Instructional Welding Lesson Plans PDF

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SMAWLESSON#1:Initiatingandmaintaininganarcusingthescratchstartmethod  OBJECTIVE:Uponcompletionofthislessonthelearnerwillbeabletostrikeandmaintainanarc usingSMAWonsteelplateusingE6010,E6011andE6013electrodes.  TEXTREFERENCE: PRACTICALEXERCISES:  Preparetheentiresurfaceofa3/8x4x 8in.steelplateforweldingbyusinga wirebrushorgrinder.    Securetheworkpiececlamp

  Settheweldingcurrentandpolarity. Becausetheytendtostarteasier, beginwithE6010,E6011orE6013.

Placethebareendofanelectrodein thejawgroovesoftheholderata90 degreeangle. 

 ScratchStartMethod  Positiontheelectrodeapproximately60 degreesfromtheplateandabout1in. abovetheedgeoftheplate.  Loweryourhelmetthenswingthe electrodedownlikestrikingamatch.  Whentheelectrodesmakescontact withtheplateanarcwillinitiate,atthat timeraisetheelectrodeabout1/4".  Lowerslightly,weldashortdistance, breakthearc,andrepeatstriking. 

SMAWLESSON#2:Weldingflatstringerbeads  OBJECTIVE:Uponcompletionofthislessonthelearnerwillbeabletoweldflatstringerbeads onsteelplateusingSMAWusingE6010,E6011andE6013electrodes.  TEXTREFERENCE:  PRACTICALEXERCISES:  1. Thefirststepinrunningaweldbeadisfortheweldertogetcomfortable.Placethehand holdingtheelectrodeholderinthepalmoftheoffhand.Placetheelbowoftheoffhandon thetable.Allowtheoff‐handtosupporttheweldinghand. 

2. ChooseanE6010,E6011orE6013electrodethenrepeatallstepsinvolvedinstrikingthe arc,SMAWLesson#1. 

3. Withthearcstruck,forma“draganglebytiltingtheelectrodeabout10‐15degreesinthe directionoftravelwhilemaintaininganarclengthofaboutthediameteroftheelectrode wire. 

4. Allowapuddletoformthatisabout2timesthediameteroftheelectrodewireandbegin todragtheelectrodewhilemaintainingthearclength. 

5. Aftertraveling1or2incheswithasimpledraggingmotion,begintomakeacircularor“C” patternwiththeendoftheelectrodemuchlikedrawingwithapencil.Keepthecircles about2‐3timesthediameteroftheelectrodewire. 

6. Continuetomakesmallcircleswhilemaintainingthearclengthuntilreachingtheendof theplate.Whenreachingtheendoftheplate,beforebreakingthearc,pausetoallowthe cratertofillin. 

7. Repeatallstepstomakeanotherbeadnexttothefirstone. 

8. Repeatallstepsusingotherelectrodes(E6010,E6011andE6013) 

Pausetoallowthecratertofillin.



SMAWLESSON#3:Duplicateflatstringerbeadstoformapaddedplate  OBJECTIVE:Uponcompletionofthislessonthelearnerwillbeabletomakeaflatpadof stringerweldbeadsusingE6010,E6011andE6013electrodes.  TEXTREFERENCE:  PRACTICALEXERCISES:  1. ThesamestepspreviouslyperformedinSMAWLessons#1and#2willbeusedtostrikethe arcandmakeweldbeads.  2. Prepareandcleanasteelplateabout3/8″x4″x8″  3. Strikeanarcandpauseuntilapuddlebeginstoform. Establishanarclengthandbegintravelingusingacircular or"C"motion.Pauseslightlyatthetopofthe"C"then movetocompletethemotionslightlyfaster,pausingagain atthetopofthe“C”.Proceedtotheendoftheplateand pauseagaintofillthecrater.  4. Cleantheslagfromtheexistingstringerbeadusingachippinghammerandwirebrush.  5. Thesecondbeadshouldoverlapthefirstbyaboutone‐thirdtoone‐halfofthefirstbead. Useadragangleof10to15degreesandusethetoeoftheexistingweldasthecenterof thecircularmotion.

 6. Eachstringerbeadshouldbeabout2to3timesthediameteroftheelectrodewire.   7. Eachnewbeadshouldcoveraboutone‐thirdtoone‐halfofthepreviousone.Continueto weld stringer beads in this manner covering the entire plate. Cool the plate as needed betweenpasses.

 8. When the plate is completely padded with stringer beads, choose another electrode and padanotherplate.

SMAWLESSON#4:WeldstringerbeadsinaTJointintheflatposition  OBJECTIVE:Uponcompletionofthislessonthelearnerwillbeabletoweldstringerbeadsina flatpositionTjointusingE6010,E6011andE6013electrodes.  TEXTREFERENCE:  PRACTICALEXERCISES:  1. ThesamestepspreviouslyperformedinSMAWLessons#1,#2and#3willbeusedtostrike thearcandmakeweldbeadsinaTjoint.  2. Prepareandcleanone3/8″x4″x8″andtwo3/8″x2″x8″steelplates. 

3. Tackweldthethreeplatestightlytogether ensuringthatnogapsexistandthattheplates areevenlyperpendiculartoeachotherasshown.  UsingE6010,placethetackweldsoneachend. 

4. PositiontheTjointintheflatpositionasshown.  5. Withtheelectrodeperpendiculartothejointruna stringerfromlefttoright.Maintainanelectrodedrag angleof10to15degrees.Useeitherthe"C"motion, orawhippingmotion. 

 6. Eachstringerbeadshouldbeabout2to3timesthediameteroftheelectrodewire.   7. Eachnewbeadshouldcover1/3‐1/2ofthepreviousone.  8. Usea10°to15°travelangleanda15°to20°workangle. Theworkanglewillchangeasnewbeadsarestackedon topofeachother,bead1centered,bead2onleft,bead3 onrightasshown.  9. Cleanandcooltheplateasneededbetweenpasses,then chooseanotherelectrodetoplace3beadsinanotherjoint.

Tacks

SMAWLESSON#5:WeldweavebeadsinaTJointintheflatposition  OBJECTIVE:Uponcompletionofthislessonthelearnerwillbeabletoweldweavebeadsina flatpositionTjointusingE6010,E6011andE6013electrodes.  TEXTREFERENCE:  PRACTICALEXERCISES:  1. ContinuefillingtheTjointusingbeadplacement asshown;withthefirstthreestringerscompleted, coverthemwithaweavebead.  2. Increasetheamperageslightly(5ampsoras needed).Startbyusingthesameelectrodeangles asusedtoweldbead#2.Strikeanarcattheleft toeofbead#2,thenmovetotheright,finishing theweaveattherighttoeofbead#3.  3. Continueweavingtheelectrodefromsidetoside pausingslightlyatthetoestofillthecrater.  4. Theweavebead(#4)shouldextendabout1/8inch beyondthetoesofbeads#2and#3beneathit.  5. Continuetorunbeads#5and#6similarly,each overlappingabout2/3ofbead#4.  

    

SMAWLESSON#6:Initiatingandmaintaininganarcusingthetapstartmethod  OBJECTIVE:Uponcompletionofthislessonthelearnerwillbeabletostrikeandmaintainanarc usingSMAWonsteelplateusingE7014,E7018andE7028electrodes.  TEXTREFERENCE: PRACTICALEXERCISES:  Preparetheentiresurfaceofa3/8x4x 8in.steelplateforweldingbyusinga wirebrushorgrinder.    Securetheworkpiececlamp

  Settheweldingcurrentandpolarity. E7014,E7018andE7028tendtocrust overatthetipandrequiretappingto Initiatethearc. 

Placethebareendofanelectrodein thejawgroovesoftheholderata90 degreeangle. 

TapStartMethod  Positiontheelectrodeapproximately90 degreesfromtheplateandabout1in. abovetheedgeoftheplate.  Loweryourhelmetthenpushthe electrodedowntotaptheplate.  Whentheelectrodesmakescontact withtheplateanarcwillinitiate,atthat timeraisetheelectrodeabout1/4".  Lowerslightly,weldashortdistance, breakthearc,andrepeatstriking.

AMPERAGEANDCURRENTSETTINGS 1/8″ AC 110to160amps E7014 5/32″ AC 150to210amps 3/32″ DCEP 115to165amps E7018 1/8″ DCEP 150to220amps 1/8″ DCEP 140to190amps E7028 5/32″ DCEP 180to250amps

SMAWLESSON#7:Weldstringerbeadsintheflatpositiontoformapaddedplate  OBJECTIVE:Uponcompletionofthislessonthelearnerwillbeabletomakeaflatpadof stringerweldbeadsusingE7014,E7018andE7028electrodes.  TEXTREFERENCE:  PRACTICALEXERCISES:  1. ThesamestepspreviouslyperformedinSMAWLesson#6willbeusedtostrikethearcand makeweldbeads.  2. Prepareandcleanasteelplateabout3/8″x4″x8″  3. Strikeanarcandpauseuntilapuddlebeginstoform.Establishanarclengthandbegin travelingusingadraggingmotionwithverylittlemanipulation,nomorethan1to2times thediameteroftheelectrode.Continuetotheendoftheplateandpriortobreakingthe arc,pausetofillthecrater.  4. Cleantheslagfromtheexistingstringerbeadusingachippinghammerandwirebrush.  5. Thesecondbeadshouldoverlapthefirstbyaboutone‐thirdtoone‐halfofthefirstbead. Useadragangleof10to15degreesandusethetoeoftheexistingweldasthecenterof thecircularmotion.

 6. Eachstringerbeadshouldbeabout2to3timesthediameteroftheelectrodewire.   7. Eachnewbeadshouldcoveraboutone‐thirdtoone‐halfofthepreviousone.Continueto weld stringer beads in this manner covering the entire plate. Cool the plate as needed betweenpasses.

 8. When the plate is completely padded with stringer beads, choose another electrode and padanotherplate.

SMAWLESSON#8:WeldstringerbeadsinaTJointintheflatposition  OBJECTIVE:Uponcompletionofthislessonthelearnerwillbeabletoweldstringerbeadsina flatpositionTjointusingE7014,E7018andE7028electrodes.  TEXTREFERENCE:  PRACTICALEXERCISES:  1. ThesamestepspreviouslyperformedinSMAWLessons#6,and#7willbeusedtostrikethe arcandmakeweldstringerbeads.  2. Prepareandcleanone3/8″x4″x8″andtwo3/8″x2″x8″steelplates. 

3. Tackweldthethreeplatestightlytogether ensuringthatnogapsexistandthattheplates areevenlyperpendiculartoeachotherasshown.  UsingE7014,placethetackweldsoneachend.

Tacks



4. PositiontheTjointintheflatpositionasshown.  5. Withtheelectrodeperpendiculartothejointruna stringerfromlefttoright.Maintainanelectrodeangle of10to15degrees.Useadraggingmotion,with verylittlesidetosidemotion. 

 6. Eachstringerbeadshouldbeabout2to3timesthediameteroftheelectrodewire.   7. Eachnewbeadshouldcover1/3‐1/2ofthepreviousone.  8. Usea10°to15°travelangleanda15°to20°workangle.Theworkanglewillchangeasnew beadsarestackedontopofeachother,bead1centered,bead2onleft,bead3onrightas shown.  9. Cleanandcooltheplateasneededbetweenpasses,thenchooseanotherelectrodetoplace 3beadsinanotherjoint. 

SMAWLESSON#9:WeldstringerbeadsinahorizontalTJointusingE6010andE6013  OBJECTIVE:Uponcompletionofthislessonthelearnerwillbeabletoweldstringerbeadsina horizontalpositionTjoint,usingE6010andE6013electrodes.  TEXTREFERENCE:  PRACTICALEXERCISES:  1. ThesamestepspreviouslyperformedinSMAWLessons#1,and#4willbeusedtostrikethe arcandmakefilletweldstringerbeads.  2. Preparesteelplatesforwelding:1ea.3/8″x3″x6″and1ea.3/8″x2″x6″ 

3. FormaTjointasshown,byplacingtackweldsontheendsofthejoint.UseE6013toweld stringerbeadsinthepositionshown(Horizontal2F). 

4. Startfromtheedgeoftheplate,positiontheelectrodeata45°anglefromthevertical member(workangle).Tilttheelectrodeabout10°‐15°towardthedirectionoftravel (travelangle).Useawhippingor“C”motionasusedpreviouslywiththiselectrode.When reachingtheendoftheplatepausetofillinthecrater.

 

5. Usethelowertoeofthefirstbeadasthecenterofthesecondbead.Useonlya30°to35° workangle.Maintainthesame10°‐15°travelangleanddraggingmotionwithapauseat theend.Cleansurfaceslagfromallbeadsthoroughlybetweenpasses.  6. Usetheuppertoeofthefirstbeadasthecenterofthethirdbead.Useonlya20°to25° workangletoplaceabeadthattotallycoversbead1andadjacenttobead2.Maintainthe same10°‐15°travelangleanddraggingmotionwithapauseattheend. 

7. Useasimilarsequenceofanglestoplace stringerbeads4,5,6overthebeads1,2,3 asshownontheright.  8. UseE6010toduplicatethe6stringerbeads madepreviouslywithE6013.   9. Eachstringerbeadshouldbeabout2to3timesthediameteroftheelectrodewire. Eachnewbeadshouldcover1/3‐1/2ofthepreviousone.

SMAWLESSON#10:WeldanAWSD1.1tackwelderqualificationtestTjoint  OBJECTIVE:InthislessonthelearnerwillweldatackwelderqualificationTjointin accordancewiththerequirementsofAWSD1.1.  TEXTREFERENCE:  PRACTICALEXERCISES:  1. AtackweldershallbequalifiedbyweldingoneTjointtestplateinthehorizontal2F positionusinganE6010,E6011orE6013electrode.  2. Thetackwelderqualificationtestplateshallconsistofa1/4″max.sizefilletweldabout 2″longononesideof3/8″thicksteelplate.Thesteelplatesshouldbeabout2″x3″and shallformanoffsetTjointthatisbrokenbyapplyingforcefromtheweldedsidebyany convenientmeans.Seetheillustrationbelow.  3. Priortobreaking,theinstructorshallverifythatthecompletedtestweldpresentsa reasonablyuniformappearancethatmustbefreefromoverlap,cracks,porosityand trappedslag.Undercutatanypointthroughouttheweldshallnotexceed1/32″deep.  4. Theweldmustfractureandmustnotrevealanylackoffusiontothebasemetal.Each indicationofslaginclusionorporosityshallnotexceed3/32″.  5. Awelderwhopassesthebreaktestmayobtainatackweldercertificationwhereby he/sheisqualifiedtomaketackweldsintheflatandhorizontalpositionsinsteelfrom 1/8″tounlimitedthicknessinlap,cornerandTjoints.Forcertification,theappropriate applicationformsmustbecompleted,submittedandacceptedbythecertifying authority. 

  

SMAWLESSON#11:WeldstringerbeadsinaflatbuttJoint(1G)withbackingusingE6010and E6013.  OBJECTIVE:Uponcompletionofthislessonthelearnerwillbeabletoweldstringerbeadsina buttjoint,usingE6010andE6013electrodes.  TEXTREFERENCE:  PRACTICALEXERCISES:  1. ThesamestepspreviouslyperformedinSMAWLessons#6,and#7willbeusedtostrikethe arcandmakeweldstringerbeads.  2. Prepare3steelplatesforwelding:2ea.3/8″x3″x6″and1ea.1/4″x2″x6″ 

3. Usethe1/4″plateasbackingwhilethe3/8″platesformasquaregrooveasshownbelow. Place3tackweldsoneachside,about1/2to3/4inchlong.Makesurethe1/4x2backing barisfittightlytothe3/8x3baseplates.Usea“C”clamptoholdthemtightwhiletacking. 

  4. Weld3stringerbeadsineachofthetwocornersusingthesametechniquesasLesson #9 andwithE6013electrodes. Withthreebeadsineachcorner,continuetofillin thecenter withstringerbeadsuntilflushorslightlyconvexwiththesurfaceofthebasemetal.  5. Eachstringerbeadshouldbeabout2to3timesthediameteroftheelectrodewire.  Eachnewbeadshouldcover1/3‐1/2ofthepreviousone.  6. Pauseattheendofeachbeadtofillinthecrater.Thoroughlycleansurfaceslagbetweenall passes.Whenthejointis filledliketheimage ontheright,repeatthislesson usingE6010 electrodes. 

     SMAWLESSON#12:WeldfilletstringerbeadsinahorizontalTJointusingE7018electrodes

 OBJECTIVE: Uponcompletionofthislessonthelearnerwillbeabletoweldfilletstringer beadsinahorizontalpositionTjoint,usingE7018electrodes.  TEXTREFERENCE:  PRACTICALEXERCISES:  10. ThesamestepspreviouslyperformedinSMAWLessons#7,and#8willbeusedtostrikethe arcandmakefilletweldstringerbeads.  11. Preparesteelplatesforwelding:1ea.3/8″x3″x6″and1ea.3/8″x2″x6″ 

12. FormaTjointasshown,byplacingtackweldsontheendsofthejoint.UseE7018toweld stringerbeadsinthepositionshown(Horizontal2F). 

13. Startfromtheedgeoftheplate,positiontheelectrodeata45°anglefromthevertical member(workangle).Tilttheelectrodeabout10°‐15°towardthedirectionoftravel (travelangle).Useadraggingmotionasusedpreviouslywiththiselectrode.Whenreaching theendoftheplatepausetofillinthecrater.

 

14. Usethelowertoeofthefirstbeadasthecenterofthesecondbead.Useonlya30°to35° workangle.Maintainthesame10°‐15°travelangleanddraggingmotionwithapauseat theend.Cleansurfaceslagfromallbeadsthoroughlybetweenpasses.  15. Usetheuppertoeofthefirstbeadasthecenterofthethirdbead.Useonlya20°to25° workangletoplaceabeadthattotallycoversbead1andadjacenttobead2.Maintainthe same10°‐15°travelangleanddraggingmotionwithapauseattheend. 

16. Useasimilarsequenceofanglestoplace 3stringerbeadsovertheexistingbeads asshownontheright.  17. ContinueusingE7018tofillintheother Sideofthejoint.   18. Eachstringerbeadshouldbeabout2to3timesthediameteroftheelectrodewire. Eachnewbeadshouldcover1/3‐1/2ofthepreviousone. SMAWLESSON#13:WeldstringerbeadsinaflatbuttJoint(1G)withbackingusingE7018.

 OBJECTIVE: Uponcompletionofthislessonthelearnerwillbeabletoweldstringerbeadsina buttjoint,usingE7018electrodes.  TEXTREFERENCE:  PRACTICALEXERCISES:  1. ThesamestepspreviouslyperformedinSMAWLessons#6,and#8willbeusedtostrikethe arcandmakefilletweldstringerbeadsinabuttjoint.  2. Prepare3steelplatesforwelding:2ea.3/8″x3″x6″and1ea.1/4″x2″x6″ 

3. Usethe1/4″plateasbackingwhilethe3/8″platesformasquaregrooveasshownbelow. Place3tackweldsoneachside,about1/2to3/4inchlong.Makesurethe1/4x2backing barisfittightlytothe3/8x3baseplates.Usea“C”clamptoholdthemtightwhiletacking. 

  4. Weld3stringerbeadsineachofthetwocornersusingthesametechniquesasLesson#10 andwithE7018electrodes. Withthreebeadsineachcorner,continuetofillin thecenter withstringerbeadsuntilflushorslightlyconvexwiththesurfaceofthebasemetal.  5. Eachstringerbeadshouldbeabout2to3timesthediameteroftheelectrodewire.  Eachnewbeadshouldcover1/3‐1/2ofthepreviousone.  6. Pauseattheendofeachbeadtofillinthecrater.Thoroughlycleansurfaceslagbetweenall passes. 

       SMAWLESSON#14:Weldhorizontalstringerbeadstoformapaddedplate 

OBJECTIVE:Uponcompletionofthislessonthelearnerwillbeabletomakeahorizontalpad ofstringerweldbeadsusingE6010andE6013electrodes.  TEXTREFERENCE:  PRACTICALEXERCISES:  1. ThesamestepspreviouslyperformedinSMAWLessons#1,#2and#3willbeusedtostrike thearcandmakestringerweldbeadsforpadding.  2. Prepareandcleanasteelplateabout3/8″x4″x8″. 

3. Insurethesurfaceoftheplateisclean. 

4. Adjusttheweldingcurrentaccordingto valuesshowninLesson#1forE6010. 