SMAWPipe WeldingTechniques

Positions1G2G5G6G1F2F2FR4F5F

1G PositionPipe rotated, Electrode is always at the topEither a split bead or weave technique may be used

2G PositionPipe Axis Vertical, Weld is Horizontal, Pipe is considered in a fixed position.Always use a split bead techniqueAlways work from the bottom up.

5G PositionAxis of the Pipe is Horizontal, The weld in vertical.Progression may be up or down.A weave bead is best used.

6G PositionPipe axis is fixed in position at a 45 degree incline. Thhe position includes flat, horizontal, vertical, and overhead welds.A split bead tecvhnique is best used.

1F PositionPipe is rotated. The pipe axis is at a 45 degree incline. Welding is to occur at the top of the pipe.Split bead or weave technique may be used.

2F PositionFixed PositionBest to use a split bead technique

2FR PositionRotatedA split bead technique is best used.

4F PositionA split bead technique is best used

5F PositionNot Rotated. Progression may be up or down. Split beads or weaves can be used on 5F-up welds, split beads are best used on 5F-down welds.

Root PassHot PassFill PassCover Pass

Always work from the bottom up when using the split bead techniqueAlways be careful not to create a tight area where slag may get trapped under the next weld.It is better to weave slightly than to leave a tight area.Plan your sequence of beads!

Always work toward the smaller side of the fillet. (It will be easier to get to)Always be careful not to create a tight area where slag may get trapped under the next weld.It is better to weave slightly than to leave a tight area.Plan your sequence of beads!

TechniquesStringer (push, drag, or whip), or Weave

Progression (vertical)Updeeper penetration Higher deposit rate (lb/hr)Use near 90 degree travel angle or slightly upDown faster (point to point)less penetration for thin metalless dilutionUse steep drag angle

Travel SpeedStay on the leading edge of the puddle

DimensionsReinforcement HeightASME flush - 1/16AWS flush 1/8 Reinforcement Width1/16 past bevel edgeSmooth transition at weld toe (45o max)

Keyholeing

BackingMetallicbacking ringconsumable inserts

Welding grooves with InsertsKeep the root opening wideMake the root pass in one beadAvoid tight areas at the weld toes

Welding a PJP grooveWorks great for limiting restrictions inside pipesmake up for loss of wall on reinforcement

Root OpeningsSmall will allow more amperage which will in turn make welding smoother and easier, as well as easier arc starts.Larger root openings will allow more penetration.

Root FacesLarger root faces will allow more amperage which will in turn make welding smoother and easier, as well as easier arc starts.Smaller root faces will allow more penetration.

Tacking, Tack Grinding3/4 longfeather both endsclean and flatten topsstart on top, burn through before endrun completely onto tack before stoppinginterpass grind lumps off before next passstagger all starts and stops betoeen passesstagger all starts and stops between beads in a single passDont overgrind tacks.

Root faces - 0450 included angleRemove all mill scales and rustTacking - not in grooveTack away from coupon area.Flush on backingButt Joint Preperation(With Backing)

600 included angleRoot facesTackingFeather TacksButt Joint Preperation(Joints without backing)

Open Root TechniqueUse root opening to allow increase in amperage for smoother weldingWhip backwards for penetrationWhip forwards to reduce penetrationDo Not Weave a root pass.Maintain a short arc gapStay slightly in front of the puddle at all times. Use the keyholing technique.

RestartsStagger all starts and stops or use runon, runoff tabsFeather all restarts & start on top, or start in front and remeltDont restart in a coupon area.Also stagger all beads on a single pass.Use a longer arc length when starting a weld.Compare interpass grinding techniques vs. no interpass grinding.

CratersFill craters by welding into the previous weld startUse a short arc length to control heat.

Wagon Tracks

Watch these areas. Be sure to keep it melted into these spots.

Electrode AnglesUp Progression - always point toward center of PipeDown Progression - use a steep drag angle

Arc LengthLonger arc lengths = increased puddle heat, flatter welds, deeper penetrationShorter arc lengths = less puddle heat, flatter welds, less penetrationUse arc length to control puddle size, penetration, and burn through.Normal arc length is 1/16 - 1/8Use a slightly longer arc length during a start or restart.

Helpful TipsClean your Welding Hood lensDrape the cable over your shoulder or kneeGet ComfortableWatch the puddle, not the arcConcentrate on steady travel speed and arc length

Basic review of position designation codes. These codes will be taught in detail later.Split bead or weave technique may be used because gravity will not act to pull the puddle to one side in this position

Emphasize the REASONS for choosing one technique over another

Recommend progressing from one side to the other on the split bead technique. Otherwise, you increase the likelihood of undercutting in previous beads and of getting a humpy contour.Using a wide weave will lead to the bead sagging toward the bottom, increasing the likelihood of overlap at the bottom, and undercut at the top.

Working from the bottom up gives you a shelf to work from which decreases the likelihood of entrapments

Recommend using a weave technique to avoid a narrow tight area at the upper side of a pass, especially the hot pass. Explain that this tight area must be avoided. You will not often burn it out. You will almost always create a massive slag inclusion. Cleaning before welding will not solve it either, because new slag will go into it from flux on the electrode as you weld.The weave technique is best used in vertical, F and OH doesnt matter much. Therefore, 5G-up will best be accomplished using the weave. There is a limit on how wide you will be allowed to weave. It will depend on the code requirements, electrode side, and electrode type.

Down vertical could use either, I prefer the split bead to increase travel speed stay ahead of the molten slag.

I tend to use a split bead technique on 6G. However, if the groove is narrow, I will sometimes use a weave bead to avoid that narrow tight area at the top toe of the weld.We tend to forget that pipe can have fillet welds too.This weld is no different than a 2F fillet weld on plate.Hot pass - one or two beads. But keep it open. If we did end up with a tight area, it would be best to open up the area with a grinder and repair it before moving to the next pass.Remember, there is a reason for a particular travel or longitudinal angle. There is also a reason for a whip or a stringer technique as well as a wide weave or a split bead technique. Think ahead and use the most advantageous technique.Welding is not magic, it is careful study and forethought.Review the effects for fast and slow travel on:penetrationcontourwidth

ExplainHow to do this techniquereasons for this techniqueeffects of root opening and root face on heat sinkwhy to never whip completely into the molten puddlethat keyhole size determines root reinforcement widthDescribe themWhy we use themWhy we dont use themshow examples