 2 2 2 2

Electrode/AWS Class Fleetweld 5P, Fleetweld 5P+/E6010

Diameter (in.) 1/4 5/16 5/16 5/16

Current (Amps) 240 325 390 410 Polarity DC+ DC+ DC+ DC+ Arc Speed In./Min.

(1)

18 18 18 18

Ft. of Weld/Hr.

(2)

45 45 45 45

Lbs. of Elec./Ft. of Weld .171 .275 .315 .330

(1) Both passes. (2) Total for all passes. 100% operating factor.

oove Welds

First Pass

3/16” Jetweld 2 E6027 300 amps. AC at 14”/Min.

Plate Size – T (in.) 5/16 3/8 1/2 3/4 1 No. of Fill Passes 2-3 2-3 2-4 2-6 2-8

Electrode /AWS Class Jetweld 2/E6027 Diameter (in.) 1/4

Current (Amps) 390 Polarity AC Arc Speed In./Min.

Ft. of Weld/Hr.

Lbs. of Elec./Ft. of weld

(1) First pass only. On later passes adjust arc speed to obtain proper

(2) Total for all passes. 100% operating factor. (3) Plus .228 lbs. of 3/16” E6027/ft. of weld for first pass.

bead size.

(2)

(1)

20 22 17 11 8.2

(

.524 .697 1.00 1.69 2.37

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Deep Groove Welds

60°

1/16"

1/8"

Back gouge before welding final pass

Joint A Pass 1 E6011

Root passes - Joints A, B & C - 3/16 Fleetweld 35 (E6011), 175-180 Amps. AC at 6-9 in/min.

JOINT A

Plate Size – T (in.) 3/8 1/2 5/8 5/8 No. of Passes 2-3 2-3 2-3 4

Electrode/AWS Class Jetweld 2/E6027

Diameter (in.) 3/16 7/32 1/4 7/32

Current (Amps) 280 340 375 340 Polarity AC AC AC AC

Ft. of Weld/Hr. Lbs. of Elec./Ft. of Weld

(1) Total for all passes. 100% operating factor. (2) Plus .160 lbs. of 3/16” E6011/ft. of weld for each root pass.

(1)

21 19 14 14

(2)

.366 .4810 .795 .235

Over E6011 Root Passes

Joint B

5/16" & 3/8" Pass 1 — E6011 1/2" - 1" Pass 1 & 2 — E6011

1/8"

Joint C

Passes 1 to 3 —

E6011

60°

5 6

2 1

1/8" Root

opening

JOINT B JOINT C

Plate Size – T (in.) 5/16 3/8 1/2 3/4 1 3/4 1 1-1/2 No. of Passes 2 2-3 3 3-6 3-10 4-5 4-7 4-9

Electrode/AWS Class Jetweld 2/E6027

Diameter

Current (Amps) 220 220 390 390 390 390 Polarity AC AC AC AC AC AC

Ft. of Weld/Hr. Lbs. of Elec./Ft. of .142 .284 .354 1.47 2.94 .728 1.45 3.04

(1) Total for all passes. 100% operating factor. (2) Plus .160 lbs. of 3/16” E6011/ft. of weld for each root pass.

(in.) 5/32 5/32 1/4 1/4 1/4 1/4

(1)

21 16 14 8.2 5.3 9.0 6.2 4.1

(2)

Weld

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Flat Fillet Welds

Also see Low Hydrogen Procedures.

Plate Size – T 14 ga 12 ga 10 ga 3/16" 3/16" 1/4" 1/4" No. of Passes 1 1 1 1 1 1 1 Leg Size – L (in.) — — — 5/32 5/32 3/16 3/16

Electrode/AWS Class Jetweld 1/E7024-1

Diameter (in.) 3/32 1/8 1/8 1/8 5/32 5/32 3/16

Current (Amps) 95 150 160 180 210 230 270 Polarity AC AC AC AC AC AC AC Arc Speed In./Min.

(1)

15 17-1/2 17-1/2 17 16-1/2 17 14-1/2

Ft. of Weld/Hr.

(2)

75 88 88 85 83 85 72

Lbs. of Elec./Ft. of .049 .076 .082 .117 .162 .20 .29

Weld

(1) First pass only. On later passes adjust arc speed to obtain proper

bead size.

(2) Total for all passes. 100% operating factor.

For X-ray quality:

1. Use low hydrogen procedures, pages 24-34. (or)

2. Weld 3/16” to 5/16” fillets with E6027 electrodes at the E7024 procedures. Weld 3/8” and larger fillets with 1/4” E6027 at about 400 amps. Travel speed will be slower.

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