Run Straight Beads with SMAW

A. Finished-Project Specification

Outcome: one flat mild-steel coupon with a series of parallel straight SMAW stringer beads, each with a controlled start, consistent arc length and angle, controlled crater termination, complete slag removal, and measured width and length recorded against the project acceptance sample. No joints, weaving, or out-of-position welding are performed as part of this chapter's finished work.

B. Bead Series Schedule (Component Schedule)

Item	Quantity	Specification	Condition
Practice coupon	1 per series	Flat mild steel, prepared and accepted per Chapters 4–6	Clean bright metal, marked with parallel bead lines and start/stop points
Stringer beads	As specified by the shop procedure, minimum 4 per coupon	Approved electrode classification and diameter, approved starting amperage	Straight, no weaving, consistent spacing without overlap unless specified
Work clamp connection	1	Clean sound metal near the coupon	Verified before each bead series
Bead-series log	1	Machine, electrode, polarity, amperage, coupon ID	Completed before the first arc and updated after each bead

C. Material Takeoff

• Practice coupons: the flat mild-steel coupons prepared and accepted in Chapters 4 through 6, sufficient for the number of beads specified by the shop procedure.
• Electrodes: the approved SMAW electrode classification and diameter identified in Chapter 3, in quantity sufficient for the full bead series plus reasonable allowance for rework.
• Consumables: none beyond the identified electrodes; no filler rod, shielding gas, or flux-cored wire is used in this chapter.
• Fastener and hardware schedule: not applicable. This chapter produces welded beads on a single coupon, not a fastened assembly.

D. Acceptance Standards

Check	Standard
Bead straightness	Follows the marked line without wandering beyond the tolerance stated in the shop procedure
Width consistency	Measured width stays within the tolerance stated in the shop procedure along the full bead length
Reinforcement	Reinforcement height matches the acceptance sample without excessive convexity or concavity
Ripple spacing	Consistent ripple spacing along the bead with no abrupt pattern changes
Start and stop	Start shows full fusion without a cold start; stop shows a filled crater without a depression
Slag and spatter	Slag completely removed; spatter within the limits stated in the shop procedure
Surface defects	No undercut, overlap, visible porosity, or arc strikes outside the bead
Distortion	Coupon remains within the flatness tolerance stated in the shop procedure after the full series

E. Preparation — Review and Coupon Setup

1. Review the approved coupon layout, electrode, polarity, position, bead length, spacing, and parameter range. Confirm the shop procedure for this exercise before staging materials.
2. Verify the work area, ventilation, fire controls, PPE, machine, leads, holder, and clamp. Confirm the Chapter 1 area record, Chapter 2 PPE, and Chapter 3 equipment record are current.
3. Prepare the coupon to clean bright metal. Confirm the weld zone matches the cleanliness standard from Chapter 4.
4. Mark parallel bead lines and start and stop points. Space bead lines per the shop procedure and confirm spacing with a steel rule.
5. Secure the coupon flat with stable access. Confirm the coupon cannot shift during welding.

F. Machine and Electrode Setup

1. Attach the work clamp to clean metal. Position the clamp close to the coupon on sound, unpainted metal.
2. Select and inspect the approved electrodes. Reject electrodes with damaged, moist, or contaminated coating.
3. Set the machine to the approved starting amperage. Confirm polarity matches the electrode manufacturer's requirement.
4. Record machine, setting, electrode, polarity, and coupon identification. Complete the bead-series log before the first arc.

G. Running the Bead Series

1. Assume a balanced position allowing uninterrupted travel. Confirm the body position supports the full bead length without repositioning mid-bead.
2. Arrange the lead so it does not pull the holder or contact hot metal. Check lead slack before striking the arc.
3. Strike the arc at the first start point. Use the approved start method from Chapter 7.
4. Establish the puddle before beginning travel. Confirm a stable puddle is visible before advancing the electrode.
5. Maintain the approved arc length. Keep arc length consistent from start to finish.
6. Maintain the approved work angle relative to the coupon. Hold the specified angle without drifting through the bead.
7. Maintain the approved travel angle. Confirm the electrode leads or trails per the shop procedure.
8. Travel along the marked line without weaving unless the exercise specifies otherwise. Follow the marked line to the stop point.
9. Observe puddle edges and slag location. Use puddle shape and slag trailing to confirm fusion at both edges of the bead.
10. Maintain a consistent travel speed. Avoid speeding up or slowing down mid-bead.
11. Fill the crater at the endpoint through the approved method. Use the crater-fill technique specified in the shop procedure.
12. Break the arc without creating an uncontrolled arc strike. Lift the electrode cleanly away from the coupon.

H. Cooling, Cleaning, and Repeat

1. Place the holder in the insulated rest. Confirm the holder cannot contact grounded metal.
2. Mark the coupon hot and allow safe cooling. Do not touch or measure the bead until it is safe to handle.
3. Remove slag completely from the bead. Wear eye and face protection during chipping.
4. Brush the bead and adjacent area. Use the approved wire brush for mild steel.
5. Inspect bead straightness, width, reinforcement, ripple spacing, start, stop, undercut, overlap, porosity, slag inclusion indicators, and spatter. Compare against the acceptance sample.
6. Measure bead width and length using approved gauges or tools. Record measurements in the bead-series log.
7. Compare the bead with the project acceptance sample. Note any deviation.
8. Identify whether defects relate to current, arc length, angle, travel speed, contamination, or electrode handling. Record the probable cause for any defect found.
9. Adjust one parameter or technique variable at a time. Do not change more than one variable between beads.
10. Run the next bead parallel to the first with consistent spacing. Confirm spacing against the marked lines.
11. Repeat across the coupon without overlapping beads unless specified. Continue until the required number of beads is complete.
12. Allow machine cooling within duty-cycle requirements. Pause between beads as required by the machine's rated duty cycle.

I. Final Review and Closeout

1. Inspect the full coupon for heat distortion and arc strikes. Check flatness against the table and inspect for stray arc marks.
2. Select the best and weakest bead for comparison. Identify which bead best matches the acceptance sample and which shows the most deviation.
3. Prepare brief corrective-action notes. Record what would change to improve the weakest bead.
4. Obtain instructor or qualified evaluator review. Present the coupon and bead-series log for review.
5. Record final settings, bead measurements, defects, corrections, and competency result. Complete the bead-series log and inspection checklist.
6. Shut down the station, store electrodes, coil leads, and complete fire watch. Follow the Chapter 1 shutdown and fire-watch requirements.