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Stick Welding Procedure stick 12/96 – ST-151 593 Weld current starts when electrode touches work- piece. Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. 1 Workpiece Make sure workpiece is clean before welding. 2 Work Clamp 3 Electrode A small diameter electrode requires less current than a large one. Follow electrode manufacturer’s instructions when setting weld amperage (see Section 11-2). 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece. A short arc with correct amperage will give a sharp, crackling sound. 7 Slag Use a chipping hammer and wire brush to remove slag. Remove slag and check weld bead before making another weld pass. Tools Needed: 1 4 3 5 2 7 6 OM-498 Page 41 11-2. Electrode and Amperage Selection Chart ELECTRODEDIAMETER 50100150200250300350400450AMPERAGERANGE 6010 & 6011 3/32 1/8 5/32 3/16 7/32 1/4 6013 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 7014 3/32 1/8 5/32 3/16 7/32 1/4 7018 3/32 1/8 5/32 3/16 7/32 1/4 7024 3/32 1/8 5/32 3/16 7/32 1/4 Ni-Cl 3/32 1/8 5/32 3/16 308L 3/32 1/8 5/32 ELECTRODEDC*ACPOSITIONPENETRATIONUSAGE 6010 EP ALL DEEP MIN. PREP, ROUGH HIGH SPATTER 6011 EP ALL DEEP 6013 EP,EN ALL LOW GENERAL 7014 EP,EN ALL MED SMOOTH, EASY, FAST 7018 EP ALL LOW LOW HYDROGEN, STRONG 7024 EP,EN FLAT HORIZ FILLET LOW SMOOTH, EASY, FASTER NI-CL EP ALL LOW CAST IRON 308L EP ALL LOW STAINLESS *EP = ELECTRODE POSITIVE (REVERSE POLARITY) EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY) Ref. S-087 985-A 11-3. Striking an Arc – Scratch Start Technique 1 1 Electrode 2 Workpiece 3 Arc 3 Drag electrode across workpiece like striking a match; lift electrode 2 slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to work- piece, use a quick twist to free it. 11-4. Striking an Arc – Tapping Technique 1 3 1 Electrode 2 Workpiece 3 Arc Bring electrode straight down to workpiece; then lift slightly to start 2 arc. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it. OM-498 Page 42 11-5. Positioning Electrode Holder S-0060 90° 90° 10°-30° 45° 45° GROOVE WELDS FILLET WELDS End View of Work Angle Side View of Electrode Angle End View of Work Angle Side View of Electrode Angle 10°-30° 11-6. Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 1 2 34 5 S-0053-A 11-7. Good Weld Bead Characteristics S-0052-B 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1/8 in. (3.2 mm) thickness in metals being welded. 4 No Overlap 5 Good Penetration into Base Metal 1 52 3 4 OM-498 Page 43 11-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. NOTE S-0061 ELECTRODE ANGLE ARC LENGTH TRAVEL SPEED Slow Normal Fast 10° -30° Drag Too Short Normal Too Long Spatter Angle Too Small Angle Too Large Correct Angle 11-9. Electrode Movement During Welding Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better. NOTE S-0054-A 1 Stringer Bead – Steady Movement Along Seam 2 Weave Bead – Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of electrode. 1 2 3 OM-498 Page 44 11-10. Butt Joints S-0662 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position before final weld. 2 Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. 3 Single V-Groove Weld Good for materials 3/16 – 3/4 in (5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels. Create 30 degree angle of bevel on materials in V-groove welding. 4 Double V-Groove Weld Good for materials thicker than 3/16 in (5 mm). 30° 2 1 1/16 in(1.6 mm) 3 4 11-11. Lap Joint 30° Or Less Or Less 1 1 2 3 30° 1 Electrode 2 Single-Layer Fillet Weld Move electrode in circular motion. 3 Multi-Layer Fillet Weld Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass. Weld both sides of joint for maximum strength. Single-Layer Fillet Weld Multi-Layer Fillet Weld S-0063 / S-0064 11-12. Tee Joint S-0060 / S-0058-A / S-0061 1 Electrode 2 Fillet Weld Keep arc short and move at definite rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface. For maximum strength weld both sides of upright section. 3 Multi-Layer Deposits Weld a second layer when a heavier fillet is needed. Use any...