Welder - SMAW 2

Course Description

PMT0073C – Welder SMAW 2 is the advanced Postsecondary Adult Vocational (PSAV) clock-hour course in Shielded Metal Arc Welding within the Florida Welding Technology program (CIP 48.0508). Building on PMT0072C (Welder SMAW 1), this course develops the advanced SMAW proficiency needed for AWS performance qualification testing in all positions and supports preparation for the field-welder career path. Students develop intermediate-to-advanced competency in unlimited-thickness plate groove welding and (where included) introductory pipe welding.

The course emphasizes consistency, quality, and productivity at the level required by employers. Students perform welds repeatedly under conditions approximating performance qualification testing, with attention to the visual inspection criteria and (where program facilities allow) destructive bend test outcomes that determine whether a weld passes qualification. Coursework integrates classroom instruction with intensive hands-on practice culminating in qualification-style testing.

This course is offered at approximately 35 Florida technical colleges as the capstone SMAW module of the Florida PSAV Welding Technology program. Hours invested count toward the program total. Many Florida welding programs administer AWS performance qualification tests in or after PMT0073C, providing graduates with industry-recognized credentials.

Learning Outcomes

Required Outcomes

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

• Apply habituated welding shop safety and lead by example for newer trainees in safe behavior.
• Perform SMAW groove welds in all positions (1G, 2G, 3G, 4G) on carbon steel plate at the qualification-test level.
• Perform open-root SMAW welds with cellulosic electrode (E6010 or E6011) root pass and E7018 fill/cap passes, including in vertical and overhead positions.
• Pass visual inspection per AWS D1.1 acceptance criteria with high consistency.
• Pass destructive bend tests per AWS D1.1 with welds free of unacceptable discontinuities (where program facilities allow bend testing).
• Demonstrate productivity at industry-relevant levels, including consistent output and minimal rework.
• Read and follow a Welding Procedure Specification (WPS), including correct selection of electrode, amperage, polarity, joint preparation, and welding technique.
• Apply principles of distortion control, including weld sequence, intermittent welding (where appropriate), back-step welding, and managing residual stress.
• Apply principles of weld repair, including diagnosing defective welds, removing defects (grinding, gouging), and re-welding to acceptable quality.
• Diagnose and troubleshoot SMAW problems, including arc starting issues, undercut, porosity, and arc blow.
• Apply basic pipe welding fundamentals at the introductory level, including pipe joint preparation, root passes on pipe, and (where included) fixed-position pipe technique.
• Demonstrate readiness for AWS performance qualification testing in 3G and 4G positions on plate using E7018.

Optional Outcomes

• Perform SMAW pipe welds in 2G (horizontal-fixed) position on schedule 40 carbon steel pipe.
• Perform SMAW pipe welds in 5G (vertical-fixed, axis horizontal) and 6G (45° fixed) positions — typically reserved for advanced pipe welding modules.
• Earn AWS Certified Welder (CW) credential through accredited testing facility (where institution is an AWS Accredited Test Facility).
• Apply SMAW to specialty materials at introductory level (low-alloy steel; introductory exposure to stainless or hardfacing).
• Develop welding instructor or lead-welder skills, including coaching newer trainees.

Major Topics

Required Topics

• Mastery of SMAW Process Variables: Voltage and amperage interplay; polarity selection for electrode and application; arc length control; travel speed control; electrode angle adjustments by position and joint; managing the puddle through visual feedback.
• Plate Groove — Vertical (3G): Vertical-up technique with E7018; stringer bead approach; weave bead approach; managing the puddle against gravity; consistency across multiple passes; pass-by-pass cleaning; achieving uniform reinforcement and contour.
• Plate Groove — Overhead (4G): Overhead technique with E7018; safety positioning; managing the puddle in overhead; managing arc length in overhead; consistency across passes.
• Open-Root Welds: E6010 (or E6011) root pass; achieving full penetration without excessive reinforcement on the back side; transitioning to E7018 hot pass and fill/cap; common in code work and pipeline applications.
• Pre-Heat and Interpass Temperature: When pre-heat is required (thick materials, low-hydrogen applications, low-temperature shop conditions); methods of pre-heat (oxyfuel, electric pad, induction); measuring and maintaining interpass temperature.
• Welding Procedure Specifications: The structure of a WPS; essential variables (process, base metal, filler metal, position, technique, electrical characteristics, pre-heat, post-heat); reading and following a WPS in production; the welder's responsibility under code.
• AWS D1.1 Acceptance Criteria — Visual Inspection: Profile (concavity, convexity); reinforcement maximum; underfill; undercut limits; cracks (any are unacceptable); arc strikes; weld appearance; common reasons for failed visual inspection.
• AWS D1.1 Bend Test Criteria: Test specimen preparation; bend test apparatus; acceptable vs. unacceptable openings on the bend specimen; the relationship between visual quality and bend test performance; the role of fusion, penetration, and freedom from cracks in bend test pass/fail.
• Productivity at Industry Level: Consistent output measured in pounds of deposited weld metal per hour; minimizing electrode waste; managing personal pace for sustained productivity; the economics of welding from the employer perspective.
• Distortion and Stress: Sources of distortion (uneven heating and cooling); types of distortion (longitudinal, transverse, angular); methods to minimize distortion (sequence, fixturing, intermittent welding, back-step welding); residual stress and its consequences; post-weld heat treatment (PWHT) at conceptual level.
• Weld Repair: Diagnosing defective welds; removing defects (grinding, oxyfuel gouging, air carbon arc gouging — where included); preparing for re-welding; managing repair to maintain overall quality.
• SMAW Troubleshooting: Difficulty starting arc (electrode condition, polarity, ground); arc instability (cable issues, machine settings); undercut (amperage too high, angle wrong, travel speed too high); porosity (electrode condition, arc length, contamination, draft); arc blow (magnetic interference, ground placement, electrode angle); slag inclusions (interpass cleaning, manipulation).
• Pipe Welding Fundamentals (Introductory): Pipe nomenclature (NPS, schedule); pipe joint preparation (bevel, root face, root opening); root pass on pipe (typically open-root or with backing); transitioning from plate to pipe technique; rolled vs. fixed positions (1G, 2G).
• Performance Qualification Test Preparation: The qualification test process; the relationship between course practice and the test; mental preparation; managing test-day pressure; understanding the scope of qualification (positions and electrode classifications qualified by passing).

Optional Topics

• 5G and 6G Pipe Welding: Fixed pipe positions; the "all positions" qualification; high-paying field-welder qualifications.
• Air Carbon Arc Gouging: Gouging equipment; gouging technique for back gouging and weld removal; safety considerations.
• Specialty Materials: Low-alloy steels (E8018, E9018, E11018); introductory exposure to stainless steel SMAW or hardfacing electrodes.
• Career Development: Building a welding portfolio; resume preparation for welders; navigating union apprenticeships (UA, Boilermakers, Ironworkers); preparing for traveling welder work.
• Lead Welder / Instructor Skills: Coaching newer trainees; leading a welding crew; the path to welding instructor and welding inspector careers.

Resources & Tools

• Common Texts: Same as PMT0072C; AWS D1.1 (Structural Welding Code—Steel) — students should have or have access to a current edition for code-related content; Pipe Welding Procedures (Hoobasarian) for pipe content
• Personal Equipment: Substantial consumption of E6010, E6011, and E7018 electrodes; pipe coupons (where pipe content is included)
• Shop Equipment: Multiple SMAW power sources; rod ovens; positioners enabling 3G and 4G testing; pipe stands and pipe coupons; air carbon arc gouging equipment (where included); bend test fixtures (where program performs bend testing)
• Reference Standards: AWS D1.1 (Structural Welding Code—Steel); AWS B4.0 (Standard Methods for Mechanical Testing of Welds); AWS QC7 (AWS Certified Welder); ASME Section IX (Welding and Brazing Qualifications) for pipe content
• Online Resources: Welding Tips and Tricks (YouTube); WeldingTube; weld.com; AWS Welding Journal; Lincoln Electric SMAW resources; Miller Electric SMAW resources

Career Pathways

PMT0073C, completing the core SMAW sequence, prepares students for the highest-paying SMAW-driven welding careers:

• Structural Welder (AWS D1.1 Qualified) — Bridge construction; high-rise buildings; structural steel fabrication; offshore platforms.
• Pipe Welder / Combo Welder — Process piping (refineries, power plants, chemical plants); pipeline welding (cross-country oil/gas/water); often the highest-paying welding work in the industry.
• Boilermaker Welder — Power plant boiler work; refinery vessel work; specialty high-pressure work; typically union-affiliated through Boilermakers Local 199 (Jacksonville, Florida) or other locals.
• Field Welder / Traveling Welder — Project-based work at large industrial sites; often work in multiple states; high pay with significant travel.
• Maintenance Welder at Industrial Facility — In-house welder at refineries, power plants, paper mills, theme parks (Disney, Universal); job security and benefits often exceed field-welder pay.
• Welding Inspector (with additional credentials) — AWS Certified Welding Inspector (CWI) — requires passing the CWI exam and meeting experience requirements; commands premium pay and supervisory responsibility.
• Welding Instructor (with additional teaching credential) — Florida technical college instruction; private welding schools; industrial training.
• Welding Supervisor / Foreman — Lead welder, foreman, superintendent in construction and fabrication.
• Welding Engineer Technologist (with additional A.S./B.S. degree) — Technical and management roles in welding engineering.

Florida's construction, infrastructure, energy, marine, aerospace, and manufacturing sectors all sustain strong demand for SMAW-qualified welders. AWS qualification tests passed during or shortly after this course position graduates for direct hire into welding positions across these industries.

Special Information

Position in the Program Sequence

PMT0073C is the capstone SMAW module of the Florida PSAV Welding Technology program. Hours invested count toward the program total. Students typically continue into specialty modules in GMAW, FCAW, GTAW, and pipe welding to expand their qualifications portfolio.

AWS Performance Qualification

The performance qualification tests prepared for in PMT0073C (AWS D1.1 plate qualifications, particularly 3G and 4G with E7018) are the most widely recognized welder credentials in the U.S. construction industry. Welders qualified in 3G + 4G are qualified for all positions on plate up to unlimited thickness for the qualified electrode classification. Florida welding programs that are AWS Accredited Test Facilities (ATFs) can administer the AWS Certified Welder (CW) examination, providing graduates with portable, employer-recognized credentials.

Continuing Welder Education

Welder qualifications expire when not used for six months in a given position/process per AWS D1.1. Welders maintain active qualifications through continuous practice in the qualified positions or through periodic re-testing. Many welders also pursue additional qualifications throughout their careers (different processes, pipe vs. plate, different base metals) to expand their employment options.

Articulation and Career Progression

Beyond initial PSAV completion, welders pursue:

• Union apprenticeship (UA Plumbers and Pipefitters, Ironworkers, Boilermakers) — Provides advanced training, journey-level wages, benefits, and pension. Florida locals provide pathways at multiple sites.
• Florida college A.S./A.A.S. in Welding Technology — Articulates from PSAV with advanced standing.
• AWS Certified Welding Inspector (CWI) — Premium credential leading to inspection careers.
• Welding Engineering Technology bachelor's degree — Available at select institutions for those pursuing welding engineering and management careers.

Physical and Long-Term Career Considerations

Sustained SMAW work is physically demanding and involves long-term occupational health considerations (exposure to welding fumes, UV, noise; ergonomic stress from holding equipment in awkward positions). Programs introduce students to professional habits supporting long-term career sustainability, including proper respiratory protection, ergonomic awareness, and the importance of varied work positions over a career.