Fig. 15-25 Job drawing J50.

Fig. 15-26 Typical appearance of a multipass fillet weld in a T-joint welded with a slight whiplike motion in the overhead
position (4F) with large DCEP or a.c. shielded arc electrodes.

Check Test Job 15-J51 Welding a Single-V

After you are able to make welds that are satisfactory in Butt Joint
appearance, make up a specimen similar to that made in
previous jobs. Use the plate thickness, welding technique, Objective
and electrode type and size specified for this job. Weld the To weld a single-V butt joint in the horizontal position
first pass only and on one side. (2G) by means of multipass groove welds, stringer bead
Break the finished weld and examine the surfaces for technique, with DCEP and/or a.c. shielded metal arc elec-
soundness. The weld must not be porous. It must show trodes (AWS E6010E6011 and E7016E7018).
good fusion and penetration at the root and to the plate General Job Information
surfaces. The joint should break evenly through the throat
The beveled-butt joint in the horizontal position is used in
of the weld.
pipe and critical plate welding. The joint and the welding

444Chapter 15Shielded Metal Arc Welding Practice: Jobs 15-J43J55 (Plate)

procedure are similar to those required for ASME plate Penetration is complete if there is a little hole at the lead-
and pipe tests. Some companies demand that the finish ing edge of the weld crater right under the tip of the elec-
bead be weaved. However, most companies prefer stringer trode. Learn how to form and keep this hole throughout
beading. the welding operation without letting it get too large and
causing you to lose control and burn through the plate.
Welding Technique The presence of this hole during welding is your assur-
ance that you are melting through to the back side of the
The angle of the electrode changes according to the pass,
groove. This is called keyhole welding.
Fig. 15-27. The angle is 90 to the top plate for the first
pass, 30 to the bottom plate for the second pass, and 45 All Other PassesCurrent control can be much higher.
to the top plate for the third pass. For the cover passes, the Electrode position should be approximately that shown in
electrode should be held at an angle of 5 to 15 to the bot- Fig. 15-27B through E. The stringer bead technique may
tom plate. The electrode should lean from 5 to 15 in the be used. It is important that each pass be fused to the pre-
direction of travel for all passes. ceding passes and to the plate surfaces. Avoid sagging and
undercut. Thorough cleaning is essential. Travel from left
First Pass The current control must not be too high. Hold
to right and from right to left.
a short arc gap so that weld metal is forced into the gap
at the root of the joint. A back-and-forth motion may be
used. Do not break the arc on the forward motion. This Operations
movement preheats the metal ahead of the deposit and al- 1. Obtain plates; check the job drawing, Fig. 15-29,
lows the deposited metal to cool to prevent sagging on the page 446, for quantity and size.
bottom plate. 2. Obtain electrodes of each quantity, type, and size
Complete penetration must be secured through the specified in the job drawing.
back side, Fig. 15-28. Keep in mind that the correct com- 3. Set the power source for 80 to 130 amperes. Set a
bination of welding current, electrode position, and speed d.c. power source for electrode positive.
of travel produces penetration through to the back side. 4. Set up the plates and tack weld them as shown on
the job drawing.
5. Place the joints in the horizontal posi-
45 Direction of Travel tion on the welding table. Make sure
90 Groove
515 that it is connected with the work
Welds
Electrode connection.
Electrode Oscillating 6. Make the first, second, and third passes
Motion
with 18-inch electrodes as shown on the
30 515 job drawing. Manipulate the electrode as
First Pass Second Pass Third Pass Cover Passes Top View shown in Fig. 15-27.
A B C D E 7. Chip the slag from the welds, brush,
and inspect between each pass. Refer to
Fig. 15-27 Electrode position when welding a V-groove butt joint in the Inspection.
horizontal position (2G). 8. Increase the power source setting to 112 to
170 amperes.
9. Make the fourth, fifth, sixth and seventh
passes with 532-inch electrodes as shown
on the job drawing.
10. Chip the slag from the welds, brush,
and inspect between each pass. Refer to
Inspection.
11. Practice these welds until you can produce
good welds consistently.
If you are burning through the plate, you
Fig. 15-28 Penetration and fusion through the back side of a V-groove may use a whiplike or circular motion to
butt joint. Note the hole at the leading edge of the weld. This is referred to as a control the size of the weld pool and the rate
keyhole. at which weld metal is added. If the pool is

Shielded Metal Arc Welding Practice: Jobs 15-J43J55 (Plate) Chapter 15445
 Fig. 15-29 Job drawing J51.

too hot and burning through, whip ahead along one of Inspection
the plate edges about 12 inch and whip back into the Compare the back side of the first pass with Fig. 15-28,
pool to deposit more metal. Alternate this whipping page 445 and all passes with Fig. 15-30. Check all passes
motion along opposite plate edges for each forward for the following weld characteristics:
movement.
If the root faces of the plates do not seem to be heating Width and height: All passes uniform
and melting enough and you are having difficulty main- Appearance: Smooth with close ripples; free of
taining the hole, keep the electrode directly in the bottom voidsand high spots. The lapover of the beads should
of the V, slow the forward movement, and main-
tain a circular motion.
Once these welds are acceptable to your in-
structor, make a horizontal V-groove butt joint
using E6010 or E6011 for the root pass and
E7016 or E7018 for all subsequent passes. Use
a steady short arc gap with the low h ydrogen
electrodes; do not use the whipping motion with
these electrodes. Use 332 or 18inch diameter
electrodes at 60 to 120 amperes and 80 to
150amperes, respectively. Perform the same in- Fig. 15-30 Typical appearance of a multipass groove weld in a V-groove butt
spection and qualification testing that was done joint without a backing strip welded in the horizontal position (2G) with DCEP or
on the previous joints. a.c. shielded arc electrodes.

446Chapter 15Shielded Metal Arc Welding Practice: Jobs 15-J43J55 (Plate)

 be well-proportioned. Restarts should be difficult to
locate. Electrode 1020
Size: Refer to the job drawing. Check convexity with a Fillet Fillet
45
butt weld gauge. Welds Weld

Face of weld: Some reinforcement

Edges of weld: Good fusion, no overlap, no undercut Direction of Travel
Starts and stops: Free of depressions and high spots Sectional View (Work Angle) Pictorial View (Travel Angle)
Beginnings and endings: Full size, craters filled
A B
Back side: Complete and uniform penetration
Penetration and fusion: Through the back side and to all Fig. 15-31 Electrode position when welding couplings with
plate surfaces. electrode negative.
Surrounding plate surfaces: Free of spatter
Slag formation: Full coverage, easily removable

Disposal
Put completed joints in the scrap bin so that they will be
available for further use. The plate can be cut and beveled
between welds for further butt welding, and unwelded
plate surfaces can be used for beading.

Qualifying Test
At this point you should be able to pass Test 2 in the hori-
zontal position. (See p. 456.) This test is similar to the
ASME test in pipe or plate.

Job 15-J52 Welding a Coupling

to a Flat Plate
Objective Fig. 15-32 Electrode and electrode holder positioned as in-
structed in Fig. 15-31. Note the typical appearance of the fillet welds
To weld pipe or coupling to a flat plate by means of a in couplings welded in the horizontal position (2F) with DCEP or a.c.
single-pass horizontal fillet weld with DCEP and/or a.c. shielded arc electrodes. Tim Anderson
shielded metal arc electrode (AWS E7016E7018.)

General Job Information Operations

This job is similar to those found in tank work in which 1. Obtain plate and pieces of pipe; check the job
couplings and fittings are welded into the shell, heads, and drawing, Fig. 15-33, page 448, for quantity and size.
bottom. It is also included in this chapter to develop flex- 2. Obtain electrodes of each quantity, type, and size
ibility in positioning the electrode and to give experience specified in the job drawing.
in welding in close quarters. 3. Set the power source for 90 to 150 amperes. Set a
d.c. power source for electrode positive.
Welding Technique 4. Place the plate in the flat position on the welding
The current adjustment should be rather high. Hold the table. Make sure the plate is connected to the work
electrode at a 45 angle to the plate, Fig. 15-31A, and tilt connection.
it 10 to 20 in the direction of travel, Fig.15-31B. The ac- 5. Tack weld the small pipe to the plate.
tual position for welding is shown in Fig.15-32. The weld- 6. Make inside and outside fillet welds with 18-inch
ing technique is not different than that for running stringer electrodes as shown on the job drawing. Manipulate
beads and single-pass fillet welds in the horizontal posi- the electrode as instructed in Fig. 15-31.
tion. The position of the electrode is constantly changing in 7. Chip the slag from the welds, brush, and inspect.
respect to the welder as it travels around the outside of the Refer to Inspection.
coupling, however, and space is limited. 8. Increase the power source setting to 140 to
Practice starts and stops. Travel in all directions. 200amperes.

Shielded Metal Arc Welding Practice: Jobs 15-J43J55 (Plate) Chapter 15447
 Fig. 15-33 Job drawing J52.

9. Tack weld the large pipe to the plate. Beginnings and endings: Full size, craters filled. Pay
10. Make inside and outside fillet welds with 532-inch particular attention to points where the end of the
electrodes as shown on the job drawing. weld overlaps the starting point.
11. Chip the slag from the welds, brush, and inspect.
Refer to Inspection, below.
12. Practice these welds until you can produce good
welds consistently.

Inspection
Compare the welds with Fig. 15-34 and check them for the
following characteristics:
Width and height: Uniform
Appearance: Smooth with close ripples; free of voids.
Restarts should be difficult to locate.
Size: Refer to the job drawing. Check with a fillet weld
gauge.
Face of weld: Slightly convex
Edges of weld: Good fusion, no overlap, no Fig. 15-34 Typical appearance of fillet welds on couplings
undercut welded in the horizontal position (2F) with DCEP or a.c. shielded arc
Starts and stops: Free of depressions and high spots electrodes. Tim Anderson

448Chapter 15Shielded Metal Arc Welding Practice: Jobs 15-J43J55 (Plate)

Penetration and fusion: To the root of the joint and plate Operations
and pipe surfaces 1. Obtain plate and pieces of pipe; check the job draw-
Surrounding plate surfaces: Free of spatter ing, Fig. 15-36, page 450, for quantity and size.
Slag formation: Full coverage, easily removable 2. Obtain electrodes in each quantity, type, and size
specified in the job drawing.
Disposal 3. Set the power source for 110 to 170 amperes. Set a
Put completed plate in the scrap bin so that it will be avail- d.c. power source for electrode positive.
able for further use. The unwelded plate surfaces between 4. Place the plate in the flat position on the welding
the couplings can be used for beading. table. Make sure the plate is connected with the
work connection.
5. Tack weld the small pipe to the plate.
Job 15-J53 Welding a Coupling 6. Make inside and outside fillet welds with 532-inch
to a Flat Plate electrodes as shown on the job drawing. Manipulate
the electrode as instructed in Fig.15-31, page 447.
Objective 7. Chip the slag from the welds, brush, and inspect.
To weld pipe or coupling to a flat plate by means of a Refer to Inspection, below.
single-pass horizontal fillet weld with DCEP and/or a.c. 8. Increase the power source setting to 140 to
shielded metal arc electrode (AWS E6010E6011). 240 amperes.
9. Tack weld the large pipe to the plate.
General Job Information 10. Make inside and outside fillet welds with 316-inch
electrodes as shown on the job drawing.
This job is identical to Job 15-J52 except that electrode 11. Chip the slag from the welds, brush, and inspect.
cellulore electrodes are used for welding. Refer to Inspection.
12. Practice these welds until you can produce
Welding Technique goodwelds consistently with both types of
The current adjustment cannot be as high as with low electrodes.
hydrogen electrodes. More care must be taken with
these electrodes. Undercut is a possibility, and arc blow Inspection
may be a problem. Note in Fig. 15-35 that the electrode
Check them for the following characteristics:
is held slightly closer to the plate. The angle is 40
instead of 45 to prevent undercut. Also note that the Width and height: Uniform
face of the weld is flat instead of convex. Review the Appearance: Smooth with close ripples; free of voids.
material concerning arc blow, Table 13-3, page 334. Restarts should be difficult to locate.
Use a welding technique like that used in the previous Size: Refer to the job drawing. Check with a fillet weld
job, but hold a closer arc gap. gauge.
Practice starts and stops. Travel in all directions. Face of weld: Flat
Edges of weld: Good fusion, no overlap, no
undercut
Starts and stops: Free of depressions and high spots
Beginnings and endings: Full size, craters filled. Pay
Electrode 1020 particular attention to points where the end of the
weld overlaps the starting point.
Fillet Welds Fillet
40 Weld Penetration and fusion: To the root of the joints and
plate and pipe surfaces
Surrounding plate surfaces: Free of spatter
Direction of
Travel
Slag formation: Full coverage, easily removable
Sectional View Pictorial View
(Work Angle) (Travel Angle)
Disposal
A B
Put completed plate in the scrap bin so that it will be avail-
Fig. 15-35 Electrode position when welding couplings able for further use. The unwelded plate surfaces between
with DCEP. the couplings can be used for beading.

Shielded Metal Arc Welding Practice: Jobs 15-J43J55 (Plate) Chapter 15449
 Fig. 15-36 Job drawing J53.

Job 15-J54 Welding a Single-V Butt Welding Technique

Joint (Backing Bar Construction) Tilt the electrode 5 to 10 in the direction of travel,
Fig.15-37A. Hold it at 90 to the surface of the plates for
Objective the first pass (Fig. 15-37B), 20 to 35 to the surface of
To weld a single-V butt joint assembled with a backing each plate for the second and third passes (Fig.15-37C
bar in the overhead position by means of multipass groove and D), and 10 to 20 to the surface of each plate for the
welds, stringer bead technique, with DCEP and/or a.c. fourth and fifth passes (Fig. 15-37E). Like the first pass,
shielded metal arc electrodes (AWS E6010E6011 and/or the last pass is made at a 90 angle to the surface of the
E7016E7018). plates, Fig. 15-37F.

General Job Information First Pass Current adjustment should be high. A short arc
The beveled-butt joint in plate with a backing bar is simi- is essential to ensure proper metal transfer. A whipping
lar to joints in pipe and tanks welded with a backing ring motion should be employed. Make sure that you are
or chill ring. This job is identical to the joint and position obtaining fusion to the backing bar and the root faces of
required by various code authorities and recommended by the two plates. Keep the weld as flat as possible.
the American Welding Society. Often the test joint is set Second Through Sixth Passes Current adjustment should
up with a 38-inch root opening. Two or three root passes be high. Use the stringer bead technique and decrease the
are necessary when welding a joint with this gap. More whipping motion. If the metal becomes too hot, lengthen
passes are necessary to complete the joint because of the arc and whip the electrode forward until the crater has
greater separation between the plates. cooled. Fusion must be secured with the preceding passes

450Chapter 15Shielded Metal Arc Welding Practice: Jobs 15-J43J55 (Plate)

 Direction of Travel and the walls of the groove. Be sure to remove
the slag between each pass. Avoid undercut for
90 2035 all passes.
Groove Electrode Practice starts and stops. Travel in all
Welds directions.
510 Back-and-forth oscillating Oscillating motion
motion first pass. second to sixth pass.
Front View First Pass (Side View) Second Pass Operations
A B C 1. Obtain plates; check the job drawing,
Fig.15-38, for quantity and size.
2. Obtain electrodes of each quantity, type,
Groove
and size specified in the drawing.
2035 Groove 90
1020 Welds Welds 3. Set the power source for 110 to
1020
170amperes. Set a d.c. power source for
Third Pass Fourth and Fifth Passes Sixth Pass electrode positive.
D E F 4. Set up the plates and tack weld them as
shown on the job drawing.
Fig. 15-37 Electrode position when welding a V-groove butt joint in the over- 5. Fasten the joint in the overhead position
head position (4G). with an overhead welding jig.

Fig. 15-38 Job drawing J54.

Shielded Metal Arc Welding Practice: Jobs 15-J43J55 (Plate) Chapter 15451