I. Core Parameter Table of Electrode
| Item | Specification Requirement | Remarks |
|---|---|---|
| Electrode Type | Titanium Cellulose Acid-Coated Electrode | The coating has lower hygroscopicity than basic electrodes, easy to operate |
| Applicable Material | Low-carbon steel (e.g., Q235, A3 steel) | Not applicable for high-strength steel, low-temperature steel, or pressure vessels |
| Power Compatibility | AC (Alternating Current) / DC Reverse Polarity (DC-) | DC reverse polarity is preferred for more stable arc and less spatter |
| Electrode Diameter & Current Range | 2.5mm: 50-80A 3.2mm: 80-120A 4.0mm: 120-160A |
Current must match diameter to avoid burn-through or incomplete fusion |
II. Pre-Welding Preparation: 3 Steps to Ensure a Solid Foundation
1. Electrode Handling: Moisture-Proofing Is Critical
Storage Requirement: Unopened electrodes should be stored in a dry warehouse with "temperature ≥ 5℃ and relative humidity ≤ 60%", away from oil/water;
Drying Standard:
✅ Moisture-affected electrodes (soft/clumpy coating): Dry at 70-150℃ for 1-2 hours, and use immediately after drying;
❌ Over-temperature prohibited (>200℃): Will burn the gas-forming agent, leading to unstable arc;
Appearance Inspection: The coating should be uniform, crack-free, and rust-free. Remove 2-3mm of coating from the electrode tip to facilitate arc striking.
2. Workpiece Cleaning: Impurities Must Be Removed
Cleaning Range: Within 20mm of the groove and its two sides, use a wire brush/angle grinder to remove oil, rust, and scale, exposing the metallic luster;
Moisture Treatment: If there is water on the workpiece surface, dry it with a flame (≤200℃) or air-dry naturally;
Groove Processing:
Thin plates (≤6mm): I-type groove (no groove required);
Thick plates (>6mm): V-type/X-type groove (angle 30-60°, root face 1-2mm) to ensure full penetration.
3. Preheating Judgment: Choose as Needed
✅ No preheating required: Low-carbon steel workpieces, normal temperature (≥0℃), thickness ≤20mm;
⚠️ Preheating mandatory: Workpieces with thickness >20mm, ambient temperature <0℃, or structures with high restraint. Preheat to 80-150℃ (detect with a temperature gauge).
III. In-Welding Operation: Core Parameters + Key Techniques
1. Equipment Debugging: Current Is the Core
| Electrode Diameter | Recommended Current (A) | Applicable Welding Position | Notes |
|---|---|---|---|
| 2.5mm | 50-80 | Vertical and overhead welding for thin plates | Too low current may cause incomplete fusion; too high may cause burn-through |
| 3.2mm | 80-120 | Flat, vertical, and horizontal welding | For vertical/horizontal welding, reduce current by 10%-15% compared to flat welding |
| 4.0mm | 120-160 | Flat and horizontal welding for medium-thick plates | For overhead welding, reduce current by 15%-20% compared to flat welding to prevent slag run-off |
Grounding Connection: Connect firmly to the rust-free/paint-free area of the workpiece to avoid unstable arc caused by poor contact.
2. Key Operation Techniques
Arc Striking Method: Use the scratching method (similar to striking a match) or tapping method (quickly lift 1-2mm) to prevent coating from sticking to the workpiece;
Arc Control: "Short arc operation" is mandatory (arc length = 1/2-1 of the electrode diameter). Excessively long arc may allow air to enter, causing porosity;
Electrode Movement:
Flat welding: Sawtooth or crescent pattern, with swing amplitude ≤ 3 times the electrode diameter;
Vertical/horizontal welding: Straight reciprocating or small sawtooth pattern, swing slowly and move quickly to prevent molten droplets from running off;
Overhead welding: Short arc and fast welding to reduce slag retention time;
Interpass Cleaning: For multi-pass welding, use a slag hammer + wire brush to clean slag after each pass to prevent slag inclusion/incomplete fusion.
IV. Environment & Safety: Must-Avoid Risks
1. Environmental Control: 3 Prohibitions
❌ Welding prohibited when humidity >85%: Preheat the workpiece (100-150℃) or set up a moisture-proof shed;
❌ Welding prohibited when wind speed >2m/s: Set up a wind shield/shelter for outdoor welding to prevent protective gas from being blown away;
❌ Welding prohibited at low temperature (<0℃) without preheating: Maintain the workpiece temperature ≥ preheating temperature during welding. For thick plates, cover with insulation cotton after welding for slow cooling.
2. Safety Protection: 4 Layers of Protection
⚠️ Personal Protection:
Wear a "welding helmet" (shade number 10-12) to prevent arc eye injury;
Wear flame-retardant protective clothing + welding gloves + insulated shoes to prevent burns/electric shock;
Wear a dust mask for indoor welding to reduce inhalation of iron oxide fumes.
⚠️ On-Site Safety:
Remove flammable materials (paint, cotton yarn) and equip with fire extinguishers;
Ensure reliable grounding of the welding machine (grounding resistance ≤4Ω);
Ensure good ventilation for indoor welding, or use a smoke extractor.
V. Applicability & Limitations: Choose the Right Scenario for Efficiency
✅ Applicable Scenarios
Welding of thin low-carbon steel plates (e.g., civil steel structures, ordinary pipelines, agricultural tools);
Flat/vertical/horizontal/overhead welding of general non-critical structures.
❌ Inapplicable Scenarios
Welding of high-strength steel, low-temperature steel, or stainless steel;
Pressure-bearing critical structures such as pressure vessels and boilers (basic electrodes like E7018 are required).
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