Shielded Metal Arc Welding (SMAW)

Shielded Metal Arc Welding (SMAW) also known as Manual Metal Arc
Welding (MMAW) is a manual arc welding process that uses a
consumable electrode (covered with a flux). Electrode is connected with one
terminal of the power source and the work is connected with the other terminal
of the power source. Welding cable (or lead) is used for this purpose. The
power source can be used in AC (alternating current) or DC (Direct current).
In AC the polarity of terminals keeps on changing (almost 100 times in
second) but in DC one terminal always acts as Positive and the other acts as
negative.

If electrode is connected with the positive terminal and the work piece with
negative terminal than it is known as DCEP (i.e. direct current electrode
positive or Reverse Polarity). Whereas if the electrode is connected with the
negative terminal and the work piece with positive, then it is known as direct
current electrode negative (ie. DCEN or Straight Polarity).

In DCEP the electricity flows into the tip of the electrode and concentrates
about two-thirds of the heat, which gives good penetration. Hence it is usually
used on thicker steels.

In DCEN the electricity flows out of the rod, concentrating about one-third of
the heat on the electrode. Hence the penetration is less, this a very good
choice for thinner steels.

In SMAW, electric arc is used to melt the base metal, this arc is generated by
striking the electrode with the work piece. Soon after generation of arc the
electrode is withdrawn from the work piece but it remains in close contact with
the work piece. The gases present between the gap (between electrode and
work piece) gets ionized and smooth flow of electrons takes place hence, in
spite of the gap between the electrode and the work piece the circuit remains
closed (or energized) and hence arc doesn’t get extinguished.

SMAW Electrodes are covered with flux. During welding these fluxes gets
decomposed and produces fumes. These fumes covers (shields) the weld
pool from external environment (or contamination). Hence we can say that the
fumes shields weld pool from external contamination. In the absence of flux
our weld pool will be exposed to the environment and chances of oxidation will
always be there that’s why shielding is necessary. Flux material is lighter in
density hence it easily floats over the weld pool and covers the weld pool. It
helps in slow transfer of heat as well as protection from environment.

Please see the below schematic diagram of SMAW for a better

understanding.

Please watch the following videos for a better understanding of Shielded

Metal Arc Welding. In the first video you will see the practical setup and the
second video is about the theory behind SMAW.