Types of Welding Positions: 1G, 2F, 3G, 4G, 6G…

In welding, people who are unfamiliar with the process, either because they haven’t taken a class or haven’t worked in the field, often have a simple mind and can picture a welder comfortably seated at a table, dealing with metal parts easily, and moving them to the desired position. However, in reality, welding on the job is rarely that easy.

In real job settings, metal parts could have been installed or fixed in difficult positions, near the ceiling, on the floor, or tucked inside a corner to make it much more complicated than it appears at first glance.

Welders have techniques to deal with different physical orientations of the workpiece.

That becomes a movement to develop four standard welding positions to accommodate various welding positions. Knowing these four welding positions is essential to knowing how to select the welding method, adjusting the parameters, and filler metal used.

Each position has distinctly different technical positions, different best practices, and knowing how to work each can make a huge difference in the quality of the weld, and productivity of achieving the weld.

We will now take a closer look at each of the four welding positions and provide some practical support to work with that position.

What Is a Welding Position?

Welders can easily identify weld joint types (i.e., a fillet or groove) and their appropriate weld position with a system of letters and numbers. There are designations such as 1G, 2G, 3G, 4G or 1F, 2F, 3F, 4F that specify the joint type and weld position.

In this system, the number indicates the welding position: “1” is flat, “2” is horizontal, “3” is vertical and, “4” is overhead. The letter indicates the joint type “F” is for a fillet weld and “G” its a groove weld.

A fillet weld is defined when two pieces of metal are connected at roughly a right angle or they intersect at an angle, they create a joint having a triangular cross section.

A groove weld is a weld made in the groove of two pieces of work or in a joint that was specifically prepared with a geometry to facilitate a groove weld. So, for example, a 2G weld would be defined as a groove weld made in the horizontal position.

These classifications are not hypothetical, you can find them frequently in Welding Procedure Specifications (WPS’s) and filler metal data sheets. They will provide the welding position with specific filler metals capabilities.

In practical terms, normally the flat position is the most ideal. Its typically easier to control a larger molten weld pool in the flat position which generally leads to more efficiency with welding speed and completing joints quicker.

However, when you are welding out of the flat position, it is considered a out of position weld. Not all types of grooves weld equally in an out of positional weld. For example, bevel joints are commonly deemed to produce quality groove welds particularly when working in the horizontal position.

MORE: What is Welding?

Different Welding Positions

The American Welding Society (AWS) divides plate welding into four main positions related to either groove (G) or fillet (F) welds. Understanding the positions is important as you learn how the weld is being executed based on the orientation of the joint. Here’s an overview of these positions:

• Flat Position (1G or 1F): The weld is made on the top side of the joint. The weld surface area is nearly horizontal, making this is a very easy position, as gravity is helping the weld pool.
• Horizontal Position (2G or 2F): Again, the weld runs along a horizontal axis, which either is primarily a fillet weld or groove weld and dictates slightly different approach. In making a fillet weld, the work is done at the top edge of a mostly upright structure. In a groove weld, the weld face is in a vertical plane.
• Vertical Position (3G or 3F): Just as the name implies, the weld axis is vertical. More skills will be needed in this one, as gravity is going to fight against the welder, and you will use uphill or downhill welding depending on application.
• Overhead Position (4G or 4F): Probably the hardest of all positions, as the weld is made from underneath the joint. Controlling the molten metal is more difficult than other positions, because if it is dripping or not fusing, it becomes very obvious!

In welding, “position” refers to how a joint or component is oriented during welding, either as found or as intended to be installed in its final application. It is important to understand and master these position for producing strong, reliable welds in a variety of real-world scenarios.

1. Flat welding position

Welding can be done in any position, but the flat position is by far the easiest to perform. When you have your workpieces horizontal—on a bench or the ground—that is the flat welding position. The flat position is preferred because it is the easiest to do since gravity is not working against you.

One of the biggest benefits is how much less strenuous it is compared to vertical or overhead. The welder can move faster with no fear of running the weld puddle and generally gets better penetration when in the flat position.

Almost any welding process MIG, TIG, stick, etc. can be done in the flat position, but you still must apply the proper technique for the process you are using.

For example, in stick welding, you will have to remember there will be slag; it is often best to use the drag technique instead of pushing the electrode.

Another factor to consider is your work angle, which is not a universal factor. Your work angle is then dependent on whether you are performing a 1G (groove weld) or a 1F (fillet weld).

If the electrode or filler wire is angled too far to one side, heat will not be concentrated in the area the joint actually is going to form, leading possibly to no fusion—something you want to avoid.

2. Horizontal Welding Position

Due to job conditions, you may not always be able to do the weld in the flat position as in the shop.

This adds complexity since welding in the horizontal position falls under out-of-position welding (along with vertical and overhead) and generally requires more skill and technique to perform.

In the horizontal position, there are generally two variations, depending on the type of weld performed: a groove weld (2G) or a fillet weld (2F).

A 2F fillet weld is performed to the upper surfaces where the horizontal and vertical members meet, and a 2G groove weld occurs along a vertical surface, with the weld face resting directly on that plane.

The 2G position is often more challenging for welders than the 2F position primarily due to the effects of gravity on the puddle of molten metal.

Welding horizontally means that if the metal gets too hot and liquid, it will have a tendency to run or sag, so it takes more precision to keep the puddle viscosity in check.

Compared to the flat position, the horizontal position provides more of a challenge and requires more practice and control; therefore, it is considered an out-of-position weld.

To be clear, the 2F is a fillet weld, typically made on a torch angle of about 45 degrees, and the 2G is a groove weld, where the weld axis is horizontal and the weld face is vertical. Therefore, it’s more of a change in technique to go from the 2F to the 2G.

For beginner and novice welders, welding in the horizontal position can be very difficult. The reason for that is there is no built up weld metal underneath the puddle to support it while it cools.

That shoulder of solid weld metal underneath the puddle helps a welder keep things in check; without it it takes finesse to keep the puddle in control.

With enough hands on experience, most welders learn how to feel comfortable with the 2G position over time anyway.

3. Vertical Welding Position

Welding on vertical surfaces, for example, upright or inclined surfaces working at 45-degrees or less, is different from flat or horizontal welding.

Welding in the vertical position is commonly required in the construction of buildings, tanks, pontoons, pipelines, and other upright structures.

The difficulty encountered with vertical welding is controlling and managing the molten weld pool, as the effects of gravity are constantly pulling it downward, which increases the chances of sagging or runoff.

There are two primary welding directions in which to work while welding in the vertical position, upward (vertical up) and downward (vertical down) welding.

The two different directions fill different needs, for example, vertical down welding is normally used with thinner metals.

Vertical down welding has a shallow penetration depth that can help eliminate burn-through, making it an advantage when working with lighter-gauge materials.

Another advantage of welding in the vertical down position is speed, which is essential in high-volume production environments where the speed to quality ratio is paramount.

Achieving good results in vertical welding requires fine-tuning your welding parameters. In order to maintain control of the welding puddle to prevent it from spilling out of the joint, it is not uncommon to see a welder lower both wire feed speed and voltage.

Individuals using machines with Auto-Set™ and similar technology typically utilize welding settings meant for thinner materials, even when welding thicker base material.

This again helps to limit the amount of heat put into the material, making it possible to maintain futurability within the weld puddle to counteract the effects of gravity.

When welding vertically, getting the electrode angle correct is important. For example, for a 3G weld you will want to stay at a 90-degree travel angle while a 45-degree angle is more appropriate for 3F welds.

When you are welding, don’t just push the puddle straight up. Pushing straight up on the puddle usually results in a ropey bead that does not tie into the edges, and that does not make for a good weld.

Instead, take the time to work the puddle side to side to create the weld bead and make sure you are contacting both edges of the joint. Take time to hold a bit longer at the toes of the weld and proceed faster through the center of the weld as you move up.

There is no one “correct” motion for working inside the weld puddle. It generally comes down to what feels right in your hands. The more common ways to manipulate the puddle include a zigzag or shaping it into upside down Ts or stacking triangles vertically.

Each of these techniques have their place depending on the joint configuration and your own ability to perform the technique comfortably.

Prior to moving to your actual workpiece, practice on some scrap metal to get your settings configured and get a feel for your motion. It is well worth the time to practice first, especially when working to perform critical welds.

4. Overhead Welding Position

Overhead welding is considered one of the most technically challenging positions in welding. This challenge comes from having to work against gravity as well as often being in an uncomfortable and awkward body position, but it can be done with good practice and good technique and can produce weld quality comparable to easier positions.

It is important to have complete control over the molten weld puddle. To keep consistent control over the puddle, one of the best ways is to have a short arc and to turn the amperage down, which is the recommended practice for overhead welding.

Like vertical welding, there is always going to be a pull of the molten weld puddle downward due to gravity, which causes drooping of the weld bead, sagging or otherwise.

There is also the potential for troublesome droops to occur if the arc is held for too long. When the arc is held for too long, the stability and consistency of transferring the molten and/or electrode metal from the electrode or gun to the base material decreases exponentially.

It creates large globs of molten metal that, again, will fall from the weld area. Controlling your arc length can help reduce the issue of creating these large globs, but again, if the molten puddle is too large then it will affect the characteristics of the weld.

One of the other difficulties with overhead welding is managing the weight and position of the cable, which can lead to arm and wrist fatigue.

A common recommendation is to drape the cable over your shoulder while standing or over your knee while seated. With experience, it can become easier to learn what comfortable position is best for cable management.

Technically speaking, overhead welding is completed with the torch tilted or held at about a 45-degree angle. The 4G and 4F position designations are generally accepted classifications to perform groove and fillet welds in the overhead position.

Since sparks and molten splatter fall downward by nature, a few additional protections are suggested. Wearing a bandana underneath a welding helmet can protect the neck, in areas due to weld spatter or dripping molten metal.

Stick welding is recommended to include use of a leather style welding jacket in case of weld splatter or droppings.

More splatter (especially when angle and technique are strict) tends to happen during stick welding, thus the full leather jacket is highly recommended as protection from both burns and splatter.

Pipe Welding Positions

The American Welding Society has divided pipe welding into five basic positions:

• 1G – Horizontal Rolled Position: The pipe will be rotated continuously, or in increments, to obtain a weld in the range of 0° to 15° from the top of the pipe. The rotation keeps the welder in a comfortable position and allows them better control of the weld pool.
• 5G – Horizontal Fixed Position: The pipe will be fixed and parallel to the ground. The pipe does not move in the 5G position like in the 1G position. The weld needs to be laid all the way around the pipe in a vertical progression in 5G, thus requiring an equal degree of competence throughout the full rotation of the pipe.
• 2G – Vertical Position: In the 2G position, the pipe will be oriented in vertical position (perpendicular to the ground surface) with the weld laid in a horizontal orientation along the pipe circumference. The orientation doesn’t change and, while keeping a more comfortable vertical weld environment, the welder must travel around the pipe to complete the joint.
• 6G – Inclined Position: The 6G position is considered one of the more difficult welding positions. The pipe is fixed at a 45° slope, and the weld must be applied in a circular pattern all the way round the pipe. Combining the vertical and horizontal angles creates difficulties in the 6G position, as the welder has to make changes as the weld progresses along each angle.
• 6GR – Inclined with Restriction Ring: The 6GR position is similar in nature to the 6G position in that the pipe will be fixed at a 45° incline. However, the 6GR pipe will have a restriction ring just below the weld groove. The restriction ring will limit access and the ability to move around while welding the circumference of the pipe, thus elevating the complexity of the weld position and typically reserved for testing welders in high kerf situations, like structural welding or pipeline welding.

5G Welding Position

In the 5G position, the pipe is held horizontally along the X-axis and will not, under any circumstances, allow the pipe to be rotated.

The welder has to move around the pipe in order to perform the weld, but the welder should only have control of the arc and technique as the position shifts.

While this is similar to the 1G position in response to the location of the pipe, the difference is that you cannot rotate the pipe in the 5G position.

This position is referred to as “PF” according to ISO/EN standards. Welding in the 5G position is typically a vertical progression, which can be performed in either an upward or downward direction, depending on the particular welding procedure used.

6G Welding Positions

The 6G welding position is considered one of the most difficult positions for welders to achieve and is often required for certification due to the skill set involved.

While there are similarities to positions such as 5G, PH, PJ, etc., the distinguishing feature of the 6G position is the placement of the pipe. The pipe is situated at a fixed 45-degree angle in relation to another pipe. It is also referred to as the 6G Uphill (H-L045) or 6G Downhill (J-L045) position.

In training or testing environments, the 6G position is generally used to assess a welder’s full range of welding ability. It is sometimes referred to as the “overhead weld position,” or simply the “certification test position.”

The difficulty of the position is attributable to the fixed 45-degree pipe angle that forces the welder to work through multiple spatial orientations, where the welder must manipulate their body into a variety of positions while controlling the weld.

Involvement in the 6G position as the three main welding orientations in horizontal, flat, and vertical when working to make the weld. Of these, the horizontal weld is typically considered the hardest due to gravitational flow of the molten filler metal while welding down.

This can complicate vertical welding, often requiring overhead welding, and requires a much higher level of dexterity and coordination.

Because of these challenges, welders need to practice the 6G position extensively, prior to performing a weld in a real-world setting.

Certified welders do not typically find themselves in 6G position, routinely in industry, however, it is still considered a standard pre-employment testing for employment as a welder, due to the caliber of skill set it tests.

The 6G welding position primarily applies to the fabrication and installation of piping systems. Industries such as chemical processing, oil and gas, and several other heavy industrial industries rely heavily on the 6G position to provide chimney piped and similar piping structures that require high strength welding procedures.

Conclusion

Before starting a welding job, it may be advisable to complete a few practice runs. These initial passes are important because they’ll help you feel the path of the weld, and make sure that you could complete the entire length of the weld in a position that felt natural and steady.

It may seem that comfort is a small detail, but it is in fact one of the factors for keeping consistent and convincing quality performance in your welds.

The type of filler metal and the method of metal transfer are both a big part of the best physical welding position.

For example, prior to welding overhead, you will want to make sure the filler metal being used is appropriate for that position. You will also want to adjust the welding parameters to better match the overhead welding condition for the best performance possible.

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