Faculty of Chemical & Natural Resources Engineering

BKG4721
Gas System Lab

Experiment 1:
SHIELDS METAL ARC WELDING (SMAW)

Name
Matric No.
Group
Program
Section
Date

Sem. 1 - Session 2009/2010

1.0 OBJECTIVES
 BKG4721 - Gas System Lab Sem I – 200/2010

To provide hands on experience and understanding on the principles of

SMAW process with correct technique to execute the welding. Students
should be able to demonstrate safe and proper action while performing
the welding activities.

A. Safety Practices
Student will be able to demonstrate then safe and proper setup,
operation and maintenance of shielded metal Arc Welding
machine.

B. Welding Theory and Knowledge

Student will be able to:
1. Recall, relate and communicate shielded metal Arc Welding
process terms and condition.
2. Explain the fundamental principles of the SMAW process.
3. Identify major components and explain the specific functions.
4. Demonstrate safe and proper procedures for equipment setup.
5. Identify and select SMAW filler metals electrodes.

C. Welder Skill Performance

Student will be able to:
1. Proper preparation of materials and fit up of weldments.
2. The correct technique for striking off and running
interrupted beads in the flat position.
3. The correct technique for running multiple continuous
passes in the flat position.
4. The correct technique for padding on 6mm carbon steel in
the flat position.

2.0 INTRODUCTION

Shielded Metal Arc Welding (SMAW), also known as Manual Metal

Arc (MMA) welding or informally as stick welding, is a manual arc

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BKG4721 - Gas System Lab Sem I – 200/2010

welding process that uses a consumable electrode coated in flux to lay

the weld. An electric current, in the form of either alternating current
or direct current from a welding power supply, is used to form an
electric arc between the electrode and the metals to be joined. As the
weld is laid, the flux coating of the electrode disintegrates, giving off
vapors that serve as a shielding gas and providing a layer of slag, both
of which protect the weld area from atmospheric contamination.

Because of the versatility of the process and the simplicity of its

equipment and operation, shielded metal arc welding is one of the
world's most popular welding processes. It dominates other welding
processes in the maintenance and repair industry, and though flux-
cored arc welding is growing in popularity, SMAW continues to be used
extensively in the construction of steel structures and in industrial
fabrication. The process is used primarily to weld iron and steels
(including stainless steel) but aluminum, nickel and copper alloys can
also be welded with this method.

3.0 Experimental Procedures

Equipment and Items Preparation

1. Welding Equipment – Shields Metal Arc Welding Machine

2. Carbon Steel Plate 200mm X 100mm X 6mm
3. Head Shields
4. Leather Welding Apron
5. Leather Welding Glove
6. Electrode E6013 (3.2mm)
7. Wire Brush
8. Chipping Hammer
9. Safety shoes

PROCEDURES DETAILS

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BKG4721 - Gas System Lab Sem I – 200/2010

1. Preparing the working 1. Clean up working plate from dust and

plate. corrosion.
2. Draw a navigation line on the working
surface according to the size given.
3. Place the working plate on the the smooth
and even surface in order to start the
welding process.

Clean the working plate

berfore start the
welding.

10mm

Kawasan kimpal
10mm semula

PROCEDURES DETAILS

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BKG4721 - Gas System Lab Sem I – 200/2010

2. Performing 1st layer of 1. Place the plate on smooth and even surface.
welding. Use clamp or jig to hold the plate.
2. Use electrode E6013 SWG 8 on welding
current 105A –175A
3. Electrode angle should be 75° - 80° according
to welding position.
4. Place the trial plate on the working plate
before starts the welding.

70°-80°

Timbunan kimpalan

1st layer of
welding

1st layer

PROCEDURES DETAILS

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BKG4721 - Gas System Lab Sem I – 200/2010

3. Performing 2nd layer of 1. Adjust the current at 105 - 175 Amp.

welding 2. Use electrode E6010 SWG 8.
3. Clean the 1st layer with wire brush to ensure
there’s no welding ashes and particles in
order to get good quality of welding.
4. Start to weld on the plate surface by
changing the direction across the 1st layer
until the end of the plate.
5. Clean up the welding surface from the
welding particles before starts the next
welding.

1st layer
2nd layer

4.0 Discussion

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BKG4721 - Gas System Lab Sem I – 200/2010

a) What is SMAW Welding?

b) What are the three major weld defects in SMAW process?

c) How do I decipher these AWS electrode classifications? E XXXX

(Explain the meaning of each of the characters in the classification)

d) Sketch and name THREE (3) main equipment of Shielded Metal Arc
Welding (SMAW)?

e) State and sketch FIVE (5) kinds of basic joints in welding?

5. Conclusion

6. Reference