1、The Everyday Pocket Handbook for Arc Welding Steel a series Compiled as a useful tool for on-the-job welding personnel by an AWS Presidential Task Group Reproduced by Global Engineering Documents With the Permission of AWS Under Royalty Agreement GLOBAL EAIGKNEERiNG DOCUIVIENTC“ American Welding Soc
2、iety 4b O 1994 by American Welding Society. All rights reserved. Printed in the United States of America Noto: Although care was taken in choosing and presenting the data in this guide, AWS cannot gurantee that it is error free. Further, this guide is not intended to be an exhaustive treatment of th
3、e topic and therefore may not include all available information, including with respect to safety and health issues. By publishing this guide, AWS does not insure anyone using the information it contains against any liabliity or injury to property or persons arising from that use. 2 Table of Content
4、s Basic Safety Precautions . 4 Electrodes: CIassication, Size, Amps, Carbon Arc Gouging Electrodes . 15 Deposition Rate for Mild Steel for GMAW 16 Recommended Copper Cable Sizes 17 Guide to Electrode Conditioning and Storage 18 Welding Positions - fillet (piate) 19 Welding Positions - Groove (plate)
5、 20 Welding Positions - Pipe 21 ThiCkms and Weight of steel Plates - 1/32 to 2 inch i 23 How to Use Weld Fillet Gage . 25 Pipe Size and Wall Thicknesses 26 Tests to Identify the Material 27 using Natural Gas 29 using Acetylene Gas 30 using Propylene Gas 31 Deposition Rate Classification System for C
6、arbon Steel Eiectrodes for SMAW . 6 SMAW E6010 Electrodes 7 SMAW E6011 Electrodes 7 SMAW E60 12 Electrodes 8 SMAW E601 3 Electrodes 8 SMAW E701 8 Electrodes 9 SMAW E7024 Electrodes 9 Classification System for Solid and Composite Carbon Steel Electrodes for GMAW 10 GMAW ER7OS-X Short Arc Electrodes 1
7、1 GMAW ER70S-X Spray Arc Electrodes 11 GMAW E70C-XX Metal Cored Electrodes 12 Classification System for Carbon Steel Electrodes for FCAW . 13 FCAW Self-shielded Electrodes 14 . Schedu, e for Oxyfuel Cuaing . . FCAW E7XT-X Gas-Shieldd Electrodes . 14 Basic Welding Symbols and Their Location 32 Locati
8、on of Elements of a Welding Symbol . 34 3 Basic Safety Precautions Burn Protection. Molten metal, sparks, slag, and hot wonk surfaces are produced by welding, cutting, and allied processes. These can cause burns if precautionary measures are not used. Workers should wear protective clothing made of
9、fire-resistant material. Pant cuffs, open pock- ets, or other places on clothing that can catch and retain molten metal or sparks should not be worn. High-top shoes or leather leggings and fire-resistant gloves should be worn. Pant legs should be worn over the outside of high-top shoes. Heimets or h
10、and shields that provide pro- tection for the face, neck, and ears, and a head covering to protect the head should be used. In addition, appropriate eye protection should be used. Electrical Hazards. Electric shock can kill. However, it can be avoided. Live electrical parts should not be touched. Th
11、e manufacturers instructions and recommended safe practices should be read and understood. Faulty installa- tion, improper grounding, and incorrect opera- tion and maintenance of electrical equipment are all sources of danger. All electrical equipment and the workpiece should be grounded. The workpi
12、ece lead is not a ground lead. It is used only to complete the welding circuit. A separate connection is required to ground the workpiece. The work- piece should not be mistaken for a ground connection. 4 Fumes and Gases. Many welding, cutting, and allied processes produce fumes and gases which may
13、be harmful to health. Avoid breath- ing the air in the fume plume directly above the arc. Do not weld in a confined area without a ventilation system. Use point-of-welding fume removal when welding galvanized steel, zinc, lead, cadmium, chromium, manganese, brass, or bronze. Do not weld on piping or
14、 containers that have held hazardous materials unless the containers have been inerted properly. Compressed Gas Cylinders. Keep caps on cylinders when not in use. Make sure that gas cylinders are chained to a wall or other struc- turai support. Radiation. Arc welding may produce ultra- violet, infra
15、red, or light radiation. Always wear protective clothing and eye protection to pro- tect the skin and eyes from radiation. Shield others from light radiation from your welding operation. AWS also recommends a personal copy of “Arc Welding Safely” and “Fire Safety in Welding and Cutting”. 5 Classific
16、ation System for Carbon Steel Electrodes for SMAW Designates an electrode. This designator may be deleted from the product imprint required for identification of the electrode. Designates the tensile strength (minimum), in ksi, of the weld metal when produced in accord- ance with the test assembly p
17、reparation procedure of this specification. Designates the welding position in which electrodes are usable, the type of covering, and the kind of welding current for which the electrodes are suitable. Optional Supplemental Designators: Designates that the elecirode meets the requirements of the abso
18、rbed moisture test (an optional supplemental test for all low hydrogen electrodes except the E7018M classification, for which the test is required). Designates that the elecwde meets the requirements of the diffusible hydrogen test (an optional supplemental test of the weld metal from low hydrogen e
19、lectrodes, as-received or conditioned - with an average value not exceeding “2” mi. of H, per 100g of deposited metal, where “Z“ is 4.8, or 16). Designates that the electrode (E7016, E7018, or E7024) meets the requirements for improved toughness - and ductility in the case of E7024. IXXYY-1HZR 6 SMA
20、W Electrodes I Il i SMAW Electrodes I E6010 II Diameter (in.) 3/32 E6011 i Amps Dep. Rale 50 0.8 I IL i 5/32 130 2.3 140 2.8 Diameter (in.) Dep. Rate 5/32 140 3.5 175 4.0 I I 130 I 2.3 I 7/32 190 3.5 190 4.5 I 3/16 1 170 1 4.0 1 t-+-+pj 220 5.1 I I1 1 1. Deposition rate in Ibar based on 100% arc tim
21、e. May vary within =IO%. The efficiency. with a 2“ stub loss, is approximately 60%. I. Deposition rate in IbAr based on 100% arc time. May vary within 110%. The efficiency, with a 2“ stub loss, is approximately 60%. 7 SMAW Electrodes I - E601 2 Diameter (fm) Amps Dep. Rate 118 100 2.4 i 30 2.9 I SMA
22、W Electrodes I i 18 100 i .8 135 3.0 E601 3 Diameter (in.) I Amps I Dep.Rate 3/16 I 75 I 1.2 1 180 3.2 220 4.1 1 I4 I 7/32 I 275 I 4.8 I 320 5.6 320 5.6 I 7/32 1 250 I 5.3 I I I 290 I 6.1 I I. Deposition :IO%. The CeQmCy. with a 2“ stub loss, is approximately 60%. in Ibsnir based on 100% arc time. M
23、ay vary within I. Deposition rate in IbsBir bascd on 100% arc time. May vary within 110%. The efficiency, with a 2” stub loss, is approximately 60%. 8 I SMAW Electrodes I Diameter (in.) 3/32 -1 - I CMAW Electrodes Amps Dep. Rate 70 1.4 110 1.7 Diameter (in.) I18 I 118 1 1 2.6 i 3 .O 5/32 3.1 Amps ep
24、. Rate 140 4.2 I E7024 I 3/16 240 7.2 245 7.5 1 5/32 I 180 I 5.3 I 114 400 11.6 12.6 I I 200 I 4.3 I I I 290 1- -9.11 7/32 250 1 340 I 7.4 I I. Deposition rate in Ibsnir based on 100% arc time. May vary within +IO%. The efficiency, with a 2“ stub loss. is approximately 60%. I 7/32 1 320 9.4 I 9 Clas
25、sification System for Solid and Composite Carbon Steel Electrodes for GMAW Indicates use as either an electrode or rod (ER), or use only as an electrode (E). Indicates, in 1.OOO psi (6.9 MPa) increments, the minimum tensile suength of the weid metal produced by the electrode when tested according to
26、 this specification. In this case, 70 indi- cates 70,000 psi. Indicates whether the filler metai is solid (S) or composite (C). (for solid wire) E 70 C - X Y (for composite wire) Indicates the type of shielding gas used for classification of composite electrodes. Carbon dioxide shielding is indicate
27、d by “C” and 75-80% Arhalance CO2 is indicated by “M”. Indicates the chemical composition of a solid electrode or the chemical composition of the weid metal produced by a composite electrode. The use of the “GS suffix designates filler metais intended for single-pass applications only. ER7OS-X GMAW
28、Electrodes Diameter (in.) I .O30 1 70 1 15 I 1.2 I Dep. Rate Volts Amps .o45 100 2.7 .o45 200 24 6.7 315 I 30 12.5 I GMAW Electrodes I 1 225 I 22 ER70S-X Spray Arc 8.0 3/32 1 350 1 29 I 600 1 33 I 1 290 I 28 1 12.0 I 10.0 20.0 1- 1/16 1 275 1 24 1 8.7 I. Deposition rate in Ibsnir based on 100% arc t
29、ime. May vary within 110%. Deposition efficiency is assumed to be 98%. 11 1. Deposition rate in ibslhr based on 100% arc time. May vary within *lo%. Deposition efficiency is assumed to be 92%. Classification System for Carbon Steel Electrodes for FCAW Designates an electrode. This designator is eith
30、er 6 or 7. it indicates the minimum tensile seen (in psi x 10.OOO) of the weid metal when the weld is made in the manner prescribed by this specification. This designator is either O or 1. It indicates the positions of welding for which the electrode is intended. (O is for flat and horizontal positi
31、on only. 1 is for all positions.) This designator indicates that the electrode is a flux cored electrode. This designator is some number from I through 14 or the letter “G with or without an “S” follow- ing. The number refers to the usability of the electrode. The “c” indicates that the external shi
32、eld- ing, polarity, and impact properties are not specified. The “S” indicates that the electrode is suitable for a weld consisting of a single pass. Such an electrode is not suitable for a multi-pass weld. An “M designator in this position indicates that the electrode is classified using 7540% argd
33、 balance CO2 shielding gas. When the “M designator does not appear, it signifies that either the shielding gas used for classification is CO2 or that the product is a self-shielded product. Designates that the electrode meets the requirements of the diffusible hydrogen test (an optionai supplemental
34、 test of the weld metal with an average value not exceeding 2” mL of H, per 1oOg of deposited metal where 27 is 4.8, or 16). Designates that the electrode meets the requirements for improved toughness by meeting a require- ment of 20 ft-lbf at 40 “F (27J at -4OOC). Absence of the “J” indicates norma
35、l impact requirements. Optional Supplemental Designators 13 E X X T - X M J HZ L FCAW Electrodes RXT-X Gas-Shielded .O52 600 430 17.6 1/16 150 i 90 6.1 500 39 500 20.1 I , , I I 1 5/64 I 112 1 12 1 250 1 1:; I 258 450 14.8 278 34 550 21.3 3/32 124 350 I. Deposition rate in Ibsihr based on 100% arc t
36、ime. May vary within 330%. I FCAW Electrodes Self-Shielded (DCEN) .O68 56 160 2.1 132 19 275 5.2 I (DCEP) ,120 450 13.0 i 23 33 550 15.5 E701-7 (DCEN) 1 3/32 1 135 1 i 1 1 8.8 200 126 7/64 120 400 11.5 175 490 15.8 1. Deposition rate in Ibsihr based on 100% arc time. May vary within *lo%. 14 Carbon
37、Arc Gouging Electrodes Suggested Current Ranges for the Commonly Used CAC-A Electrode Types and Diameters 1 5/32 3/16 I Electrode Diameter 1 DC Electrode with DCEP, A 1 AC Electrode with AC, A I - - 4.0 90 150 4.8 150 200 150 200 1 in. I mm I min I max I min I max I 114 1 6.4 200 400 200 300 318 if2
38、 5/8 15 9.5 350 600 I 300 500 12.7 I 600 1000 400 600 15.9 800 1 i200 - - CI K si m g f Deposition Rate for Mild Steel for GMAW PLOT OF WIRE FEED SPEED AND DEPOSillON RATE 32 30- 20 - 26- 24 - 22 - 20- 18- 16- 14- 12- lo- 0- 6 - 4 - 2 - O O 100200300400500 600 700 800 900 lo00 WIRE FEED SPEED IN INC
39、HES/MlNUTE 16 Recommended Copper Cable Sizes Amperes 100 I Cable Sizes for Combined Lengths of Electrode and Work Cables 50 to iooft io0 to 15oft 150 to 200 n Percent Duty Cycie O to 50 ft. 20 8 4 3 2 225 201413 2 1 17 250 40 21 2 1 1 Guide to Electrode Conditioning and Storage AWS Elecbode Classinc
40、ation EXXIO. EXXII, EXxIZ EXX13 Air Conditioned Holding Reconditioning Temperature and Time Storage Before Opening Temperature to Affect Weld Quality RH = Relative Humidity After Opening Recondition Step #i Rebake Step #2 IOO“F(2254 1300 Keep Dry Room Not Required Not Required Temperature NEVER STOR
41、E 60%(210%)RH BELOW 50% RH 404 20F Exx2o,w(30 I 700F (250“) ONE HOUR ONE-HALF HOUR ONE NOT ROTATED DURING WELDING. WELD HORIZONTAL (il 57. 21 Welding Positions - Pipe (contd) 15 PIPE OR TUBE HORIZONTAL (115); NOT ROTATED DURING WELDING. WELD FLAT, VERTICAL, OVERHEAD. 6GR T, K, Y CONNECTION RESTRICTI
42、ON RING TEST WELD PIPE INCLINED FIXED (4515); NOT ROTATED DURING WELDING. 22 1 13/32 1 7/16 1 15/32 1 1/2 0.406 10.319 16.575 0.438 11.112 17.850 0.469 11.906 19.125 0.500 12.700 20.400 Thickness and Weight of Steel Plates: 1-2 inch 1-7/16 1-15/32 1-112 1-5/16 1 1.313 I 33.338 1 53.550 1-11/32 1.344
43、 1 34.131 I 54.825 i .438 36.5 i 3 58.650 1.469 37.306 59.925 1 SOO 38.100 61.200 1-318 I 1.375 I 34.925 I 56.100 1-13/32 I 1.406 1 35.719 I 57.375 I - 19/32 40.481 65.025 I 1-518 41.275 1 66.300 1 I 1-314 I 1.750 1 44.450 I 71.400 I 1-25/32 1.781 45.244 72.675 1-13/16 1.813 46.038 73.950 1 -27/32 4
44、6.831 75.225 1-718 1.875 47.625 76.500 1-29/32 48.419 77.715 1-15/16 1.938 49.213 79.050 1-31/32 1 1.969 1 50.006 1 80.325 2 I 2.000 1 50.800 1 81.600 24 How to Use Weld Fillet Gage PLACEMENT CONVEX WELDS CONCAVE WELDS BE CERTAIN BLADE EDGE IS SQUARE WITH WELDED PARTS. FOR CONVEX WELDS USE BLADE WIT
45、H SINGLE ARC AT APPROPRIATE SIZE. FOR CONCAVE WELDS: USE BLADE WITH DOUBLE ARC AT APPROPRIATE SIZE. 25 Commercial Pipe Sizes and Wall Thicknesses (ASA-BS. and 836.19) NOTES: I. Schedules 5s and 10s are available in conusion resistant materials and Schedule 10s is also available in carbon steel in si
46、zes 12 in. and smaller. 2. Thicknesses shown in irolics are also available in stainless steel, under the designation Schedule 40s. 3. Thicknesses shown in ircrlics are also available in stainless steel, under the designation Schedule 80s. 26 Material Identification equipment. (Cir. XltP.M. -) = S.F.
47、 per Min. Test I Low Carbon Steel Long Yellow Carrier Lines (Approx. 20% Carbon or Below) Appearance Est I Dark Grey Chius Easily e FractureTest 1 Bright Grey Melts Fast Becomes Bright Red Before Melting Flame Est - *For best resulu, use at least 5.000 surface feet per minute on grinding Med. Carbon
48、 Steel Dark Grey Strongly Magnetic Continuous Chip Smooth Edges Chips Easily Very Light Grey Melts Fast Becomes Bright Red Before Melting - &- Yellow Lines Sprigs Very Plain Now (Approx. 20% to 45% Carbon) 27 High Carbon Steel Dark Grey Strongly Magnetic Hard to Chip Can Be Continuous Very Light Gre
49、y Melts Fast Becomes Bright Red Before Melting - #- Yellow Lines Bright Bunt Very Clear Numerous Star Bunt (Approx. 45% Carbon and Above) High Sulphur Steel Dark Grey Strongly Magnetic Continuous Chip Smooth Edges Chios Easilv Bright Grey Fine Grain Melts FaFt Becomes Bright Red Before Melting Swelling Canin Lina cigar shape Material Identification (contd) Twt Manganese Steel Stainless Steel Cast Iron Dull Grey Dull Bright, Evidence of Silvety Smooth 9and Mnld 3 rae res cast Surface Extremely Hard to Chisel r& Chisel Test Con
