Lincoln Electric Fleetweld 180, Fleetweld 5P, Fleetweld 22, Shield-Arc 85, Shield-Arc HYP+ User Manual

STICK ELECTRODE

WELDING GUIDE

Procedures and Techniques

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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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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

Table of Contents

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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.

Pr

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.

Alter

nate Electrodes

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

V

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.

Electr

ode, Current and Polarity

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.

-5-

Vertical Up Techniques for Fillet and Groove Welds

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

, tend to be humped in the middle.

Therefore, a box weave

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

.

Whip

first pass

Box weave

second pass

Straight weave

1

1

2

2

3

3

Vertical Up Groove Welds

Vertical Down Welds

Weld thicker plate with vertical up techniques.

-6-

Groove Fillet

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

—

5/32

No. of Passes 1-2 1

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

Diameter (in.) 5/32

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

(1)

10-11

Ft. of Weld/Hr.

(2)

26 55

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

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

1/8"

1
2

1/8"

T

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

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

3/32" gap

L

T

3/16"

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

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

-7-

V

ertical Up Fillet Welds

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

(in.)

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

Current (Amps) 130 170 170 170 170 170 170 170
Polarity DC+ DC+ DC+ DC+ DC+ DC+ DC+ DC+

Arc Speed In./Min.

(2)

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

Ft. of Weld/Hr.

(3)

38 45 25 18 12 6.9 4.4 3.1

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

Weld

or

L

L

(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.

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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.

Pr

ocedures

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

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

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

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

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

Alter

nate Electrodes

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

Recommended

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

Jetweld Operating T

echniques

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.

-9-

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.

1/8" root gap between
electrode coating and plate

Slow travel

Fused metal

Plate

WRONG

Fast Travel

Fused metal

Electrode coating

touches plate lightly

Plate

RIGHT

60 to 80°

Slag

Slag

-10-

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

End view Side view

45°

60°

1

1

2

2

3

4

Lap Welds

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

Cor

ner Welds

-11-

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

L

T

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

L = 1/2 T

L

T

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.

Groove Welds

Do not use for code quality work

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

Gr

oove Welds

First Pass

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

-12-

1/16" ± 1/32"

T

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.

30¡

5/16"Steel backup

T

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.

(1)

14

Ft. of Weld/Hr.

(2)

20 22 17 11 8.2

Lbs. of Elec./Ft. of weld

(

3)

.524 .697 1.00 1.69 2.37

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

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

-13-

Deep Groove Welds

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.

Over E6011 Root Passes

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

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

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

Ft. of Weld/Hr.

(1)

21 16 14 8.2 5.3 9.0 6.2 4.1

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

Weld

(2)

60°

1/8"

1/8"

Joint B

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

Joint C

Passes 1 to 3 —
E6011

T

2

1

1/8" Root

opening

T

9

8

7

4

5
6

2

1

3

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

60°

1/16"

1/8"

Back gouge before
welding final pass

T

1

2

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.

(1)

21 19 14 14

Lbs. of Elec./Ft. of Weld

(2)

.366 .4810 .795 .235

JOINT A

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

-14-

Flat Fillet Welds

Also see Low Hydrogen Procedures.

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.

T

L

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.