Stick welding procedure theory

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I haven't been able to find anything on the net that gives a good explianation on the theory behind how stick welding procedures are developed. As an example In Linoln's stick electrode welding guide for a 10 gage mild steel horizontal fillet weld, they list a 3/16" 6013 electrode on AC at 210 amps, arc travel speed of 16 in/minute. I'm looking to learn some of the theory behind how they come up with that. Hoping to find something that gets into the technical aspects, with out two much engineering mumbo-jumbo, actually some mumbo-jumbo will be alright if they provide an explianation to it. I'm new and looking to learn. Any suggestions were I might be able to find sumptin like that?
Reply:thanks fer askin the question. i always assumed they  dialed it in and experimented, then took the best acceptable result and that became the procedure..
Reply:A good welding procedure produces welds with actual mechanical properties that meet the design requirements.  Mechanicals are determined in part, by the chemistry of the weld metal and the heat input, or cooling rate, of the weldment.  The cooling rate is in part controlled by the welding technique and power supply settings; stringers, weaves, volts, amps, etc.I suspect that the general recommendations you see in the Lincoln manual were developed through trial and error.  But somebody, sometime in the past must have done some destructive tests (bend straps, tensile tests, impact tests) to confirm that the end results of the weld were good.For critical applications, the weld procedure gets set up, all the mechanical testing is done, and then every welder performing that procedure gets to test out as well.  There's a lot of time and money tied up in all this testing, and that's why any given company is reluctant to change their welding procedures.Likewise, engineers, if they're efficient, use the same joint designs and materials repeatedly, whenever possible.  That way they don't have to work through all the testing to confirm that the welds will be adequate for the task.Benson's Mobile Welding - Dayton, OH metro area - AWS Certified Welding Inspector
Reply:Originally Posted by dakookI haven't been able to find anything on the net that gives a good explianation on the theory behind how stick welding procedures are developed. As an example In Linoln's stick electrode welding guide for a 10 gage mild steel horizontal fillet weld, they list a 3/16" 6013 electrode on AC at 210 amps, arc travel speed of 16 in/minute. I'm looking to learn some of the theory behind how they come up with that. Hoping to find something that gets into the technical aspects, with out two much engineering mumbo-jumbo, actually some mumbo-jumbo will be alright if they provide an explianation to it. I'm new and looking to learn. Any suggestions were I might be able to find sumptin like that?
Reply:Originally Posted by paweldor3/16" rod, on 10 ga, at 210 amps?  I think Lincoln had an excess inventory of 3/16" 6013 to get rid of.
Reply:Must be a typo.  I'd weld that setup with 1/8" 60XX or 70XX  at about 80 amps or 100amps, respectively.No way I'd try to run 3/16" rod on material that thin.  That diameter might allow you to make the weld in one pass, but you'd never be able to set the amps high enough to get the rod to burn right... Originally Posted by paweldor3/16" rod, on 10 ga, at 210 amps?  I think Lincoln had an excess inventory of 3/16" 6013 to get rid of.
Reply:Originally Posted by A_DAB_will_doMust be a typo.  I'd weld that setup with 1/8" 60XX or 70XX  at about 80 amps or 100amps, respectively.No way I'd try to run 3/16" rod on material that thin.  That diameter might allow you to make the weld in one pass, but you'd never be able to set the amps high enough to get the rod to burn right...
Reply:woops double post
Reply:I have read a lot of those procedures in the Lincoln procedure handbook for arcwelding.  If you read closer, they are going for all out speed.  6013 is a "follow" rod used in the right application.  It was made for sheet metal.  I have never tried those settings.  I do not have any 3/16" 6013 and probably never will.   If you read closly, they say travel at a speed that welds most of the metal.  Don't forgeet, Lincoln is selling amps!David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:That is just craziness.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Originally Posted by DesertRider33That is just craziness.
Reply:You got to burn  to learnthe more you burn  the more you learnthe more you learn the more you earn
Reply:I worked for a test lab for 6 months just after I got my CWI stamp. We would develop and test procedures for the oil patch. In most cases the procedure submitted (by the contractor) would pass (way exceed) the design limits. The few that did not pass first time out, would fail so horribly, you would have thought one was welding aluminum to stainless. Some of the failures were due to the welder that the contractor sent out to prove the procedure, when I would attempt the same procedure it would pass, (I never had a bust while there) When all this would happen it would end with some pi$$ed off welders and claims of cheating or that we did not provide their welder with the proper support...On a vary few occasions the lab I worked for was asked to develop a procedure from scratch, (twice on stainless once for aluminum) In these cases we would start off with a base line of what we knew would work form experience, make a test while recording the parameters, if it passed we would then write a procedure ,matching what we did in making the test.  (sort of back engineering)    All the materials we were dealing with were not exotic. 90% of the procedures I signed off on (as CWI) were based 99% on AWS D1.1 prequalified procedures. The owner would change some non essential variables and sell it back to the customer written in the customers name. Customer is happy they have a procedure in their name. (not so likely to be questioned by inspectors and contractors in the future) The system in the USA is flawed. The persons that should most like to see the procedures (the guy making the weld) almost never see them or have nay understanding of them) So the system in the USA ends up being a paper chase between the bean counters and the lawyers, the engineers and the inspectors. Less time (read money) needs to be spent on the paper and more spent on building the future of this country. Do America a favor and shoot a lawyer today... lol