Metal Works Lesson 1

Title: Parts and Types of Electrode

Learning Outcomes:
At the end of the lesson, the students should be able to:
1. Enumerate the factors to be considered in choosing electrode for fillet and plate
welding;
2. Identify the parts of an electrode;
3. Discuss the electrode classification number according to the American Welding
Society (AWS); and
4. Classify the electrodes according to their number, width sizes and lengths.

Introduction
Basic Shield Metal Arc Welding (SMAW) practically utilizes an electrode. With this, it is
a vital to know the basic parts of an electrode and classification number according to requirements
set by AWS. It is also essential to consider the factors in choosing an electrode to be use.

Factors to consider in choosing electrode for fillet and plate welding

In bonding metal, both in fillet weld and groove weld, the choice of electrode plays a crucial
role in the result of the weld penetration, weld bead and strength of the weld. Fillet weld refers to
the process of joining two pieces metal in a perpendicular or right angle and it is commonly called
as tee joints. Groove weld is used to create beveled opening in a weld joint before welding to
achieve the necessary penetration.

Kind of metal to be weld. There are different kinds of metal that can be weld such as aluminum,
cast iron, copper, stainless steel and steel. An appropriate electrode according to its kind allowed
to ensure its bonds.

Welding machine to be used. There are various welding machine and they have specific current
requirement such as flux welding, MIG welding, Shield Metal Arc Welding and Gas Tungsten Arc
Welding. By these, it should be noted that not all electrodes can be use in both AC and DC
machines.

Thickness of metal to be welded. The thickness of the metal to be welded varies. In SMAW or
stick welding is commonly used to weld metal with a thickness of 1/8 of an inch (3.2 mm) or
thicker. While it is can be used for thinner materials. It is better suited for thicker section due to its
high heat input and deep penetration capabilities.
Welding position. It is very important to consider the welding position prior to purchasing
electrode:
1. Flat welding position is the easier position to weld since its not against the gravity. The
weld puddle stays fluid and wets into the joints evenly. Any type of electrode can do for
these position. These represents 1 in the third digit of the electrode.

2. Horizontal welding position. The weld in the horizontal position share many similarities
with the flat position. To combat the effect of gravity on the weld puddle in horizontal
groove weld, favor the top edge of the joint slightly with the work angle knowing the
puddle sag a bit. In horizontal fillet weld, keep a 450 angle to the joint to focus the heat
where the two pieces come together.

3. Vertical welding position. Vertical up is typically more common, specially on thicker

material. Moving up the plate for vertical weld, the puddle will naturally want to sag out
of he joint. Use a reduce wire feed speed and voltage to ensure the puddle does not fall out
of joint.

4. Overhead welding position. Overhead weld maybe required when your working on a fixed
piece or project. When welding in the overhead position, the sparks drop down. You may
have extra protection on the head such as cap under your welding helmet. Use fully leather
welding overall.
Parts of the Electrode

Flux Coating. It melts during the welding process and forms a gas shield that will protect the arc
and the weld pool. It also becomes slag that shall cover the deposited weld from any form of
impurities.

Core wire. It comes either in aluminum, brass, bronze, cast iron, copper, mild-steel, high-tensile
steel or stainless steel to correspond the type of metal to be weld. The wire melts during the welding
process and creates fusion with the base metal.

Electrode number. The number located in the welding rod or electrode indicates the tensile
strength, welding position and power bond coating.

Electrode Classification Number according to American Welding Society

Common Electrode Sizes

3/32”Ø = 2.38 mm, 1/8” Ø = 3.17mm, 5/32” Ø = 3.96mm, 3/16” Ø = 4.76mm, 7/32” Ø = 5.55mm,
¼” Ø = 6.35mm
The length of the electrode can be bought in 14 and 18 inches.

Common Mild Steel, Low Hydrogen and Stainless Electrodes

E-6011 is an electrode best for all welding position. The material is deep penetration electrode,
light slag, medium deposition rate and it is x-ray quality.

E-6012 is an electrode best all welding position except for vertical downward.
E-60-13 It is best for all welding position, it can achieve mild penetration wit good quality and
heavy slag.

E-7018 is an all purpose electrode. It is low-hydrogen type electrode for mild and low alloy.

E-308 L-16 an electrode with extremely low carbon for welding stainless steel.
Metal Works Lesson 2

Title: Weld Defects

Learning Outcomes:
At the end of the lesson, the students should be able to:
1. Describe the weld defect;
2. Identify the different weld defects;
3. Discuss the different causes of weld defects; and
4. Perform the steps in repairing weld defects.

Introduction
The defect in weld will particularly happen in diverse cases and for various reasons. To
help the future welder avoid making defects, it is imperative that this weld defects should be
identified. It is equally important for the welders to know why such defects exist in order to provide
them opportunity to repair the defects.

Weld defect. It refers to the inadequacy of the welded part . Defects happen when inappropriate
welding process occur such as arc length, speed travel and angle of electrode. Material being used
could be a contributor such as mismatched electrode to the joining metal. The presence of these
on the metal joints will cause weakness on the weld at the same time creates a undesirable
appearance.

Common Weld Defects

1. Spatters. It is a droplets of molten materials that are scattered during the welding process.
They can be plainly identified as they form like a small ball that stick on the base metal.

Possible Causes of Spatters Corrective measures

Current is too high Reduce the current

The arc is too long Have a short arc

Excessive arc blow Alternating current is recommended

Electrode angle is incorrect Angle of the electrode is vertical to the

surface
2. Welding distortion and warpage. This defect is due to excessive heat being applied to the
base metal during the welding process where the metal expands and bend and swing to
different direction.

Possible Causes of Distortion Corrective measures

Extreme heat applied Use correct current, electrode

Proper system base metal

Improper tacking of base metal Proper tacking of joint edge before

Welding

Faulty preparation of the base Clean the base metal to perform proper
metal welding procedure

Improper root gap Proper gap according to the thickness

of the base metal

3. Porosity. It is a stuck gas in the weld metal making it part of the weld and weakens the
metal joints.

Possible Causes of Porosity Corrective measures

Unprepared base metal Clean the metal using steel brush

Fast travel speed which result to Correct travel speed to allow sufficient
insufficient puddling time pudding time

The arc length is too short Maintain correct arc length

Apply proper waving to eradicate

pinholes

4. Slag inclusion. It is slag that is stuck in the weld metal.

Possible Causes of Slag Corrective measures

The manipulation of the electrode Perform moderate speed travel in order

during the weld process is to manipulate the electrode properly to
inappropriate get enough weld puddling time

The arc is too short Maintain correct arc length

The current is too low Adjust the current to higher to have

proper fusion
 Applying the next pass with Remove all the slag by cleaning with a
unclean bead chipping hammer or steel brush or a
grinding stone.

5. Undercut. It is a groove cut in the toe of the weld that is left unfilled.

Possible Causes of Undercut Corrective measures

The current is too high Reduce the current to lower

The size of the electrode is Replace the electrode with the

inappropriate specified code

Incorrect angle electrode and Manipulate the electrode with the

improper manipulation corresponding proper angle

6. Incomplete fusion. It is the fusion between the base metal and weld bead is not complete
or one sided only.

Possible Causes of Incomplete Corrective measures

Fusion

The current is low which is unable Adjust the current that would allow
to melt the metal correct fusion result

The travel during the process is too Maintain correct travel in order to make
fast weaving motion that is enough to melt
the metal

The electrode size and type being Use an electrode that would match the
used is not appropriate to the task joint to be weld

Incorrect electrode angle Consider the electrode angle and travel

7. Poor penetration. It is an improper penetration between the base metal and the filler metal.

Possible Causes of Poor Corrective measures

Penetration

Travel too fast that cause improper Avoid too much fast travel to allow
penetration penetration of filler

The electrode use is too large Use appropriate electrode in a certain

task
 The root gap was incorrect The root gap will be the size of the core
of the electrode being used

The current is too low which The current should be enough to create
unable to melt the metal desired penetration.

8. Crack of Weld. It is the crack in the weld metal or the base metal from excessive stress on
the metal during welding process.

Possible Causes of Incomplete Corrective measures

Fusion

Weld bead is too small for the base Create a larger weld bead for a thick
metal plate

Wrong preparation of the base Pre heat the metal needed. Clean the
metal metal

The electrode is mismatch Use appropriate size of electrode