Welding Positions and Joint Types: 1G, 2G, 3G, 4G, 5G, and 6G

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Welding, as a general process, has a lot of small details that must be configured if you're going to have a positive end result.

There are many different ways to make sure you do everything right. Experience is part of it, but a large part is technical documentation. Welder operators are rarely just told, 'Join these two pieces of material at a 90-degree angle.' Instead, they're given a WPS, or Welding Procedure Specification, which is a document that specifies all of the critical details of the welds they must create.

Among the many pieces of information in this document is the type of weld. This is generally denoted by a letter and number combination, such as 1G or 4G, or even something slightly more complex, like 6GR.

What do these mean? Knowing their definitions is a key part of making sure you're welding properly. So, let's run down the salient information you need to know.

What Does the Number Mean?

Since the welding specification is made up of a number and letter pair, it's easy to break it down and define each of them individually.

The number is the easiest. Different welding specification standards, like AWS, ASME, and ISO, have different names for their tables of data, but the general information is the same across the board

There are six numbers. As you might expect, these are appropriately labeled 1 through 6.

The number is, specifically, the position you're using when you're welding.

They are:

1. Flat. Flat welding is welding below the torch. It's among the most common, easiest to manage, and least complex of the welding positions. Because you're working from above, you have good visibility. Because the workpiece isn't at a strange angle (in general), you don't need to worry about things like the weld pool dripping out of position or the danger of it dripping on you from above.

2. Horizontal. This is a position most commonly used for butt welds. Butt welds are joints where two workpieces are aligned on the same plane. The horizontal position means you're moving side-to-side across the weld rather than pulling or pushing toward or away from you, as in position one.

3. Vertical. This means the materials are positioned in front of you such that you need to move either upwards or downwards along the seam to weld a joint. These are usually specified as either PF or PG for uphill and downhill. Downhill, in particular, is common and good for productivity since you aren't fighting gravity nearly as much as you are with other positions.

4. Overhead. This is one of the most challenging and dangerous welding positions. Welding over your head means holding your welding torch above you, positioned so that you can safely weld without risking personal injury, damage to the workpieces, or other catastrophes. Experienced operators should be in charge of these kinds of welds, if not using machines to do it.

5. Pipe welding. The numerical specification five is complex because there are both uphill and downhill positions labeled PH and PJ in ISO nomenclature. Since pipe welding, by necessity, requires going around the circumference of a tube, it passes through flat, vertical, and horizontal overhead positions. The difference between uphill and downhill is where it starts; uphill starts at the bottom and ends up overhead, while downhill is the opposite.

6. Another form of pipe welding, specification six, is required for pipe welding certification. It's a combination of all of the most complex elements of welding; it's a pipe weld, so you have to go through all of the other positions in a smooth motion, and it's joining two pipes at a 45-degree angle, adding an additional challenge to the whole production.

Again, numerical designators are mostly used in AWS documentation; other standards, like ISO, use different names for the same processes, sometimes with additional granularity.

Are There Special Considerations for Specific Numbers?

Of course. Different positions have different challenges. While 1G is generally considered the simplest and easiest kind of weld, each other type of weld offers its own challenges.

For example, 2F welding is more challenging than 1F welding.

'In the 2F/2f position, the butt weld is a bit more difficult than flat welding. This happens due to the molted metal flowing downward of the joint and the torch heat rising upward of the joint. Consequently, a uniform deposit cannot be applied to joints.

For better welds, welders need to align the metals and weld them at both ends. The movements of the torch should be slightly up and down to spread equal heat to both sides of the joint. In this way, the molten metal will not flow to the lower side of the joint and solidify the weld metal faster. For a master, a welder needs a lot of experience in 2f or any horizontal position. 2f is one of the horizontal positions for the fillet test.' ' Welding Info

There's also a kind of horizontal welding in pipe welding called rolled welding. Rolled welding is when the entire pipe apparatus is rotated so the operator can maintain a horizontal position and the workpiece moves under it. This is potentially easier and more convenient, though issues with rotation can cause problems with the weld along the way. It requires both welding automation and a skilled operator to keep pace with the rotation.

Higher numbers, in particular #4, is a very challenging type of weld. Different types of welding require different processes, and overhead welding adds additional considerations to the decision-making. Luckily, it's not an unsolvable problem; both welding standards and skilled operators know what to do. You can read a complete rundown of this problem here.

What Does the Letter Mean?

Now that you know what the number means, you can learn what the letter means. As you might imagine, it's another part of the overall welding specification. Since we're talking about 1G, 2G, 3G, 4G, 5G, and 6G, it's easy enough to give you a simple definition of the G.

G is a Groove Weld.

That's it! Simple, right? Well, not so fast. There are a few complications to this.

The first is that G is not the only letter; it's just the only one in the title of this post. While we could technically leave it here, that wouldn't be very educational, would it?

There are two other letters that come up.

F is Fillet.

Groove and Fillet welds are the two most common kinds of weld. The primary difference between them is simply where the weld joint occurs on the workpiece. If there's a gap between the two pieces, which is filled with filler material melted into the weld pool, that's a groove weld. Groove welds can be performed on pieces that don't touch flush with one another, or the surfaces can be prepared with a bevel or grinder.

Conversely, if the two materials are touching with no gap and the filler material is deposited on the outside of the weld, that's a fillet weld. You can read a lot more about these, as well as see diagrams of them in action, here.

So, what's the third letter?

R, which is an add-on specifically for 6G to create 6GR.

So, what does this stand for? It's 'Restricted,' and it's generally just used in welding certification tests. What is it, though?

'It is another form of a 6G test. The letter R stands for 'restricted'. It means the weld is performed in a 'ring mode' by placing a steel plate below the weld site with an inch gap. Basically, this is another difficulty level for welders in the certification process. In 6GR, welders need to make joints near the impediments like brackets and walls and attach the pipe to another structure.' ' Welding Info.

In other words, it's a restriction on your mobility. After all, in the real world, you aren't always going to have perfect access and ideal positioning for your welds. You'll have to work around, between, and under objects, and that can cause problems. Being able to successfully produce a complex weld like a 6G weld while under these challenging circumstances is a sure sign that you're ready for certification.

The second complication is that not all welds with the same designation are the same. This is because the designation only describes the position of you, the operator, and your welding torch. The position, kind of joint, and angle of approach can vary.

For example, a simple 1G weld, where you're positioned above the workpiece and moving horizontally, can occur as both a butt joint, a corner joint, a tee joint, a lap joint, or an edge joint. All of these have different positions for the workpieces, different angles of approach, and different considerations to ensure you're getting the best quality joint you can out of your operation. However, they're all labeled either 1G or 1F.

Comparing AWS and ISO

AWS and AMSE use the same designation, while ISO has their own. Here's the conversion.

• 1G or 1F is PA

• 2F is PB

• 2G is PC

• 4F is PD

• 4G is PE

• 3G uphill is PF

• 3G downhill is PG

• 5G uphill is PH

• 5G downhill is also PH

• 6GR is PH or PJ, depending. Usually, it's also specified as L045.

The reason that 5G uphill and 5G downhill are the same, PH, is that from a physics and mechanics standpoint, the operation is identical. In ISO nomenclature, the direction and starting point don't matter, only the operation itself.

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You may have noticed that there's no PI; it skips from PH to PJ. There's probably a reason for this buried somewhere in the documentation for ISO welding specifications, but it's not terribly important. If you want to dig in, the full ISO specification is ISO -1: and can be found here.

How Valuable is Knowing the Terminology?

Knowing what the number and letter combinations mean can be valuable, or it might not be.

Why? Two reasons.

The first is that, for the most part, these designations are really only used in technical documentation, reporting, planning, and testing. Many welding operators are going to learn all of this information while they're learning how to weld and how to read WPS documentation. In the real world, often, there are no specific classifications, and you just have to know what a situation will be and how to handle it.

Moreover, depending on where you live and work, you may never see the 1G/2G/etc designations. ISO specifications may be more commonly used or even used exclusively.

So, the general answer is that you should learn and know the terminology, but you may not really use it that much.

A more common visual language is welding symbols. Welding symbols are a challenge of their own. Sometimes, they're clear; other times, they're arcane and disruptive because of the time and effort necessary to interpret them. They can also be misapplied fairly frequently. Here's a rundown of the situation.

Picking the Right Tool for the Job

A key element of successful welding is making sure you're using the right machine for the job. Different welding processes have different pros and cons, as well as different specific considerations for the challenges you'll face in using that process in various situations.

In order to weld successfully, knowing the position and angle of attack is just one small part of the process. You also need to know the type of joint, the materials involved, the environment, and even the tools.

Therefore, it's always critical to pick the right tool for the job. Thankfully, that's where we come in. At Red-D-Arc, we have a wide range of different welding machines available for rent. Whether you need a single-process machine you can cart from location to location, a larger multi-process machine you can make a centerpiece of your shop, or even a whole automation or fabrication setup and turnkey solution, we're here for you.

All you need to do to get started is drop us a line to chat with one of our experts.

You can also browse our catalog of available machines and see if anything catches your eye. Get started today!

Red-D-Arc, an Airgas company, rents and leases welders, welding positioners, welding-related equipment, and electric power generators ' anywhere in the world. Our rental welders, positioners and specialty products have been engineered and built to provide Extreme-Duty' performance and reliability in even the harshest environments, and are available through over 70 Red-D-Arc Service Centers, strategically located throughout the United States, Canada, the United Kingdom, France, and the Netherlands, as well as through strategic alliances in the Middle East, Spain, Italy, Croatia, and the Caribbean. From our rental fleet of over 60,000 welders, 3,700 weld positioners, and 3,700 electric-power generators, we can supply you with the equipment you need ' where you need it ' when you need it.

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Non-welders might assume that experienced welders sit in a work area throughout their shift and weld the metal components on their worktable, moving around the table occasionally while repositioning the workpiece as necessary.
However, in the real welding world, that's not the norm. Joining two metal parts is challenging since workpieces are often attached to the floor, ceiling, or an out-of-the-way location.
Thus, welding positions are essential to every welding operator's workday.

What is a Welding Position?

A welding position is a technique of joining metals from different angles. Typically, welders use five welding positions: horizontal, flat, vertical, overhead, and inclined. The most frequently-used welds are grooves and fillets, which welders can perform in all five positions, while other welds might use only one or two positions.

Unique letters designate fillet and groove welds (image credit: https://weldguru.com):

Fillet Weld (F): A welding method for vertically combining two metal parts Groove Weld (G): A groove weld is created when filler material is deposited in a groove between two metals

The Welding Positions

The letters associated with the numbers listed below are F and G. As mentioned, F is fillet, and G is groove.

#1 Flat Position: When the welder locates the workpiece on the floor or workbench, the position is called the flat position. It is considered the most accessible position because you are not welding against gravity. When using the flat position, it's best to maintain the tip angle, flame position, and consistent motion. The tip should be at a 45-degree angle with the plate surface.

In the flat position, the weld puddle goes into the joint evenly in a fluid state. The molten metal might be hotter than usual, and the deposition rate will be higher because gravity draws the metal downward at the joint. You can do every welding process in a flat position.

A 1F welding position indicates a flat welding position (1) with a fillet weld (F), while a 1G tells you it's a flat position (1) but with a groove weld (G).

In the flat welding position you will do your weld on the top side of your joint.
Image credit: https://www.millerwelds.com

#2 Horizontal Position: As the name implies, the welding axis stays horizontal during this process. For a 2F fillet weld, the welding is done on the upper side of the horizontal and vertical surfaces, and for a 2G groove weld, the welding is done on the vertical plane, and the face of the weld lies on the plane.

A 2G weld is slightly more challenging than a 2F weld since the weld puddle can sag. Gravity will take over if you run the molten metal too hot horizontally, so ensure the weld puddle is not too fluid. Compared to the flat position, the horizontal position needs more practice to perfect and is considered an out-of-position weld.

The 2F is a fillet weld position, with the torch angled at 45 degrees, and 2G is a groove weld position involving the weld axis in a horizontal plane and the weld face in a perpendicular plane.

Welds in the horizontal position has similarities with flat position welds.
Image credit: https://www.millerwelds.com

#3 Vertical Position: In this process, the axis of the weld remains vertical'it can be vertically up or down. You can change the flame's angle to control the metal flow, with the 90-degree angle suitable for 3G welding and the 45-degree angle for 3F welding. The primary consideration in the vertical position is puddle manipulation, and you can use a zigzag, upside-down, or triangular motion to do this.

The workpiece and the weld are perpendicular or almost perpendicular in this welding position. 3F is the vertical fillet position, and 3G is the vertical groove. One issue when performing this weld is the molten metal flowing downward and accumulating.

In the Vertical position welding the welds axis is almost vertical.
Image credit: https://www.millerwelds.com

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#4 Overhead Position: When the welding is done from the lower surface of a joint, it is called the overhead position. The metal you deposit can sag, and the beads have higher crowns. Overhead welding is required when the workpiece is fixed and cannot be moved.

The flame should be regulated, so the metal gets enough time to freeze quickly. The techniques of the vertical positions are also valid with overhead, but it is critical to be aware of the falling sparks as you weld.

The challenging overhead position is performed with the torch at a 45-degree angle, and the 4G and 4F welding positions are appropriate for groove and fillet welds. Remember, the metal can sag from the plate, causing a crown, so keep the molten metal puddle small to avoid this.

In the overhead welding position you will do the welding beneath the joint.
Image credit: https://www.millerwelds.com

#5 Inclined Position: The workpiece is placed in an inclined plane, and gravity causes the molten metal to flow downward in a flat position. A small arc produces the proper beads in the inclined position.

5G Welding Position: The 5G pipe welding position is used when the pipe's axis is stable horizontally and cannot be turned or rotated. Two methods exist to complete these welds: 5G uphill and 5G downhill. In the former, welders start from the overhead position, go to the horizontal, and finally to the flat position. In contrast, with the downhill position, welders start from the flat position, progress to the horizontal position, and end with the overhead position.

6G Welding Position: One of the most challenging welding positions, 6G is similar to 5G, but the pipe is positioned at 45° to the other. The 6G position requires three welds: horizontal, flat, and vertical.
The difficulty comes from filling metal flowing downward and the fact that in the vertical position, it is overhead welding. The 6G weld position is primarily used for fabricating and installing pipes and pipelines in oil and gas plants, industrial plants, and any industry using pipes and pipelines.

The horizontal fixing port of the pipeline ' 5G position and 6G position ' 45 °oblique welded junction of the pipe.
Image credit: https://www.weldingandndt.com

Conclusion

The information on welding positions like 1G, 2G, 3G, 4G, 5G, and 6G/6GR (see chart below) benefits students, welders, educators, and other professionals. Welding positions are essential in the welder certification process since new welders could be tested for jobs from 1G to 6G for fillet and groove welds.

Welding is a critical process in product design and mechanical engineering, joining various components and structures together. Different types of welding, such as arc welding, MIG welding, and TIG welding, can be utilized depending on the application. A key factor in determining the success of a welding process is the welding position, which dictates the technique and approach required for achieving a strong and stable joint. This text will discuss four common welding positions: 1G, 2F, 3G, and 4G, highlighting their applications in pipe welding and the creation of fillet welds.

1G Welding Position
The 1G welding position, also known as the flat position, is the simplest and most comfortable welding position for most welders. In this position, the welder lays the workpiece horizontally, enabling them to deposit the weld bead using gravity. This position is frequently employed in pipe welding, where it is used to join pipes or tubes with a straight, horizontal axis. 1G is also suitable for creating fillet welds in a flat orientation. The use of filler metal in this position is straightforward, as it is fed consistently into the weld joint without the need for complex manipulation.

2F Welding Position
The 2F welding position, or the horizontal position, involves welding a workpiece positioned vertically, with the weld joint running horizontally. In this position, the welder must control the filler metal deposition carefully to prevent it from sagging or dripping due to gravity. Pipe welding in the 2F position requires the welder to maintain a steady and controlled motion, ensuring a consistent weld bead profile. Fillet welds can also be created in the 2F position, with the welder using appropriate techniques to compensate for gravity's influence on the filler metal.

3G Welding Position
The 3G welding position, or vertical position, refers to welding a workpiece positioned vertically, with the weld joint running vertically as well. This position presents a higher level of difficulty, as the welder must manage the filler metal and weld bead while combating the effects of gravity. Pipe welding in the 3G position requires a high degree of skill and technique to ensure a consistent and robust weld. Similarly, creating fillet welds in this position demands precise control of the welding process and filler metal manipulation.

4G Welding Position
The 4G welding position, also known as the overhead position, involves welding the underside of a workpiece positioned horizontally. In this position, the welder must contend with the most challenging conditions, as gravity works against the filler metal and weld bead deposition. Pipe welding in the 4G position necessitates excellent technique and control to prevent the filler metal from falling out of the joint. The creation of fillet welds in the 4G position is also a complex task, requiring a high level of skill and expertise in the welding process.

In summary, the four welding positions, 1G, 2F, 3G, and 4G, play a significant role in the success of various types of welding processes in product design and mechanical engineering. These positions influence the approach and techniques required for pipe welding and the creation of fillet welds. A welder's ability to master these positions and manipulate the filler metal and weld bead effectively is crucial for ensuring strong, durable, and high-quality welds.

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