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Lincoln Electric C2.410 manual

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Table of contents for the manual

  • Page 1

    S TICK ELEC TRODE WELDING GUIDE Procedur es and T echniques[...]

  • Page 2

    -2- 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, pur- chasers may ask Lincoln Electric for advice or information about their us[...]

  • Page 3

    -3- W elding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 Out-of-Position Welding (V ertical and Overhead) . . . . . . . . . . . . . . . . . . . . . .4-7 High Deposition Welding . . . . . . . . . . . . . . . . . . . .8-15 W elding Inclined Plates . . . . . . . . . . . . . . . . . . . .16-17 High Speed Welding (Sheet Metal) .[...]

  • Page 4

    -4- WELDING PROCEDURES Out-Of-Position Welding (V ertical and Overhead) When welding out-of-position, the molten metal tends to spill out of the joint. T o offset this tendency , an electrode with a fast freezing deposit is needed. W elding made with out-of-position electr odes is slow , relatively expensive and requir e a high degree of operator s[...]

  • Page 5

    -5- V ertical Up T echniques for Fillet and Gr oove W elds 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 r etur ning the electrode tip to the crater area to add mor e weld metal. 2. Root pass beads, particularly when made with a whipping[...]

  • Page 6

    V ertical Up Gr oove W elds V ertical Down W elds W eld 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 [...]

  • Page 7

    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) 85 32 4-1/2 4-1/2 4-1/2 Ft. of Weld/Hr . (3) 40 25 [...]

  • Page 8

    -8- 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 electr odes because the high iron powder content i[...]

  • Page 9

    -9- T ravel 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 ar c causing erratic bead shape, spatter , and poor penetration. Deep Groove Gr oove Welds – T o hold the large pool of molten weld metal from Jet[...]

  • Page 10

    -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. W eld single pass fillets using a drag technique with the tip of the[...]

  • Page 11

    Lap W elds Use fillet weld procedur es 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 2[...]

  • Page 12

    Gr oove W elds Do not use for code quality work This square edge gr oove joint requires the deep penetration of Fleetweld 5P or 5P+. Gr oove W elds 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 [...]

  • Page 13

    -13- Deep Gr oove W elds 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 [...]

  • Page 14

    -14- Flat Fillet W elds Also see Low Hydrogen Procedures. For X-ray quality: 1. Use low hydrogen pr ocedures, pages 24-34. (or) 2. W eld 3/16” to 5/16” fillets with E6027 electrodes at the E7024 procedur es. Weld 3/8” and larger fillets with 1/4” E6027 at about 400 amps. T ravel speed will be slower . T L Plate Size – T 14 ga 12 ga 10 ga [...]

  • Page 15

    -15- Horizontal Fillet W elds Also see Low Hydrogen Procedures. Plate Size – T 14 ga 12 ga 10 ga 3/16 1/4 5/16 3/8 1/2 5/8 3/4 3/4 1 No. of Passes 1 2-3 1 2-3 1 2-4 1 2-5 1-2 1-3 1-4 1-5 Leg Size – L (in.) —— — 5/32 3/16 1/4 5/16 3/8 1/2 9/16 5/8 3/4 Electrode/ AWSClass Jetweld 1/E7024-1 Diameter (in.) 3/32 1/8 1/8 5/32 3/16 7/32 1/4 1/4 [...]

  • Page 16

    -16- W elding Inclined Plate These procedur es are used when: 1. The work cannot be positioned in the level position for high speed welding with High Deposition Jetweld electrodes. 2. The weld is made partly in the level position and partly downhill. Fleetweld 47 electrodes have a fairly high ir on powder content in the coating, which provides a go[...]

  • Page 17

    -17- W elding Inclined Plate Downhill Angle (deg.) 0 60 (1) 90 (2) 03 0 (1) 60 (2) 01 0 (1) 35 (2) 01 0 (1) 20 (2) 0-5 (2) No. of Passes 1 1 1 1 1 Leg Size – L (in.) 5/32 1/4 1/4 5/16 3/8 Electrode/AWS Class Fleetweld 47 / E7014 Diameter (in.) 5/32 3/16 7/32 1/4 1/4 Current (Amps) 200 250 310 370 400 Polarity AC AC AC AC AC Arc Speed In./Min. (3)[...]

  • Page 18

    -18- High Speed Welding (Sheet Metal) W elding sheet steel (18 thr ough12 gauge) requires electr odes that weld at high travel speeds with minimum skips, misses, slag entrapment, and undercut. Procedur es Groove welds . . . . . . . . . . . . . . . . . . . . . . . . . page 20 Edge Welds . . . . . . . . . . . . . . . . . . . . . . . . . . page 20 Fil[...]

  • Page 19

    -19- When welding with High Speed electrodes (E6012 and E6013) deposit the entire weld in one pass using non-weave beads or a slight weave. Drag the electrode on the joint and stay ahead of the molten pool. Use enough drag angle so the arc for ce pushes the weld metal back. Use currents in the high portion of the elec- trode’ s range. When weldin[...]

  • Page 20

    -20- Plate Size 18ga 16ga 14ga 12ga 10ga Electrode/AWS Class Fleetweld 5P , Fleetweld 5P+ /E6010 Diameter (in.) 3/32 1/8 1/8 5/32 3/16 Position (1) 0-30° Downhill Current (Amps) 40 70 80 120 135 Polarity (2) DC- DC- DC+ DC+ DC+ Arc Speed - In./Min. (3) 24 32 28 22 19 Lbs of Elec./Ft. of Weld .024 .029 .026 .049 .070 Position (1) 30-90° Downhill C[...]

  • Page 21

    -21- Fillet W elds Also see High Deposition Procedur es on page 28 for 14 to 10 gauge fillet welds with Jetweld electrodes. Lap W elds Flat Horizontal V er tical (welded down) Plate Size 18ga 16ga 14ga 12ga 10ga Electrode/AWS Class Fleetweld 37/ E6013 Diameter (in.) 3/32 1/8 5/32 5/32 3/16 Position (1) 0-30° Downhill (5) Current (Amps) 70 105 155 [...]

  • Page 22

    Cor ner Welds -22- W eld T ype/ Position 18ga 16ga 14ga 12ga 10ga Fillet W elds 0-30º 15 16 17 16 16 30-90º 18 19 21 20 18 Lap W elds 0-30º 17 18 18 16 15 30-60º 21 22 23 21 18 Groove W elds 0-30º 22 30 29 27 25 30-60º 26 32 30 29 27 Edge Welds - Same as DC Corner Welds - Same as DC Flat Ve r tical  (welded down) 18 to 10 gauge Pe r mis[...]

  • Page 23

    -23- Burnthrough Spot Welds (Roof Decking to Beam) Roof Deck Thickness 22 ga 20 ga 18 ga 16 ga Electrode/AWS Class Fleetweld 22 /E6022 Diameter (in.) 1/8 1/8 5/32 1/8 5/32 5/32 Position Flat Current (Amps) 110 120 150 150 165 180 Polarity DC- DC- DC- DC- DC- DC- &A C &A C & AC & AC & AC & AC Roof Deck Roof Beam Flange[...]

  • Page 24

    -24- Low Hydrogen W elding Low hydrogen electr odes are recommended for thr ee broad areas of application: 1. On low alloy , high carbon, high sulfur , or other steels wher e cracking is a problem. 2. When specified by governing codes. 3. For lowest costs on vertical, overhead and horizontal groove welds on heavy (over 1/2”) plate. Pr ocedur es V[...]

  • Page 25

    -25- Drag the electrode lightly . Since low hydrogen electr odes rely on the molten slag for shielding, never hold a long arc, whip, leave the crater , or move rapidly in any direction. Failure to follow these techniques may result in por osity and/or reduce mechani- cal properties. For Clean Tie-Ins – Strike the arc ahead of the crater , move qu[...]

  • Page 26

    -26- 2. For multipass welds, deposit a first pass bead using a slight weave. We emphasize the importance of moving into the corner to assure penetration into the corner . W eld additional layers with a side-to-side weave hesitating at the sides long enough to melt out any small slag pockets and minimize undercut. T ravel slow enough to maintain the[...]

  • Page 27

    V ertical Up Gr oove W elds Also see Out-of-Position Procedur es, page 4. Overhead Gr oove W elds -27- 1/8" First Pass 3/16" Fleetweld 5P (E6010), 150 amps DC + , 4-1/2 in./min. 1/8" Last Pass - back gouge before welding. T T 60° Plate Size – T (in.) 1/2 5/8 3/4 1 1-1/4 No. of Passes 3 4 5 7 9 Electrode/AWS Class Jet LH-78MR, Exca[...]

  • Page 28

    -28- V ertical Up Fillet W elds Overhead Fillet W elds Also see Out-of Position Procedur es, page 4. No. of Pass 1 1 1 1 1 2 3 Leg Size – L (in.) 3/16 1/4 5/16 3/8 1/2 5/8 3/4 Electrode/AWS Class Jet LH-78MR, Excalibur 7018 /E7018 Excalibur 7018-1 /E7018-1 Diameter (in.) 3/32 1/8 1/8 5/32 5/32 5/32 5/32 Current (Amps) 80 130 130 155 155 155 155 P[...]

  • Page 29

    -29- Horizontal Gr oove W elds Back gouge first bead as needed 1/8" T 45 ° 15 ° Plate Size – T (in.) 1 2 No. of Passes 1-2 3-12 1-20 21-38 Electrode/AWS Class Jet LH-78MR, Excalibur 7018 /E7018 Excalibur 7018-1/E7018-1 Diameter (in.) 3/16 Current (Amps) 230 200 230 200 Polarity DC+ DC+ DC+ DC+ Arc Speed In./Min. (1) 9 8.5 9 8.5 Ft. of Weld[...]

  • Page 30

    -30- Horizontal Gr oove W elds Use steel backing (as on page 29). T T/2 45 ° Plate Size – T (in.) 1-1/2 3 No. of Passes 4 9 12 22 Electrode/AWS Class Jet LH-78MR, Excalibur 7018 /E7018 Excalibur 7018-1 /E7018-1 Diameter (in.) 3/16 Current (Amps) 230 200 230 200 Polarity DC+ DC+ DC+ DC+ Arc Speed In./Min. (1) 9 8.5 9 8.5 Ft. of Weld/Hr . (2) 3.6 [...]

  • Page 31

    -31- Flat Fillet W elds Also see, High Deposition Procedures, page 8. L (1) First pass only . On later passes, adjust ar c speed to obtain proper bead size. (2) T otal for all passes. 100% operating factor . Note: E7028 can produce code quality welds. E7028 is recommended for making high speed low cost welds using High-Deposition electrode (high ir[...]

  • Page 32

    -32- Flat Fillet W elds Also see High Deposition Procedures, page 11. (1) First pass only . On later passes, adjust ar c speed to obtain proper bead size. (2) T otal for all passes. 100% operating factor . Note: E7018 can produce code quality welds. E7018 procedur es are used when E7028 is not available and for electrodes E8018 and E11018. No. of P[...]

  • Page 33

    -33- Horizontal Fillet W elds (1) First pass only . On later passes, adjust ar c speed to obtain proper bead size. (2) T otal for all passes. 100% operating factor . Note: E7028 can produce code quality welds. E7028 is recommended for making high speed low cost welds using High-Deposition electrode (high iron powder) techniques, described on pages [...]

  • Page 34

    -34- Horizontal Fillet W elds (1) First pass only . On later passes, adjust ar c speed to obtain proper bead size. (2) T otal for all passes. 100% operating factor . Note: E7018 can produce code quality welds. E7018 procedur es are used when E7028 is not available and for electrodes E8018 and E11018. No. of Passes 1 1 1 1 2 3 4 5 Leg Size – L (in[...]

  • Page 35

    -35- Minimum Preheat and Interpass T emperature (1) For stick electrode welding only Based on AWS Specification D1.1 Definitions T – Thickness of the thickest part at point of welding. Col. 1 – For the following steels when welded with other than low hydrogen electr odes ASTM A36; A53 Grade B; A106 Grade B; A131 Grades A, B, CS, D, DS, E; A139 [...]

  • Page 36

    -36- Stick Electrode T ypical Operating Procedur es Sizes & Current Ranges (Amps) Product AWS Electrode Name Class Polarity 3 / 3 2 ” 1/8” 5/32” 3/16” 7/32” 1/4” Fleetweld ® 5P E6010 DC+ 40-70 75-130 90-175 140-225 200-275 220-325 Fleetweld 5P+ E6010 DC+ 40-70 65-130 90-175 140-225 --- --- Fleetweld 35 E6011 AC 50-85 75-120 90-160 [...]

  • Page 37

    -37- Sizes & Current Ranges (Amps) Electrodes are manufactured in those sizes for which current ranges are given Product AWS Electrode Name Class Polarity 3/32” 1/8” 5/32” 3/16” 7/32” 1/4” Fleetweld 7 E6012 DC- --- 80-135 110-180 155-250 225-295 245-325 AC --- 90-150 120-200 170-275 250-325 275-360 Fleetweld 37 E6013 AC 75-105 (1) 1[...]

  • Page 38

    -38- Sizes & Current Ranges (Amps) Electrodes are manufactured in those sizes for which current ranges are given Product AWS Electrode Name Class Polarity 3/32” 1/8” 5/32” 3/16” 7/32” 1/4” 5/16” Excalibur 7018 E7018H4R DC+ 70-110 85-150 125-200 170-260 --- --- --- Excalibur 7018-1 E7018-1H4R AC 80-120 95-160 130-210 180-280 --- --[...]

  • Page 39

    -39- PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJUR Y OR DEA TH. KEEP CHILDREN AWA Y . P ACEMAKER WEARERS SHOULD CONSUL T WITH THEIR DOCTOR BEFORE OPERA TING. Read and understand the following safety highlights. For additional safety infor- mation it is strongly recommended that you purchase a copy of “Safety in W elding & Cutting - [...]

  • Page 40

    -40- ARC RA YS can burn. 2.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 2.b. Use suitable clothing made from durable flame-resistant material to protect your skin and tha[...]

  • Page 41

    -41- FUMES AND GASES can be dangerous. 3.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which requir e special ventilatio[...]

  • Page 42

    FOR ELECTRICALL Y power ed equipment. 6.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 6.c. Ground the equipment in accordance with the U.S. National Electrical[...]

  • Page 43

    -43- 7.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. 7.c.Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when [...]

  • Page 44

    THE LINCOLN ELECTRIC COMP ANY Local Sales and Service through Global Subsidiaries and Distributors Cleveland, Ohio 44117-1199 U.S.A. TEL (216) 481-8100 F AX (216) 486-1751 WEB SITE www .lincolnelectric.com Stick C2.410 12/04[...]