Welding Guidelines; General - Campbell Hausfeld GW4510 Manual De Instrucciones De Operación Y Lista De Partes

Operating Instructions and Parts Manual

Welding Guidelines

GENERAL

This line of welding machines utilizes
a process known as Shielded Metal-Arc
Welding (SMAW) . This process is used
to bond metals by heating them with
an electric arc created between the
electrode and the work piece .
Electrodes used for shielded metal arc
welding have two parts . The inner
core is a metal rod or wire that should
be similar in composition to the base
metal . The outer coating is called
flux . Various types of flux exist . Each
coating is used for a particular welding
situation .
While the metal is molten, it can be
contaminated by elements in the air .
This contamination could weaken
the weld . The flux coating creates
a protective barrier called slag that
protects the molten metal from
contaminants .
When current (amperage) flows
through the circuit to the electrode, an
arc is formed between the end of the
electrode and the work piece . The arc
melts the electrode and the work piece .
The melted metal of the electrode flows
into the molten crater and forms a bond
with the work piece as shown in
Figure 4 .
NOTE: Discontinue using and discard
electrodes that burn down to 1 to 2
inches from the electrode holder .
Flux
Slag
Weld
Work Piece
figure 4 - Weld Components
www.chpower.com
STRIKING AN ARC
Place the bare end of the electrode in
the holder . Grip the holder lightly to
reduce tiring of the hand and arm .
NOTE: Always keep the jaws of the
holder clean to insure good electrical
contact with the electrode .
or welding bench with the electrode as
this causes arc flashes.
The best method of striking an arc is the
scratching method . Drag the electrode
at an angle along the surface much like
striking a match . Upon contact with the
plate, lift the electrode approximately
1/16" off the surface or it will stick (See
Figure 5) .
NOTE: Should the electrode stick to the
work piece, break it loose by quickly
twisting or bending at the holder
while pulling upward . If the electrode
does not break loose, disengage the
electrode by releasing it from the
holder .
Same as Electrode Diameter
figure 5 - Scratching method
Wire
ELECTRODE TypE AND SIzE
Four types of electrodes are
recommended for this welder . The
electrodes are commonly known by
the AWS (American Welding Society)
Crater
designation as follows:
1. E-6011 Deep penetrating
• Flat bead with deep penetrating
arc .
• For rusted or dirty mild steel
general repair work .
2. E-6013 General purpose
• All position, smooth deposit rod
with low spatter .
• For all mild steel and general
purpose work .
3.
•
•
4.
•
Be careful not to
touch the work piece
•
NOTE: Only the E-7018-AC electrode
is recommended for use with these
welders . Other E-7018 electrodes are
designed for use with higher open
circuit voltages than these welders are
capable of producing . Recommended
electrode diameter is 3/32 inch or 1/8
inch .
ARC WELDING BASICS
Four basic techniques affect weld
quality . These are: amperage setting,
weld angle, arc length, and travel
speed . Proper use of these techniques is
necessary for good weld quality .
AmpERAGE SETTING
The correct amperage involves the
adjustment of the welding machine
1/16 inch
to the required amp setting . This is
regulated by a knob on the welder . The
amperage required depends on the size
(diameter) of electrode used and the
thickness of the work piece .
Consult specifications listed on the
welder . Excessive amps burn through
light metals and the weld bead is flat
and porous (See Figure 7) . The bead
appears high and irregular if the
amperage is too low .
WELD ANGLE
Weld angle is the angle at which the
electrode is held during the welding
process . Using the correct angle
ensures proper penetration and bead
formation . Electrode angle involves
two positions - travel angle and work
angle (See Figure 6) .
Travel angle is the angle in the line
of welding and may vary from 5º to
45º from the vertical, depending on
welding conditions .
10
E-7014 fast fill
Smooth bead and fast deposition
Ideal for joints with poor fitup and
general repair work .
E-7018-AC High Strength
Ideal for pipes and structural
applications .
Low hydrogen reduces porosity for
a strong weld .