ITW Welding

Educational Resources
Welding Process Training Series

Introduction To Welding
and Product Guide
 ™

WE BUIL
ITW Welding: Committed to the Future of Welding
Training in welding is mission critical — and weld instructors like you are helping the next generation of welder
operators shape our future. Miller and Hobart are committed to the future of welding, just as you are. That’s why
we work to provide you with the resources and tools you need to educate your students for today’s demands and
tomorrow’s needs.
From instructional classes and class materials to apps and weld training systems, you’ll find a wide variety of Miller
and Hobart welding educational aids within this pamphlet that can help you prepare your students for the future —
The Miller® LiveArc™
and their roles in improving our world.
Performance Welding
Management System

Welding Instructor Seminars

North America Training Center Locations These seminars are designed to provide welding instructors in
Appleton, WI Chicago, IL Mississauga, Ontario the public, private, and industrial sectors with an opportunity
Edmonton, to learn about new innovations in welding equipment and
Alberta
process developments in welding. The seminars consist of a

Careers
Helena, MT
series of classroom presentations, followed by hands-on lab
Portland, OR
Meridian, ID
activities. Throughout the seminars, participants will also be
Troy, MI able to review the latest training materials available from
Training in welding is mission critical. It’s a must to build operator
Ogden, UT Miller and Hobart. These materials include books, training
Swedesboro, NJ
skills faster, screen job applicants, even improve existing techniques Pittsburgh, PA aids, videos, computer and Internet-based programs.
Troy, OH
for today’s demands. For Chris Lacenski and Doug Tennant, welding Due to the variety of programs offered, please call for a
student and instructor at Northeast Wisconsin Technical College, Rancho
Cucamonga, CA
description of the course offered in the location that you wish
combining a weld simulator with a live arc MIG welder is the solution. Denver, CO Atlanta, GA to attend.
With LiveArc, we build careers. Dallas-Ft. Worth, TX To register Contact Peggy Moehn, 920-735-4016 or
Miller Corporate Headquarters
® Houston, TX email pmoehn@millerwelds.com
Learning with LiveArc
changes everything.
See it in action:
MillerWelds.com/livearc
1 2
 Welding Publications
Weld Process and Filler Metal Publications
Available in both English and Spanish, these full-color booklets were developed for the purpose of providing a basic set of
educational materials that can be used individually or in a classroom setting that are continually updated to contain the latest
Classroom Posters
Miller Posters
RMD/Root Pass TECHNIQUES GMAW-S Drag (Short circuit MIG)
A baseline weld was made using automated welding equipment. Voltage, Wire Feed Speed, Travel Speed and
This is a basic set-up and technique guide to welding the root pass on pipe with the Miller PipeWorx Contact-Tip-to-Work Distance were then adjusted individually from baseline weld settings to illustrate how
When it comes to choosing the right MIG transfer process for your application, there
400 System or the PipeWorx 350 FieldPro™ System using RMD® (Regulated Metal Deposition). each parameter affects a fillet weld when raised and lowered. Icons in grey indicate the specific parameter
are many variables to consider. How thick is the metal? How important is a good bead?
adjusted; in the case of amperage, the icon represents the value measured.
How will the final product be used? Find the answers to your questions below.

technologies and developments . RMD®

Wire Type: Transfer Mode:
130

Baseline Weld Variables

Root Pass Welding 0.035 ER70S-6 (Quantum Arc 6) Short Circuit (SCMT)

Shielding Gas: 75% Argon / 25% Carbon Dioxide Travel Direction: Backhand (Drag)

RMD® Carbon Steel

A precisely controlled short-circuit metal transfer that provides a calm,
stable arc and weld puddle. This provides less chance of cold lap or lack
of fusion, less spatter and a higher quality root pass on pipe. The stability
of the weld process lessens the weld puddle manipulation required by
RMD® Ball Transfer Base Metal: 1/8 in. Cold Rolled Carbon Steel Nozzle Diameter: 5/8 in. A Short Circuit Transfer Globular Transfer
the welder and is more tolerant to hi-lo conditions, reducing training <-Wet-> Pinch Clear Blink Ball Background Pre-short
requirements. Weld bead profiles are thicker than conventional root
pass welds which can eliminate the need for a hot pass, improving weld
productivity. In some stainless steel application, it may be possible to 220 10.5 -10° 35 3/8”
(Flush Tip)
45° 18.0 Advantages
● Suitable for thin materials
Generally not
recommended
eliminate the backing (purge) gas to further improve productivity and Good for:
for use
V
- + ●

reduce welding costs. CFH - Out-of-position work

- +
IPM Drag Push Excessive spatter
- Ideally suited to root pass welding - Open root ●

IPM - Poor fit-up ● High risk for:

- Consistent side wall fusion

RMD® Stainless

Current - Incomplete penetration

- Less weld spatter Limitations - Cold lap
Wave Form
- Tolerant to hi-lo fit-up conditions Lack of penetration on - Incomplete fusion
Decreased Increased
●

- More tolerant of tip-to-work distance thicker materials

<-Wet-> Pinch Clear Blink Ball Background Pre-short
- Less welder training time ● Unsuitable for aluminum
- Thicker root passes can eliminate hot pass ● Produces spatter

Voltage
- Eliminate backing gas on some stainless steel applications
15.3 20.7 Common Applications
● Sheet metal
Automotive repair and
37.5 Bevel pipe end to 37.5° Tack pipe ends together in 125 136 ●

V V
restoration

Tack Locations
(standard pipe bevel) four locations approximately Start welds on a tack or side

Feather Tacks
1 in. (25.4 mm)
TACK WELDS
Root passes on pipe

Joint Fit-up
A A
90 ●
1/16-3/32 in.
(1.6-2.4 mm)
leaving a knife edge to 1/16 90° apart and 1 in. (25.4 wall to help establish the
Root Face
in. (1.6 mm) root face. mm) long on pipe that is weld puddle. Stop welding on
6 in. (152.4 mm) or larger a tack or side wall to avoid
Align pipe ends together diameter. Use appropriate pin hole porosity in the weld
leaving a minimum of 1/8 sized tack welds on smaller crater.
Decreased Increased

Wire Feed Speed

1/8 in.
in. (3.2 mm) root opening. pipe.

Hold the arc in the center of

187 253

Arc Starts/Stops
Start welds on a tack or side
wall to help establish the the weld pool. Use a tapered nozzle and
Short Circuit Transfer

Arc Position

Gas Nozzle
weld puddle. If too far back in the weld a tapered contact tip for
pool, the arc will become proper gas coverage 115 146
Stop welding on a tack or unstable. and better visibility of the
side wall to avoid pin hole If too far forward, the wire
will push through and leave
weld pool.
IPM A IPM A Spray Transfer Pulsed Spray Transfer
porosity.
wire on the back of the joint.
Advantages Advantages
High deposition Effective in all positions
Decreased Increased
● ●

Start and Stop the arc on a tack at the 1:30 10° - 15°
● Good fusion and penetration ● No spatter

Travel Speed
position. Start the weld on a tack or side wall ● Good bead appearance ● Suitable for thick or thin
● Ideal for larger-diameter wires materials
10° - 15°
Perfect for joining all weldable
8 13.5
Hold the arc in the center of the weld puddle ● Very little spatter ●
Rotate pipe away while maintaining the arc

1G

2G
(A slight weave can be used to achieve a metals
at the 1:30 to 2:00 position. Limitations
flatter bead) Limitations
131 132 ● Suitable only on material
thicker than 1/8 in. ● Equipment is more expensive
Hold the arc in the center of the weld pool. Maintain a 10 to 15° drag angle IPM IPM Effective only in the flat and Cannot be used on poor fit-up
A A
● ●

horizontal fillet positions ● Difficult to use on open root

● Good fit-up is always required
Common Applications
10° - 15° Common Applications ● Sheet metal

Contact Tip To Work

Start on the tack at 12:00 position. Heavy plate Heavy plate
Decreased Increased
● ●
10° - 15° Start the weld on a tack or side wall ● Aluminum ● Aluminum, stainless steel,
12:00 to 1:00 - Weave quickly side to side. ● High volume manufacturing carbon steel and exotic metals
Hold the arc in the center of the weld puddle ● Automotive

5G

6G
(A slight weave can be used to achieve a
1/4” 1/2”
1:00 to 5:00 - Hold arc in center of joint. ● Heavy equipment
flatter bead)

These publications are available for free as an Epub for Apple

● Piping systems
(FLUSH TIP RECESS)
5:00 to 6:00 - Weave quickly side to side.
Maintain a 10 to 15° drag angle 137 123
Stop on a tack at 6:00.
A A

Spray Transfer Pulse Spray Transfer

and Android mobile devices. MillerWelds.com

© 2015 Miller Electric Mfg. Co. #272 427
MillerWelds.com
© 2013 Miller Electric Mfg. Co. #263868
MillerWelds.com
© 2012 Miller Electric Mfg. Co.

Apple Users: Available free through iBooks

Pulse/ Pass TECHNIQUES FCAW-G (Gas-Shielded FLux Core)
• Link to the Applet E-Pubs: http://tinyurl.com/hwhpvoh This is a basic set-up and technique guide to welding the fill and cap passes on pipe with the Miller
PipeWorx 400 System or the PipeWorx 350 FieldPro™ System using Pulsed (GMAW-P) Gas Metal Arc
Welding Transfer methods.
A baseline weld was made using automated welding equipment. Voltage, Wire Feed Speed, Travel Speed and
Contact-Tip-to-Work Distance were then adjusted individually from baseline weld settings to illustrate how
each parameter affects a fillet weld when raised and lowered. Icons in grey indicate the specific parameter
adjusted; in the case of amperage, the icon represents the value measured.
The standardized alphanumeric system shown below is used to specify a fillet weld or a
groove weld, and whether the weld is to take place in the flat, horizontal, vertical or overhead
position. Knowing this alphanumeric system will help you make the right weld every time.

• Downloading instructions: Pulsed MIG (GMAW-P)

Wire Type: Transfer Mode:
275 Fillet Weld Groove Weld

Baseline Weld Variables

Fill and Cap Pass Welding 0.052 E71T-1 (ExcelArc 71) FCAW/Spray

Pulsed Gas Metal Arc Welding (GMAW-P) using the PipeWorx 400 System Shielding Gas: 75% Argon / 25% Carbon Dioxide Travel Direction: Backhand (Drag)

Pulse MIG Carbon

A
Pulse Wave Forms for Amps and Volts

1F 1G
or the PipeWorx 350 FieldPro™ System provides a shorter arc length,
narrower arc cone and less heat input than traditional pulsed spray Base Metal: 1/4 in. Cold Rolled Carbon Steel Nozzle Diameter: 5/8 in.

• Open iBooks on your device

transfer systems. Since the process is closed-loop, arc wandering and Flat Position Horizontal Position Vertical Position Overhead Position
(CV Peak Background) Flat Position Horizontal Position Vertical Position Overhead Position

Flat Position
variations in tip-to-work distances are virtually eliminated. This provides
Taught Peak

Welding Process Training Series

easier puddle control for both in-position and out-of-position welding,
reducing welder training time. The process also improves fusion and
fill at the toe of the weld, permitting higher travel speeds and higher
Voltage Voltage
Taught Back-
381 20 -20° 35 7/8”
(Flush Tip)
45° 28.0
deposition. This process coupled with RMD® for root pass welding permits ground Voltage

V
- +
welding procedures with one wire and one gas to eliminate process CFH
- +
switch-over time. Fixed current beginning points IPM Drag Push

Pulse MIG Stainless

Introduction To Welding
- Ideally suited to fill and cap pass welding IPM
- Easier puddle control than conventional spray pulse

• Click search in the bottom right

Current
- Shorter arc lengths and narrow arc cone for out-of-position welding Min Current Limit
- More tolerant of tip-to-work variation
- Improve fusion and fill at toe of weld CC Ramps CV Peak CV Peak Decreased Increased 1F 2F 3F 4F
1G 2G 3G 4G

- Less heat input reduces interpass cooling time and improves weld CV Background CV Background

2F 2G

Voltage
cycle time

Horizontal Position
- Enables one-wire with one-gas weld procedures
24.1 32.1 Flat Position Horizontal Position Vertical Position Flat PositionPosition
Overhead Horizontal Position Vertical Position Overhead Position

267 294
V V
• Type “Miller Electric” in the search bar at the top of the screen
Prior to welding each layer, prepare

Pass Tie-ins

Excessive Silicon
Starts and Stops
the weld for the Fill and Cap passes by
A A

(when not on a tack)

High Spots
Grinding
grinding:
- All high spots
- All arc starts and Stops

Decreased Increased
- All tie-ins

Root

Wire Feed Speed

- Any excessive silicon islands

For the 1G and 5G positions, 1G 1F 2F 3F 4F

• Download the E-pub

321 442 1G 2G 3G 4G
Maintain a Travel Angle

Weave Pattern

Torch Position
use a Z-weave pattern for fill Perpendicular to “1:30” Maintain a perpendicular

Gas Nozzle
and cap passes. Travel Angle (90 degrees).
Use a 5/8 in. straight nozzle D CAP ROTA

3F 3G
AN
Move quickly across the 251 303

TIO
L
and tip to ensure proper

FIL

N
Maintain a contact tip to

Vertical Position
shielding gas coverage. middle and pause at the
sides to ensure the weld
fuses and fills in along the
5G
work distance of 3/8 in. to
5/8 in. IPM A IPM A Flat Position Horizontal Position Vertical Position Flat Position
Overhead Position Horizontal Position Vertical Position Overhead Position

= Pause toes of the weld. Maintain a Perpendicular Travel Angle

Start and Stop arc at the 1:30 position. Deposit stringer beads with the arc cone Decreased Increased

Travel Speed
directed at the toes of the previous weld for
Rotate pipe towards you while maintaining sufficient tie in.

Android Users: Available for $.99-$1.99 through Amazon

the arc between 1:30 to 2:00.
16 24

1G

2G
Weave from side to side in a Z-pattern. Move
quick through the middle and pause on the Avoid weaving as gravity could cause cold 281 276 1F 2F 3F 1G
4F 2G 3G 4G

= Pause
sides. lap on the bottom portion of the weld. IPM IPM
A A
4F 4G
= Pause

Overhead Position
Flat Position Horizontal Position Vertical Position Overhead Position

Contact Tip To Work

Start at the at 6:00 position.

• Link to the E-Pubs: https://www.amazon.com/s/ref=dp_byline_sr_ebooks_1?ie=UTF8&text=Miller+Electric&sear

Deposit stringer beads with the arc cone
Decreased Increased
Flat Position Horizontal Position Vertical Position Overhead Position
directed at the toes of the previous weld for
sufficient tie in.
Weave from side to side in a Z-pattern while

5G

6G
traveling up the pipe. Move quick through
the middle and pause on the sides. 5/8”
(FLUSH TIP RECESS)
1-1/8”
Avoid weaving as gravity could cause cold
= Pause

lap on the bottom portion of the weld. 314 247

Pause
End at the 12:00 position.

=
A A 1G 2G 3G 4G

ch-alias=digital-text&field-author=Miller+Electric&sort=relevancerank
1F 2F 3F 4F

MillerWelds.com

• Instructions for reading E-Pubs: https://www.amazon.com/gp/digital/fiona/kcp-landing-page

© 2015 Miller Electric Mfg. Co. # 272 426
MillerWelds.com MillerWelds.com
© 2013 Miller Electric Mfg. Co. #263872 © 2012 Miller Electric Mfg. Co.

These publications are also available in printed format.

Miller Posters
FCAW-G
Part #
263872
Pricing
FREE
Hobart® Posters
Description
Introduction To Welding
Part #
247358
Pricing
$19.00
Discounted Education Pkg. FCAW-S
Welding Positions
263873
261666
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FREE Mild Steel Covered Electrodes,
SMAW Process
AWS Classifications
Causes and Cures
of Common Welding Troubles
Low Alloy
Covered Electrodes
ElectrodeCauses

Hobart Filler Metals continues to advance the science of welding, bringing new, innovative solutions
Technicaland Cures
Information
of Common Welding Troubles
Causes
Common andTroubles
Welding Cures
of Common Welding Troubles
Causes and Cures of

E7018-1 H4R E8018-B2 to customers around the world. Hobart is dedicated to providing the technology, the expertise and

Welding Safety* 247359 $4.00 Welding Joint Types 261664 FREE Electrode
Tensile in ksi
Position
Electrode
Tensile in ksi
Position
the commitment to quality required to keep pace with an evolving industry.

Porous Welds
Why
Cracked Welds
Why
Undercutting
Why
Distortion
Why
Type of coating and current 1. Excessively long or short arc length 1. Insufficient weld size 1. Faulty electrode manipulation 1. Improper tack welding and/or faulty joint
Meets lower temperature impact requirements
Type of coating and current
Types of Welds 2. Welding current too high
3. Too fast travel speed
2. Excessive joint restraint
3. Poor joint design and/or preparation
2. Welding current too high
3. Too fast travel speed
preparation
2. Improper bead sequence

GMAW SCMT DRAG 263868 FREE

Chemical composition of weld metal deposit
Hydrogen: H4 = Less than 4 ml/100 g. H8 = Less than 8 ml/100 g 4. Base metal surface covered with oil, grease, 4. Filler metal does not match base metal 4. Arc blow 3. Improper set-up and fixturing

Basic Electricity For Welding* 247360 $14.00

moisture, rust, mill scale, etc. 5. Rapid cooling rate What to Do 4. Excessive weld size
Meets requirements of absorbed moisture test 5. Wet, unclean or damaged electrode 6. Base metal surface covered with oil, grease, What to Do
moisture, rust, dirt or mill scales 1. Pause at each side of the weld bead when
What to Do using a weaving technique 1. Tack weld parts with allowance for distortion
Chemical Composition of Weld Metal Deposit Fillet Face Groove Angle Plug or Slot Arc Seam or Spot Size (Height) of Weld Surface 1. Maintain proper arc length What to Do 2. Use proper electrode angles 2. Use proper bead sequencing
Toe Reinforcement
AWS Suffix C Mn Si Ni Cr Mo V P S Cr Al Nb N Face Groove 2. Use proper welding current 1. Adjust weld size to part thickness 3. Use proper welding current for electrode size 3. Tack or clamp parts securely
Leg Throat 3. Reduce travel speed 2. Reduce joint restraint through proper design and welding position 4. Make welds to specified size
Position
E7018 A1 0.12 0.90* .80 — — .40-.65 — .03 .03
Toe Root 4. Properly clean base metal prior to welding 3. Select the proper joint design 4. Reduce travel speed
E8018 B2L .05 .90 0.80 — 1.00 -1.50 .40-.65 — .03 .03
Weld Size
Face Surfacing 5. Properly maintain and store electrode 4. Use more ductile filler 5. Reduce effects of arc blow
Leg
1 Flat, Horizontal, Vertical, Overhead E8018 B2 .05-.12 .90 0.80 — 1.00-1.50 .40-.65 — .03 .03 Root
Root Reinforcement
5. Reduce cooling rate through preheat
E9018 B3L .05 .90 0.80* — 2.00-2.50 .90-1.20 — .03 .03 Diameter Diameter 6. Properly clean base metal prior to welding
Root Opening

GMAW SCMT PUSH 263869 FREE

2 Flat and Horizontal only
E9018 B3 .05-.12 .90 0.80* — 2.00-2.50 .90-1.20 — .03 .03

Engine Driven Welding Power Sources 247362 $13.00

E8018 B6 .05-.10 1.0 .90 .40 4.0-6.0 .45-.65 — .03 .03
E8018 B8 .05-.10 1.0 .90 .40 8.0-10.5 .85-1.20 — .03 .03

Types of Coating & Current

E9015
E8018
B9
C1
.08-.13
.12
1.20
1.25
.30
0.80 *
2.00-2.75
8.0 8.0-10.5 .85-1.20 .15-.30
— — —
.01
.03
.01 .25 .04 .02-.10 .02-.07
.03 Welding Positions
E8018 C2 .12 1.25 0.80* 3.00-3.75 — — — .03 .03
AWS DIGIT TYPE OF COATING WELDING CURRENT
E8018 C3 .12 .40 -1.25 .80 .80-1.10 .15 .35 .05 .03 .03
6010 0 cellulose sodium DCEP Flat Position Horizontal Position Vertical Position Overhead Position
E10018 D2 .15 1.65-2.00 0.80* .90 — .25-.45 — .03 .03
6011 1 cellulose potassium AC or DCEP EXXXX G** — 1.00 Min .80 Min .50 Min .20 Min .20 Min .10 Min .03 .03 .2
6022 2 titania sodium AC or DCEN

GMAW Spray 263870 FREE

E9018 M .10 .60-1.25 .80 1.40-1.80 .15 .35 .05 .030 .030

Fillet Weld
Throat of Weld–Vertical
Axis of Weld Spatter Lack of Fusion Overlapping Poor Penetration
6013 3 titania potassium AC or DCEP or DCEN Axis of Weld

Shielded Metal Arc Welding* 247363 $17.00

E10018M M .10 .60 -1.25 .80 1.40-1.80 .15 .35 .05 .030 .030 Vertical Plate Vertical Horizontal Plate
Horizontal Why Why Why Why
7014 4 iron powder titania AC or DCEP or DCEN E11018M M .10 1.30-1.80 .60 1.25-2.50 .40 .25-.50 .05 .030 .030
1. Arc blow 1. Improper travel speed 1. Too slow travel speed 1. Travel speed too fast
E12018 M .10 1.30 -2.25 .60 1.75-2.50 .30-1.50 .30-.55 .05 .030 .030
7018 8 iron powder low hydrogen AC or DCEP 2. Welding current too high 2. Welding current too low 2. Incorrect electrode angle 2. Welding current too low
E7010 P1 .20 1.20 .60 1.00 .30 .50 .10 .030 .030 3. Too long an arc length 3. Faulty joint preparation 3. Too large an electrode 3. Poor joint design and/or preparation
DCEP – Direct Current Electrode Positive E8010 P1 .20 1.20 .60 1.00 .30 .50 .10 .030 .030 (4F) 4. Wet, unclean or damaged electrode 4. Too large an electrode diameter What to Do 4. Electrode diameter too large
DCEN – Direct Current Electrode Negative Axis of Weld 5. Unclean welding surface 5. Magnetic arc blow 5. Wrong type of electrode
*
Amount depends on electrode classification. Single values indicate maximum. (1F) (2F) 6. Wrong electrode angle 1. Increase travel speed 6. Excessively long arc length
AC – Alternating Current **
All G Classifications have the same chemical minimum requirements. Horizontal What to Do 2. Use proper electrode angles
1. Attempt to reduce the effect of arc blow What to Do 3. Use a smaller electrode size What to Do
Axis of Weld–Horizontal Horizontal Plate
(3F) Vertical Plate
Vertical Plate 2. Reduce working current 1. Reduce travel speed 1. Decrease travel speed

Mild Steel Solid Electrodes, 3. Reduce arc length 2. Increase welding current 2. Increase welding current

GMAW PULSE 263871 FREE

Low Alloy Solid Electrodes, 4. Properly maintain and store electrodes 3. Weld design should allow electrode accessibility 3. Increase root opening or decrease root face

Gas Tungsten Arc Welding* 250833 $29.00

5. Clean welding surface 4. Use smaller electrode
GMAW, GTAW and PAW
to all surfaces within the joint

GMAW, GTAW and PAW 4. Reduce electrode diameter

5. Reduce effects of magnetic arc blow
5. Use electrode with deeper penetration
characteristics

ER70S-3 ER80S-D2
Plates Horizontal 6. Use proper electrode angles 6. Reduce arc length

Electrode or rod
Electrode or rod
Tensile in ksi (1G)
Tensile in ksi (2G) (3G)

Good & Bad Welds 211604 FREE

Solid (4G)

Groove Weld
Solid Plates Vertical

Gas Metal Arc Welding* 250834 $50.00

Plates and Axis of Pipe–Horizontal
Chemical composition & shielding gas Plates and Axis of Pipe–Vertical Axis of Weld–
Chemical composition Vertical

Magnetic Arc Blow Inclusions

Why Why
Chemical Composition of Solid Wires Using CO2 Shielding Gas Pipes Shall Not Be Turned or Rolled While Welding
1. Unbalanced magnetic field during welding 1. Incomplete slag removal between passes
2. Excessive magnetism in parts or fixture 2. Erratic travel speed
Tensile Yield % Elongation Impact strength CHEMICAL COMPOSITION
What to Do 3. Too wide a weaving motion
AWS Shielding Strength Strength min. in 2" Min. 4. Too large an electrode

Good & Bad Welds—Spanish 257992 FREE

classification gas ksi (MPa) ksi (MPa) (50 mm) ft-lbs at °F (J at °C) C Mn Si P S Ni Cr Mo Cu Other 1. Change the location of the ground connection 5. Letting slag run ahead of arc

Metal Cutting 250836 $15.00

on the workpiece
ER70S-2 C02 70 (500) 60 (420) 22 20 at -20 (27 at -29) .07 .90-1.40 .40-.70 .025 .035 — — — .50 Ti, Zr, Al (1R) (6G) 2. Reduce welding current and arc length What to Do
(2G) (5G) 3. Use alternating current 1. Completely remove slag between passes
ER70S-3 C02 70 (500) 60 (420) 22 20 at 0 (27 at -18) .06-.15 .90-1.40 .45-.70 .025 .035 — — — .50 —
2. Use a uniform travel speed
ER70S-4 C02 70 (500) 60 (420) 22 — .07-.15 1.00-1.50 .65-.85 .025 .035 — — — .50 — Pipe Shall Be Rolled While Welding
Inclined Position (45°) 3. Reduce width of weaving technique
4. Use a smaller electrode size for better access
ER70S-5 C02 70 (500) 60 (420) 22 — .07-.19 .90-1.40 .30-.60 .025 .035 — — — .50 Al
to joint
ER70S-6 C02 70 (500) 60 (420) 22 20 at -20 (27 at -29) .07-.15 1.40-1.85 .80-1.15 .025 .035 — — — .50 — 5. Increase travel speed or change electrode angle
or reduce arc length
ER70S-7 C02 70 (500) 60 (420) 22 20 at -20 (27 at -29) .07-.15 1.50-2.00 .50-.80 .025 .035 — — — .50 —
ER80S-D2 C02 80 (550) 68 (470) 17 20 at -20 (27 at -29) .07-.12 1.60-2.10 .50-.80 .025 .025 .15 — .40-.60 .50 —

Troubleshooting Welding Processes 250837 $27.00 MIG Processes 261665 FREE

PipeWorx Pulse Fill and Cap 272426 FREE
Submerged Arc Welding 265558 $16.00
Hobart Posters Part # Pricing
Introduction To Metals 247380 $14.00 PipeWorx RMD Root 272427 FREE Tension, Strength & Impact Tests

Oven Storage & Reconditioning of 275468 FREE Electrode Technical Information

Safety 172103 FREE Stick Electrodes

Hobart Filler Metals continue to advance the science of welding, bringing new, innovative solutions to customers around

Low Alloy Steel 247842 $10.00 the world. Hobart is dedicated to providing the technology, the expertise and the commitment to quality required
to keep pace with an evolving industry.

Stainless Steel 247843 $27.00 OXY-Fuel Safety #1 270131 FREE AWS Classifications 275469 FREE All Weld Metal Tension Test

Educational Package - #211611

Tension testing involves deforming a structure to the point of
fracture, with a gradually increasing load applied along the
long axis of the specimen. The specimen is mounted into the
testing machine and subjected to a load until it breaks. The

OXY-Fuel Safety #2 270132 FREE Tension, Strength & Impact Tests 275471 FREE
test results are recorded on a chart as shown.

Aluminum 247844 $18.00 Yield and Tensile Strength

When stress is applied to a metal structure, deformation or
yielding occurs. Yield point is defined as the stress level at

(6) Posters
which the metal begins to deform and will not go back to

(5) Miller Process Books: OXY-Fuel Safety #3 270133 FREE Electrode Technical Information 275472 FREE
its original dimension. The tensile strength is the maximum

Hardfacing 250838 $15.00 stress that can be maintained by the structure. If the stress
continues, fracture will result.

*Educational Package 211611 $100.00 •• Welding Safety Book •• Safety Warning OXY-Fuel Safety #4 270134 FREE Causes and Cures of Common Weld- 275473 FREE Impacts

•• Good weld/Bad weld

Impact Testing

•• Basic Electricity for Welding ing Troubles Impact testing ascertains the fracture characteristics of
materials. It is used when laboratory tensile test results cannot

OXY-Fuel Safety #5 270135 FREE

be used to predict fracture behavior. One of the most common

Guidelines for Shielded Metal Arc Welding (SMAW) 155095E FREE

impact testing techniques is the Charpy method, designed to

•• Welding Careers
measure impact energy, or the toughness of the metal.

•• Shielded Metal Arc Welding Complete Set of Hobart Classroom 275474 FREE
Testing Technique
The V-notch bar-shaped specimen is placed in the test
machine where it is struck by a weighted pendulum hammer

Guidelines for Gas Metal Arc Welding (GMAW) 154557C FREE OXY-Fuel Safety #6 270136 FREE that deforms, cracks and fractures the specimen at the

•• Welding Positions Posters (5)

notch. The impact strength of a metal is then determined by

•• Gas Tungsten Arc Welding

measuring the amount of energy absorbed in the fracture.

Complete Set of Miller Classroom Posters

HobartBrothers.com

Guidelines for Gas Tungsten Arc Welding (GTAW) 215994D FREE •• Gas Metal Arc Welding •• Welding Joints
©2013 Hobart Brothers Corp.

274532 FREE
Hobart and the Hobart logo are trademarks of Illinois Tool Works, Inc.

(18)
Pipe Welding Handbook M247250B FREE •• MIG Processes
Welding & World of Metals 003336A FREE
(3) Miller Calculators — Stick, MIG, and TIG
Hobart Helpful Hints to Basic Welding
®
FREE Poster ordering information
Publication ordering information Call: 1-866-931-9732 or E-mail: literature@MillerWelds.com

3
Call: 1-866-931-9732 or Email: literature@MillerWelds.com 4
 Multimedia Resources Instructor Website
The Instructor web page is a useful tool for instructors to find information and resources for the classroom and the lab. Use
iPad® and iPhone® Learning Applications this site to find welding training related articles, welding resources for the classroom, sign up for the Instructor e-newsletter,
and find recommended equipment and filler metals for the classroom.
iPad and iPhone Applications https://www.millerwelds.com/applications/industry/welding-instructors
Currently available in the App Store®, there are three FREE apps that interactively discuss the Find best practices and welding
fundamentals of the welding process. You will find videos, images, and interactive pages that will training related articles.
display information when touched. Search for Miller Electric Mfg. Co. in the App Store.
Additional Apps
•• Mobile Weld Settings Calculator GTAW GMAW SMAW
•• Miller Discussion Forums
•• Mobile Owners Manuals
Available for Android and in the App Store

Online Learning Modules Hobart Filler Metal Calculator

Hobart® Filler Metals Selector for iPhone, iPad and Android
now available on the App Store®. The Hobart Filler Metal
Selector and Calculator is a FREE quick reference tool with a
number of functions. These functions include a Filler Metal
Selector for: Aluminum, Carbon Steel, Stainless Steel. A Heat
input calculator, Hardfacing Product Cross Reference tool,
and a Filler Metal Volume Calculator.

Find welding resources for the

classroom.

Students can learn about the basics of electricity and GMAW

through online learning modules.
https://www.millerwelds.com/resources/welding-resources/
mig-welding-resources/basic-mig
https://www.millerwelds.com/resources/welding-resources/
basic-electricity Find products for the welding lab and
classroom, and search for a local Authorized
Miller Distributor to see if you can save using

Presentations and Quizzes Videos the Educational Discount.

Web based PowerPoint presentations are available for

instructors, assisting them in classroom discussions. Topics
range from basic electricity for welding, SMAW, GTAW,
GMAW, aluminum, etc. The presentations coincide with the
Weld Process and Filler Metal publications available in print
and epub format. When finished delivering the PowerPoint,
quizzes are available to gauge student learning.
https://www.millerwelds.com/resources/welding-resources/
presentations-and-quizzes VISIT OUR YOUTUBE CHANNEL: Sign up for the Instructor
https://www.youtube.com/user/nielsmiller e-newsletter.

5 6
 Education and Training Solutions LiveArc™
Education and Training Solutions
AugmentedArc™ Welding performance
Augmented reality
welding system
management system AugmentedArc Augmented Reality Welding System
™

The industry's most realistic welding simulation system

The AugmentedArc system improves the efficiency and economy of
classroom education with augmented reality technology that's ideal
for beginner and intermediate-level students. Users wear a specially
designed helmet that shows them images of the real world, augmented
with computer-generated images of metal workpieces, weld arcs and
weld beads. The result is a simulation that closely resembles live-arc
welding — without using an actual arc or consuming wire, shielding
gas or coupons.

LiveArc Welding Performance Management System

™

The industry's most complete live arc welding training system

From classroom to laboratory. Ideal for lab training, the Miller LiveArc welding performance management
From laboratory to career. system provides both a simulation/pre-weld setup mode as well as a live-arc
training mode, allowing the user to gain experience and build techniques in
Miller welding education systems help weld students build skills and confidence, keeping them fully engaged and delivering pre-weld exercises before seamlessly transitioning into real welding on
immediate feedback. Using the Miller® AugmentedArc™ augmented reality welding system in the classroom, beginner GMAW, FCAW and SMAW processes.
and intermediate-level students can experience the most realistic multiprocess welding simulation available — and then
seamlessly transition to the Miller® LiveArc™ welding performance management system in the laboratory for the industry’s
most complete live arc experience. When it’s time to interview for that first job — or maintain qualifications in an existing job —
LiveArc can evaluate candidates and employees, too.

The best tools build the best weld operators

Miller welding education systems deliver exceptional benefits:

Optimize instructor efficiency Minimize material cost

Deliver real-time feedback

Enhance job candidate recruiting and screening

Reduce overall training time

Build a largeer, more-skilled workforce

Access weld operator skills and performance For more information visit:
MillerWelds.com/trainingsolutions
7 8
 Miller Product Offering Miller Product Offering
® ®

Miller is committed to the future of welding and providing you with the resources and tools you need to educate your students.
For special educational pricing, visit an authorized Miller welding distributor.

Multiprocess TIG

XMT® Series
Portability and excellent multiprocess
arc performance make the XMT family
the most popular in the industry. With
many models to choose from the XMT
family has the right solution for your
business.
PipeWorx Welding System
Simplicity-driven performance for pipe
fabrication with simple process setup,
and quick process changeover in a
streamlined system.
Dimension™ Series Dynasty® Series Maxstar® Series Syncrowave® 210
Multiprocess performance in a reliable Advanced AC/DC TIG technology for all Industry standard DC TIG/Stick for Total system solution designed to
package. Designed for demanding metals. Provides faster travel speeds, exceptional welding performance. meet your TIG and Stick welding
applications, with 100 percent duty optimum arc and puddle control in a Compact designs offer superior arc process needs with optional MIG
cycle for extended arc-on time. compact and mobile design. performance and control that set new capabilities. This design features an
standards for productivity and weld operator-friendly interface and offers
quality, while lowering the cost of superior arc performance.
installation and operation.

Shopmate™ 300 DX Multimatic™ 215 Weldcraft™ Series TIG Torches

An economical single-phase DC Easy-to-use and versatile MIG, Stick Synonymous with versatility and performance, Weldcraft™ TIG
multiprocess power source that and TIG welder that helps build skills. torches can handle the most demanding TIG welding
provides versatility and outstanding Color screen featuring Auto-Set™ Elite. challenges. From 125-amp hand-held MicroTIG® torches to
arc performance in CV mode (MIG) and This all-in-one welder connects to 120 900-amp machine-held water-cooled models, there’s a
CC mode (Stick and TIG). or 240 volt input power. Welds up to Weldcraft torch for nearly every TIG application.
3/8 inch mild steel.

Stick MIG Plasma Cutters

Maxstar® 210 STR CST™ 280

Designed for Stick/TIG welding pipe and plate in the
Millermatic® Series Spectrum® Series
Provides maximum flexibility by automatically connecting to
construction industry, this small, durable, goes-anywhere Millermatic all-in-one MIG welders come in a variety of Spectrum plasma cutters provide big cutting power in
any input power while maintaining the best DC Stick welding
welder delivers 280 amps of superior Stick performance, up packages to fit your needs and budget in the classroom. portable packages.
performance in its class.
to 3/16 inch diameter. LiftArc™ delivers smooth TIG starts
without high frequency.
9 10
 Miller Product Offering Miller Product Offering
® ®

Miller is committed to the future of welding and providing you with the resources and tools you need to educate your students.
For special educational pricing, visit an authorized Miller welding distributor.

Engine-Driven Welding Safety and Health Additional models available on MillerWelds.com

HEAD & FACE HAND & BODY

Bobcat™ Series Trailblazer® Series Classic Series MIG (Unlined) TIG Work
Unbeatable, smooth, stable arc performance and an
Cost-effective multiprocess machine with dependable power
independent welder and generator power system. Available
Helmets for the value minded welder. Models feature a 5.15 Performance Gloves
and weld output. Available in gas (EFI), LP, & diesel. sq. in. viewing area, variable lens shades, industry-leading
in gas (EFI), LP, & diesel. Three-dimensional pattern provides an excellent fit, resulting
graphics and auto-on/off circuitry. Backed by Miller's 2 year in unprecedented comfort and dexterity. Premium materials
warranty. enhance wear, extending glove life.

Submerged Arc Welding Automation WELD FUME

FILTAIR 130 FILTAIR Capture 5 FILTAIR SWX

FILTAIR Fume Extraction

PA 250M Automation Solution
Small footprint, high productivity and ROI makes it ideal for
first-time users with a lower volume of automation projects.
The manually activated table allows you to control the table
index, eliminating unexpected table motion and keeping
operators safe.
®
The complete line Miller FILTAIR fume extractors are
designed specifically for welding – drawing weld fumes away
from the welder’s breathing zone and keeping your facility
clean. We offer many types of Fume Extraction equipment to
best fit your environment and fume control needs.
Classic Cloth Apparel
Protect your welders with preshrunk, flame-resistant
garments that features finished hems and reinforced
stitching for enhanced durability. Barracuda style stand-up
collar provides necessary neck protection. Available in
jackets, sleeves, cape sleeves, bibs and aprons.

SubArc Digital Portable Welding System

SubArc Portable Welding System is a ready-to-weld sub-
merged arc system for pressure vessel, pipe and welding N95 Disposable Masks
that requires positioning equipment which can adapt to your Features a flame retardant outer layer that offers necessary
application. - See more at: https://www.millerwelds.com/ protection for welding applications.
equipment/welders/submerged-arc/subarc-portable-welding-
systems-m30092#sthash.z5lTqAwm.dpuf
Starter & Performance Paks
Arc Armor Protection Paks group welding protection products
into ultra-convenient packages appropriate for the hobbyist to
the professional welder.

11 12
 Hobart Product Offering Bernard and Tregaskiss Product Offering
® ™
™

Products Include: MIG Gun Product Offering

u Hobart is pleased to support educational facilities with a measurable discount on filler metals through the distributor of Equip your students with the same industrial-duty, semi-automatic MIG guns
their choice. This program includes stick electrodes, tubular wires and solid wires. from Bernard that are used by top companies in agriculture, ship-building and
Contact your distributor for full product list. fabrication shops across North America. For special educational pricing,
visit an authorized
BTB MIG Guns Bernard welding distributor.
Our rugged, flexible BTB MIG Guns are designed with maximum
configuration options and the industrial grade performance that
customers depend on.
One year manufacturer’s warranty.
Amperages: 200, 300, 400, 500, and 600 amps
Cable lengths: 8, 10, 12, 15, 20, and 25 feet
Hobart 418 Hobart 335A Hobart 610
Wire size range: 0.023" (0.6 mm) to 1/8" (3.2 mm)
Stick Electrode Stick Electrode Stick Electrode See Bernard literature no. SP-BTB or visit BernardWelds.com/BTB
Provides low-hydrogen, x-ray Superior arc drive for deep joint Delivers consistent, superior arc
quality welds with self-peeling penetration. Ideal for galvanized, control without fingernailing — from
slag and low spatter. Excellent dirty, or coated metals. E6011 the first electrode to the last. Excellent Fume Extraction MIG Guns
arc starts and re-starts. E7018 vertical down capabilities. E6010 Maintaining a clean working environment is important and Bernard understands the need for a reliable fume
extraction solution. Extract fumes at the weld using Bernard FILTAIR® or Clean Air™ Fume Extraction MIG Guns.
See Bernard literature no. SP-FFE (FILTAIR) & SP-CLA (Clean Air) or visit BernardWelds.com/FumeGuns

Dura-Flux™ Self-Shielded Flux-Cored Guns

For structural steel applications, bridge construction and heavy equipment repair, Bernard offers its 350 amp
Bernard Dura-Flux Guns.
FabCO® Excel-Arc™ 71 Fabshield® XLR-8 Quantum Arc™ 6 See Bernard literature no. SP-DF or visit BernardWelds.com/Dura-Flux
Gas-Shielded Self-Shielded Solid Wire
Flux-Cored Wire Flux-Cored Wire Features high deoxidizer levels to
weld through light rust or mill scale.
Automation Products
Low-hydrogen, high-penetrating weld Excellent mechanical properties within
deposit, along with best-in-class a wide range of heat inputs. Usable Excellent wetting characteristics Teach your students about the importance of uptime and throughput in today’s
operability and easy slag removal. for AWS D1.8 Demand Critical Welds. and feedability. ER70S-6 industrial manufacturing plants by equipping your facility’s robotic cells with
E71T-1 E71T-8 Tregaskiss Robotic MIG Guns and Peripherals.
For special educational pricing,
TOUGH GUN™ CA3 MIG Guns visit an authorized
It’s the tie that binds TOUGH GUN CA3 Robotic Air-Cooled MIG Guns are designed for
dependable performance in high volume production environments.
Tregaskiss welding distributor.

The new replaceable unicable increases uptime through faster

replacement and extended service life.
See Tregaskiss literature no. SP-CA3 or visit Tregaskiss.com/CA3

Filler metals are more than just a component of welding – they are
The tie that binds science and people.  TOUGH GUN TA3 MIG Guns
Designed for today's through-arm style robots, the TOUGH GUN TA3 Robotic Air-Cooled MIG Gun is designed for
You shape the future of welding with your students, training to make
durability and ease of maintenance to ensure maximum production uptime and throughput.
them more successful welders – the people part of welding.
See Tregaskiss literature no. SP-TA3 or visit Tregaskiss.com/TA3
The proper filler metal can make a welding process more efficient,
more productive and more cost effective. Hobart Filler Metals
collaborates with our customers to develop the right solutions. TOUGH GUN TT3 Reamers
We provide the strength of science behind the weld. This robotic nozzle cleaning station is tough on spatter and operates reliably in even the harshest welding
Contact your distributor for more information about environments. NEW! TT3E Ethernet model provides greater control optimization, remote monitoring capability
our educational program. Let us collaborate with you! and faster troubleshooting to facilitate increased productivity.

13 14
 ITW Welding

MillerWelds.com
273593 © 2015 Miller Electric Mfg. Co.
Miller and the Miller logo; Hobart and the Hobart logo; Bernard and Tregaskiss are
registered trademarks of Illinois Tool Works, Inc
iPad, iPhone, and App Store are registered trademarks of Apple Inc.
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