Tack Welding
Ship Terms
• Introduction
• Course Overview
2
Course Objectives
• Practice safety
• Distinguish
between welding
and tack welding
• Follow tack
welding standards
• Identify tack
welding parts,
types and
materials
• Setup and
operate SMAW
equipment
3
Benefits
How would an entry-level shipfitter benefit from
learning to produce quality tack welds?
4
Tack Welding Safety
• Practice safety
regulations
• Wear correct PPE
• Recognize safety
signs and signals
5
What’s the Difference?
The size of the weld!
6
Site Accidents
•
Mental/physical
stress
•
Foot & vehicle
traffic congestion
•
Medications, illness
or injury
•
Hurried shift
changes
•
Alcohol and drug
abuses
•
Faulty or
damaged
equipment
7
PPE Illustration
8
Lab 1: Wear PPE
• Observe how Personal Protective
Equipment should be worn when welding.
9
Observe Tack Welding
• Activity 1: Pay attention to what you see,
hear, feel and smell in the environment
while observing tack welding in action.
10
Safety Precautions
11
Welding Accidents Video
• Activity 2: Watch video and discuss
questions.
Insert (welding) Photo Here
12
Lab 2: SMAW Tack Welding
• Observe and listen as SMAW tack
welding is being performed.
13
Tack Welding Safety Quiz
Test Your Knowledge!
14
PPE Application
Assessment
Test Your Knowledge!
15
Tack Welding Basics
• Follow tack welding
quality standards
• Identify tack weld
types and structural
components
• Prepare weld
surfaces
16
Welding Defined
• A fabrication process
that joins materials
into one piece by
melting and adding a
filler to form a pool of
molten material that
cools to become a
strong joint.
17
Tack Welding
• Tack welding is a
“Short” weld.
18
Good and Bad Tack Welds
Travel to Fast
Travel Too Slow
Amperage Too Low
Amperage Too High
Arc Too Short
Arc Too Slow
A Good Weld!
19
Lab 3: Tack Welding Demo
• Observe a good and bad tack weld being
demonstrated.
20
Tack Welding Preparation
• Insert Photo
Here
(Preparation
of weld
surface)
21
Lab 4: Tack Weld Surface Prep
• Observe a tack weld surface being
prepared.
• Insert Photo
Here
(Preparation
of weld
surface)
22
Tack Welding Standards
• This course will
provide you with
knowledge to
perform tack welding
procedures generally
required of entrylevel shipfitters at
most any shipyard.
23
AWS Welding Standards
• Activity 3: Study tack welding standards
and American Welding Society (AWS)
Codes
24
Tack Welding Positions
1—Flat
2—Vertical
3—Horizontal
• Insert Photo
Here (A tack
welding
position)
4—Overhead
25
Welding Position Designations
• Activity 4: Identify welding position
designations.
–
–
–
–
2G
1F
3F
4G
26
Lab 5: Welding Position Demo
• Observe welding positions being
demonstrated and explained.
• Insert Photo
Here
(Welding
Positions)
27
Structural Components/Shapes
1. I-Beam
2. H-Beam
3. Tee Bar
4. Angle
5. Channel
7. Square Tubing
9. Flat Bar
28
Component Identifiers
29
Lab 6: Structural Components
• Study structural components.
30
Tack Welding Terms
Rod
• Use the glossary
of terms in your
PG to learn new
words!
31
Tack Welding Basics Quiz
Test Your Knowledge!
32
SMAW Equipment
• Setup and operate
SMAW equipment
safely
• Adjust basic power
supplies
• Attach welding leads,
cables, electrodes
and ground clamps
33
SMAW
• Shielded Metal Arc
Welding is the main
welding process
used in tack welding.
34
SMAW Features
1. Stick Welding Power Source—Constant Current
(CC), AC or DC
2. Insulated Electrode Holder (whip)
3. Workpiece
4. Work Clamp
35
Lab 7: SMAW Demo
• Observe basic hook up and features of
SMAW process.
Welding Machine
Ground Lead
On
Electrode Holder
Off
+
Electrode
-
Arc
Workpiece
Electrode Lead
36
Voltage and Current
• Voltage is actually the measure of
current flow:
– Voltage and Current
– Voltage (Volts)
– Current
LEARN THIS SYMBOL!
This is the international safety symbol for high voltage. It
means “CAUTION, RISK OF ELECTRIC SHOCK.”
37
Amperage
• Amperage = Intensity
38
Welding Leads and Polarity
Polarity =
Direction of
current flow
Welding lead that
holds ground clamp
Welding lead that
holds electrode
holder
39
Lab 8: Hooking Up Weld Leads
• Observe the hook up of DCEP and DCEN
weld leads.
40
SMAW Equipment
• AC—alternating
only
• DC—direct only
• AC/DC—both
alternating and
direct
41
SMAW Equipment Selection
• Identify:
– Welding process
– Welding current
– Maximum
amperage
– Primary power
connections
42
Exercise: Equipment Selection
• Welding process?
• Welding current?
• Maximum
amperage?
• Primary power
connections?
43
Electrode/Amperage Selection
44
Lab 9: Weld Machine Demo
• Observe how a welding machine
functions and how the power sources
vary.
45
String Welding Lead
• After machine
selection, first
string the
welding lead.
Welding
lead.
46
Weld Lead End Connections
• Proper end connections need to be made
to effectively setup welding leads.
Ground Clamp
Lugs
Electrode Holder
47
Line Control
Use the line control quick reference guide!
48
Lab 10: Cable Connections
• Observe how to make cable connections
and string cable safely.
• Practice working with a partner.
49
Electrode Holders
Electrode holders are used to
grip the electrode while the tack
weld is being completed.
50
Ground Clamp Location
Ground clamps form a
connection between the
material being worked and the
lead serving as a return path for
electrical current.
51
Ground Clamp Location
Use the Workpiece Clamp Location Quick
Reference Guide!
52
Lab 11: Attach a Ground Clamp
• Observe how to attach a ground clamp
for SMAW.
• Practice working with a partner.
53
Tack Weld Cleaning
Common Cleaning Tools:
•Chipping hammers
•Wire brushes
•Needle guns
•Grinders
•Scaling guns
54
Lab 12: Use Hand Tools
• Observe how to use hand tools to clean
and prepare surfaces.
55
Welding Equipment Safety
Use the Welding Equipment Safety Cheat Sheet!
56
SMAW Equipment Quiz
Test Your Knowledge!
57
SMAW Electrodes
• Recognize and
select electrodes
• Identify electrodes
based on code
classifications
• Determine
applications of low
hydrogen electrode
groups
• Handle and store
electrodes according
to procedures
58
SMAW Electrodes
• Consumable
electrodes melt into
the weld joint and
become part of the
initial weld.
59
Electrode Flux
• SMAW electrodes have a metal core with
a flux coating.
– Flux—shields the weld
– Wire core—transfers the current to the
material.
60
Lab 13: Tack Welding Demo
• Observe how to use electrodes to tack
weld.
Insert Photo Here
61
Electrode Classification
62
Electrode Classification
• Activity 5: Locate the classification of
each electrode and describe what each
number and letter represents.
63
Electrode Groups
Insert Photo Here
64
Electrode Selection
65
Compatibility Demonstration
• Activity 6: Watch how to test for base
metal and electrode compatibility.
66
Electrode Storage & Handling
• Store filler metal in
warm, dry area away
from floor.
• Place them to avoid
possible damage.
• Put electrodes in
oven if containers
have been opened.
67
Lab 14: Low Hydrogen Demo
• Observe how a low hydrogen E7018
electrode works when tack welding.
Insert Photo Here
68
SMAW Electrodes Quiz
Test Your Knowledge!
69
SMAW Techniques
• Setup SMAW
equipment
• Strike an arc
• Tack weld using
6010 and 7018
electrodes
70
Weld Coupons
71
Preparing Test Coupons
1. Use hand tool to realign
workpieces on the sides
and ends
2. Tack the far ends of
workpieces
3. Make intermediate tack
welds as needed to
maintain workpiece
alignment
72
Compatibility Demonstration
• Activity 7: Observe and listen to
information about different weld coupons.
Insert Photo
73
Lab 15: Tack Welding Demo
• Observe how the first steps of tack
welding are performed.
Insert Photo Here
74
SMAW Components
• Find the following:
– Stick welding
power source
– Insulated
electrode holder
– Workpiece
– Ground clamp
75
Stick Welding Setup
• Follow steps 1-7
in PG for simple
setup.
76
Lab 16: Setup Equipment
• Observe how to setup SMAW equipment:
– Workpiece
– Work clamp
– Electrode holder
Answer the questions in your PG.
77
Striking an Arc
• Two Techniques:
– Scratch start
– Tapping
78
Scratch Start Technique
• Remember:
– Welding current
starts as soon as
you touch the
workpiece
Part 1—Electrode
Part 2—Workpiece
Part 3—Arc
79
Tapping Technique
• Bring electrode
straight down to
workpiece
• Lift slightly
Part 1—Electrode
Part 2—Workpiece
Part 3—Arc
80
Lab 17: Striking an Arc
• Observe how to strike an arc:
– Scratch start technique
– Tapping technique
81
Positioning Electrode Holder
• Best Results:
– Hold a short arc
– Travel at uniform speed
– Feed electrode downward at constant rate
Fillet Welds
82
Lab 18:Fillet Welding Demo
• Observe the techniques of fillet tack
welding.
83
Electrode Movement
1. Stringer Bead
2. Weave Bead
3. Weave Patterns
84
Conditions Affecting Beads
1. Electrode Angle
2. Arc Length
3. Travel Speed
85
Poor Weld Beads
1.
2.
3.
4.
5.
Large spatter deposits
Rough, uneven bead
Slight crater during welding
Bad overlap
Poor penetration
86
Good Weld Beads
1.
2.
3.
4.
5.
Fine spatter
Uniform bead
Moderate crater during welding
No overlap
Good penetration into
base metal
87
Lab 19: Good and Bad Demo
• Observe the differences between good
and bad tack welds.
88
Welding Coupon Test
• Strike weld joint in the direction shown
• When test coupon breaks, weld will be
examined for proper penetration and tieins
89
Lab 20: Creating Tack Welds
• Integrate your skills!
90
SMAW Techniques Quiz
Test Your Knowledge!
91
Summary
Tack Welding Safety
Tack Welding Basics
SMAW Electrodes
SMAW Equipment
SMAW Techniques
92
Tack Welding Application
Assessment
Test Your Skills & Knowledge!
93
What’s Next?
• Let’s take a look at what’s next in the
course curriculum.
94