Welder - SMAW 1

Course Description

PMT0072C – Welder SMAW 1 is a Postsecondary Adult Vocational (PSAV) clock-hour course in the Florida Welding Technology program (CIP 48.0508) focused on developing intermediate-level proficiency in Shielded Metal Arc Welding (SMAW), commonly known as "stick" welding. SMAW remains the most widely used welding process in construction, infrastructure, repair and maintenance, and out-of-position work, and proficiency in SMAW is foundational to the welding profession.

Building on the introductory SMAW exposure in PMT0070C and PMT0071C, this course develops in-depth competency with the most commonly used SMAW electrodes (E6010, E6011, E7018) across welding positions and joint configurations on carbon steel. Students master fillet and groove welding in flat, horizontal, vertical, and (where included) overhead positions, working toward the consistency and quality required for AWS performance qualification testing in subsequent modules.

This course is offered at approximately 35 Florida technical colleges as a core specialty module within the Florida PSAV Welding Technology program. Successful completion qualifies students to advance to PMT0073C (Welder SMAW 2) and supports preparation for AWS performance qualification testing in groove welding positions.

Learning Outcomes

Required Outcomes

Upon successful completion of this course, students will be able to:

• Demonstrate habituated welding shop safety, including consistent PPE use, safe handling of hot material, and safe shop conduct.
• Set up and adjust SMAW machines proficiently for given electrode types, sizes, and joint configurations.
• Select and store SMAW electrodes appropriately, including proper rod oven storage and rebaking of low-hydrogen (E7018) electrodes.
• Perform SMAW fillet welds with E6010, E6011, E6013, and E7018 electrodes in the 1F, 2F, 3F (vertical-up), and 4F (overhead) positions on carbon steel.
• Perform SMAW groove welds with backing on carbon steel plate in the 1G (flat) position with E7018, including root, fill, and cap passes.
• Perform SMAW groove welds in the 2G (horizontal) and 3G (vertical-up) positions on carbon steel plate.
• Perform open-root SMAW welds with E6010 or E6011 root pass and E7018 fill/cap passes (where included).
• Recognize and prevent common SMAW defects, including porosity, undercut, lack of fusion, slag inclusions, and arc strikes.
• Apply visual inspection to completed welds, identifying acceptable and unacceptable conditions per AWS D1.1.
• Perform weld preparation, including beveling, fit-up, and tacking for plate groove welds.
• Apply weld cleaning and finishing, including chipping slag, wire brushing, grinding, and managing arc strikes and spatter.
• Apply productivity practices, including efficient electrode use, minimizing rework, and managing personal pace.

Optional Outcomes

• Perform SMAW pipe welds at the introductory level in fixed positions (1G, 2G; 5G and 6G typically reserved for advanced courses).
• Apply SMAW with cellulosic electrodes (E6010) for pipeline-style welding using vertical-down technique.
• Begin preparation for AWS D1.1 plate qualification testing in 3G, 4G groove positions.
• Apply SMAW with low-hydrogen electrodes for code applications, including pre-heat, interpass temperature, and proper electrode handling.

Major Topics

Required Topics

• SMAW Equipment Mastery: Power source types (transformer, inverter, engine-driven); polarity (DCEP, DCEN, AC) and applications; amperage settings; cable selection and length effects; ground clamp placement.
• SMAW Electrode Selection and Storage: Common electrodes in depth — E6010, E6011, E6013, E7016, E7018, E7024, E11018; fast-freeze vs. fast-fill; cellulosic, rutile, low-hydrogen classifications; rod oven temperatures (typically 250-300°F for low-hydrogen storage); rebaking electrodes; expiration of low-hydrogen electrodes; AWS classification system.
• SMAW Technique — Flat Position (1F, 1G): Stringer beads; weave beads; electrode angle (work angle, travel angle); travel speed; arc length; restarting beads; managing the puddle.
• SMAW Technique — Horizontal Position (2F, 2G): Adjustments for horizontal work; managing puddle to prevent sag; the difference between horizontal fillet (2F) and horizontal groove (2G).
• SMAW Technique — Vertical Position (3F, 3G): Vertical-up technique with stringer beads (E7018); vertical-up with weaves; vertical-down with E6010/E6011 (where included); managing the puddle against gravity.
• SMAW Technique — Overhead Position (4F, 4G): Overhead technique; managing the puddle in overhead; safety considerations (positioning, hot slag drop, PPE); overhead with E7018 stringers.
• Plate Groove Weld Joint Preparation: Single-V groove preparation; bevel angle (typically 60° included for plate); root face (land); root opening (gap); back gouging; backing strip use.
• Open-Root Welds: Open-root V-groove with E6010 or E6011 root; common in pipeline-style welds (vertical-down) and many code applications; technique for maintaining penetration without burn-through.
• Multi-Pass Welds: Root pass; hot pass (where used); fill passes; cap pass; managing interpass cleaning; sequencing of passes; uniform appearance.
• Code Welding Considerations: Pre-heat for thicker materials; interpass temperature limits; storage of low-hydrogen electrodes; the welder's responsibility for following written welding procedures.
• Common SMAW Defects and Prevention: Porosity (electrode condition, arc length, contamination); undercut (amperage, angle, travel speed); lack of fusion (technique, joint preparation); slag inclusions (interpass cleaning, technique); arc strikes (control, repair); cracks (heat input, hydrogen, base metal).
• Visual Inspection per AWS D1.1: Acceptance criteria for plate groove welds; weld profile; reinforcement; undercut limits; underfill; cracks (any are unacceptable); using weld inspection gauges.
• Productivity: Efficient electrode handling; minimizing electrode stub waste; minimizing rework; physical conditioning for sustained welding; the relationship between technique and productivity.

Optional Topics

• Introductory Pipe Welding: Fixed-position pipe (1G rolled, 2G fixed); the transition from plate to pipe technique; pipe joint preparation.
• Pipeline Welding Technique: Vertical-down with cellulosic electrodes; the "keyhole" technique; common pipeline welding standards.
• Welding Procedure Specifications (WPS): Reading and following a WPS; PQR (procedure qualification record); the role of qualified procedures in code work.
• Weld Repair: Removing defective welds; preparing the area for re-welding; managing repair to maintain quality.

Resources & Tools

• Common Texts: Continuation of Welding: Principles and Applications (Jeffus); SMAW-specific manuals and curriculum from NCCER (Welding Level 2 and 3); Lincoln Electric SMAW guides
• Personal Equipment: Same as prior welding modules; substantial consumption of E6010, E6011, E6013, and E7018 electrodes during the course
• Shop Equipment: Multiple SMAW power sources; rod ovens for low-hydrogen storage; positioners (flat, horizontal, vertical, overhead simulation); welding tables and fixtures; angle grinders; weld inspection gauges
• Reference Standards: AWS D1.1 (Structural Welding Code—Steel); AWS A5.1 (Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding); AWS A5.5 (Specification for Low-Alloy Steel Electrodes); AWS QC1 (Welding Inspector certification standard)
• Online Resources: AWS Welding Journal articles on SMAW technique; weld.com; Tig Time (YouTube); Welding Tips and Tricks (YouTube — particularly recommended for technique videos)

Career Pathways

PMT0072C develops the SMAW competency that is foundational to many of the highest-paying welding careers. SMAW remains the dominant welding process in:

• Structural Steel Construction — High-rise buildings, bridges, structural fabrication; AWS D1.1 work.
• Pipeline Welding — Cross-country pipelines (oil, gas, water); often the highest-paying welding work; typically requires vertical-down SMAW with cellulosic electrodes.
• Pipefitter Welding — Process piping in refineries, power plants, chemical plants; ASME Section IX work.
• Boilermaker Welding — Power plant, refinery, paper mill boiler and pressure vessel work.
• Heavy Equipment and Field Repair — Construction equipment repair; crane and industrial machinery repair.
• Shipbuilding — Florida shipyards (Eastern Shipbuilding, BAE Systems Jacksonville); Navy shipyards.
• Maintenance Welding — In-house welders at large facilities (refineries, power plants, paper mills, theme parks); often the highest job-security welding positions.

The combination of plate groove competency in 3G and 4G positions developed in this course (and continued in PMT0073C) is the gateway to AWS D1.1 unlimited-thickness plate qualifications, which qualify welders for a broad range of structural welding work. Florida construction, infrastructure, energy, and shipbuilding sectors all sustain strong demand for SMAW-skilled welders.

Special Information

Position in the Program Sequence

PMT0072C is a core specialty module of the Florida PSAV Welding Technology program. Successful completion is typically required before progression to PMT0073C (Welder SMAW 2). Hours invested count toward the program total.

AWS Performance Qualification Preparation

The plate groove welding skills developed in PMT0072C — particularly in the 3G (vertical) and (where included) 4G (overhead) positions — directly prepare students for AWS D1.1 unlimited-thickness plate qualification tests. Many Florida welding programs administer AWS qualification tests in or after PMT0072C/PMT0073C, giving graduates documented industry credentials.

Practice Time Expectations

SMAW skill develops through repetition. PMT0072C provides substantial structured practice time, but students who excel typically also practice extensively beyond required class time. Many Florida welding programs allow open-shop practice time for enrolled students; students should take advantage where available.

Articulation

See PMT0070C — Florida technical college PSAV welding programs may articulate to Florida college Welding Technology A.S./A.A.S. programs at participating institutions, with the SMAW competency developed in this course directly applicable to associate-degree welding curricula.

Physical Demands

SMAW requires sustained physical effort — holding the welding gun in awkward positions, working in vertical and overhead positions, and managing the heat of the arc and the heated metal. Programs build students' physical conditioning over time. Florida's hot, humid climate adds to the physical demand of welding work, particularly outdoor work.