Have you ever wondered when the first weld was done? Where and how? Did they define different types of welding positions or the weld was done regarless of that? Pretty interesting question, right?
Let me answer that. Welding was invented around 3000 B.C. Some of you are shocked to hear that and wondering if this is true. I am talking about the time when iron and bronze were new to people.
However, it gained more popularity in the late 80s when Russians re-established the welding method by doing some modifications to the old process. Now you see different welding equipment, welding arc, metals, and much more.
Let’s talk about something unique and different today. We are here to give you a detailed overview of the different types of welding positions used in the welding process.
Contents
Welding position
First of all, we need to have a keen understanding of what a welding position is.
For the areas which are easily accessible, welding is not a problem there. But when it comes to congested places like corners, vessels, submarines, ceilings, etc, it can be very problematic.
Because in such areas, even a person cannot stand normally. That is why a skillful and experienced person is required to perform welding even in such challenging situations.
A welding position can be defined as a specific plane or direction in which a welder can complete the weld successfully.
Besides, not every welder is capable of performing welds in all possible directions. Some welders might only be experienced in welding in a specific direction.
Types of welding positions
Depending on the welding positions that a welder can face more often at his workplace, these positions are divided into four main types:
- 1G welding position
- 2G welding position
- 3G welding position
- 4G welding position
1G welding position
1G welding position is also named “flat welding position”. In this welding position, the welder’s head is bent down on the welding metal. It is the same when you bend your head down to look at something on the ground. That is why this welding position is also referred to as the “Down hand welding position”.
If you are a newcomer, this is the first welding position that you will be taught. It is the most convenient position as compared to others. Also, this is the most used position in the everyday working of a welder.
Welding characteristics of 1G welding position
- In this welding position, we can easily manage and control the shape and movement of the welding pool.
- If you are welding two metals with the same thickness, the weld production is very efficient. Why? Because as compared to any other welding positions, the welding current supplied is much greater.
- However, it gets difficult to prevent the mixing of the weld pool and slag which is formed as a result of welding. Both of them can easily mix up because you are welding in a flat position.
- Also, failure in welding equipment or improper use of welding techniques can cause welding defects such as undercut and deformation, etc.
Important things to remember during welding
- The diameter of the welding rod and welding current should be adjusted according to the thickness of the metal plate.
- The electrode should make an angle of 60 to 80 degrees during welding. Also, the weld pool and slag should be controlled and kept separated to prevent any obstacles.
- In case slag gets mixed with the weld pool, lean the electrode in the forwarding direction. To prevent slag incursion, increase the length of the arc as well.
- If you are doing multi-layer welding, make sure that each layer is around 4-5mm.
2G welding position
2G welding position is also known by another name that is “Horizontal welding position”. As the name suggests, welding is done horizontally.
In this welding position, the metals which are to be joined together make an angle of 90 degrees with each other. Welding in this position is difficult as compared to the 1G welding position.
Welding characteristics of 2G welding position
- Here, the weld pool and slag can be easily separated and we can prevent slag incursion.
- There is a chance of molten metal falling because of its weight. This can result in various welding defects in both the upper side and lower side of the weld.
- On the upper side, it causes an undercut. While on the lower side, it can result in a teardrop or incomplete penetration.
Important things to remember during welding
- You should use an electrode with a small diameter along with a short length arc. Because the welding current is smaller as compared to the flat welding position.
- If you are welding two heavy metal plates having a considerable thickness, then multi-layer welding with multi passes is advised for effective results.
- Overlapping distance between each welding pass should be carefully controlled while doing multi-layer welding.
- The welding electrode should be placed at a specific angle and the welding speed should be maintained uniformly and a little slow throughout the welding process.
3G welding position
3G welding position also has a second name that is “Vertical welding position”. As the name suggests, the metal pieces which are to be welded are placed in a vertical plane.
Now there is a debate about whether to do “Downhill welding” or “Uphill welding”. If some of you don’t know what these terms are, I will let you know.
In Uphill welding, welding is done in a downward to an upward position. Whereas in downhill welding, an upward to downward direction is used.
However, during welding, most welders prefer welding in the uphill direction. That’s because, in the case of a downhill welding position, there is a greater chance that the molten metal will mix with slag resulting in slag incursion.
Welding characteristics of 3G welding position
- Just like the 2G welding position, it is a lot more convenient to separate the weld pool and slag from each other.
- Welding defects can occur if the temperature of molten metal is quite high. You might have to face undercut, uneven weld, weld beading, etc.
- There are chances of incomplete penetration.
- As compared to flat welding, weld production is not efficient.
Important things to remember during welding
- Similar to both welding positions discussed above, the electrode should be kept at a right angle to the metal piece.
- Here, use a small-sized electrode.
- Also, the welding current is smaller in comparison with the 1G welding position around 10 to 15 percent.
- To decrease the distance between the welding arc and the metal pool, an arc with a short length is used.
- Crescent-shaped welding beads are often advised to guarantee a high-quality weld.
4G welding position
4G welding position can also be called “Overhead welding position” for your convenience. It is indeed the most difficult position and requires extensive training and practice.
In this case, a welder needs to weld metals above his head. You might have to work in narrow and closed places while adjusting your posture at the same time. Sometimes it gets difficult to perform a weld in such a situation.
There is also a risk that molten metal will fall on your face and body if you are not careful enough. That is why only a skilled person can finish such welds with success without hurting himself.
In addition to that, you are advised to wear welding mask and safety goggles to prevent yourself from any danger.
Welding characteristics of 4G welding position
- Molten metal can fall because of its weight as an act of gravity. That is why it gets difficult to maintain and control the shape and size of the weld pool.
- There is a greater probability of the occurrence of welding defects like uneven weld, weld beading, slag formation, and incomplete penetration.
- As discussed above, the molten metal can fall easily causing many accidents.
- Compared to other welding positions, the efficiency of the overhead welding positions is quite low.
Important things to remember during welding
- The welding electrode should be chosen carefully and the welding current should be kept moderate.
- Depending on the thickness of metals, a multi-layer welding technique can be used.
- If you are doing T-joint welds, the single-layer welding technique is advised to use.
FAQs
Which welding test is the hardest?
6G pipe weld is considered to be the most difficult. This test demands a lot of practice and you must have enough experience in welding pipes using a 6G welding position to make successful welds. In this type of weld, first of all, the pipe which is to be welded is fixed at a specific position. Then during welding, it is rotated at an angle of 45 degrees.
What are 1G, 2G, 3G, 4G, 5G, and 6G welding positions?
While welding, a welder not only changes his posture but also the angle of the electrode, and arc length is also determined by the the nature of weld to be done. 1G, 2G, 3G, 4G, 5G, and 6G welding positions are different welding positions also known as flat welding position, horizontal welding position, vertical welding position, overhead welding position, horizontal fixed welding, and 45 degrees inclined fixed welding respectively.
Which welding position is very common to use?
When it comes to the most convenient and most used welding position, the 1G welding position takes the first place. Almost all kinds of shielding arc welding processes are done in this position. It not only gives stronger welds but also ensures the prevention of slag and bead formation is quite smooth.
Wrapping up
Besides flat, horizontal, vertical, and overhead welding positions, there are two more welding positions that we have not explained in today’s discussion. These are horizontal fixed welding and 45 degrees inclined fixed welding. Both of these welding positions are used to weld pipes.
However, the four welding positions mentioned are enough for you to build a proper understanding of them. Make sure you are doing enough practice of welding regardless of the welding position.