Campbell-hausfeld WS0990 User Manual download pdf (Page 5)

Welding Guidelines

G e n e r a l

This welding machine 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 6.

NOTE: Discontinue using and discard

electrodes that burn down to 1 to 2

inches from the electrode holder.

STRIKING AN ARC

Attach work clamp to work piece. The

jaws of the work clamp must make good

contact with clean bare metal of the

work piece for good welding results.

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 ensure good electrical

contact with the electrode.

Be careful not to

touch the work

piece 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 in. off the surface or it will stick (See

Figure 7).

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.

ELECTRODE TYPE AND SIZE

Two types of electrodes are

recommended for this welder. The

electrodes are commonly known by the

AWS (American Welding Society)

designation as follows:

1 . E-6013 GENERAL PURPOSE

• All position, smooth deposit rod with

low spatter.

• For all mild steel and general purpose

w o r k .

2 . E-7014 FAST FILL

• Smooth bead and fast deposition

• Ideal for joints with poor fitup and

general repair work

NOTE: E-6011 and E-7018 are not

recommended for use with these

welders. Recommended electrode

diameter is 1/16 in. or 5/64 in.. Call

(800) 746-5641 for availability.

A r c 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 to

the required amp setting. This is

regulated by selecting the appropriate

high or low setting. The amperage

required depends on the size

(diameter) of electrode used and the

thickness of the work piece.

Excessive currents burn through light

metals and the weld bead is flat and

porous (See Figure 9). The bead

appears high and irregular if the

current 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 8).

Travel angle is the angle in the line of

welding and may vary from 5º to 45º

from the vertical, depending on

welding conditions.

Work angle is the angle from

horizontal, measured at right angles to

the line of welding.

Slag

Weld

Wire

Flux

Work

Piece

Crater

Figure 6 - Weld Components

Same as Electrode Diameter

Figure 7 - Scratching Method

M o d e l WS0970 and WS0990

w w w . c h p o w e r . c o m

Figure 8 - Weld Angle

- 45

Travel Angle

Work Angle

1 2 3 4 5 6 7 8 9 10 ... 35 36

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Campbell-hausfeld WS0990 User Manual Page 5

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