Shield Metal-Arc Welding (SMAW)

In shielded metal-arc welding, the intense heat from an electric arc is used to
melt and fuse metals to form a weld. It is one of the oldest and most widely used
welding processes. Although used chiefly for joining iron and mild steels,
shielded metal-arc welding is well suited to maintenance tasks because the
equipment is relatively inexpensive, simple to operate, and can be used for
welding many different kinds of metals.

Below, you will find explanations describing the shielded

metal-arc welding process and how the welding machines
and accessories are set up and used. You will also find
information on selecting an electrode. The personal safety
equipment and precautions are also described.

How the Process Works

A typical SMAW outfit consists of an electric welding
machine, two welding cables, a ground clamp, an electrode
holder, and a covered metal electrode. Electric current
from the welding machine is used to form an electric arc between the tip of the
electrode and the work.

Welding is started by touching the end of the electrode to the base metal, then
lifting the electrode about ¼ inch. This forms the arc, which produces
temperatures up to 5550°C. The intense heat at the arc area instantly melts the
base metal and begins to burn the covering off the electrode and melt the core.
The melted core becomes filler metal for the weld and the decomposition of the
flux forms a protective gaseous atmosphere around the arc area. The gas forms
a shield against contamination from oxygen and nitrogen in the surrounding air.
Additional shielding is provided by the electrode flux, which forms a deposit
called slag.

The shielding gas is ionized, and conducts electricity and maintains the stability
of the arc.

Welding Voltage and Current

Either direct current (DC) or alternating current (AC) is used. The arc voltage or
working voltage is the voltage present in the welding circuit while an arc is struck
and welding is being done. The arc voltage ranges from 15V to 40V depending
on the arc length.

The open circuit voltage is the voltage generated by the welding machine when
no welding is being done. Open-circuit voltages are normally set between 50V
and 100V, but drops to the arc voltage level when an arc is struck and welding
begin.
Arc Length
In any electrical circuit, there is a correlation between the voltage, current and the
resistance. The best results are normally obtained with an arc length about the
diameter of the electrode. 

When the arc length is increased, less current flow occurs because of the
increased resistance. The result is a cooler arc and a greater tendency to spatter.
There will be less penetration of the weld, increased exposure to oxidation and
contamination, and an erratic, unstable arc.

When the arc length is reduced, less resistance more current flows with less
voltage and the arc becomes hotter. With thin material, the heat can melt a hole
in the welding, porosity, and undercutting of the adjacent base metal. 

Polarity
For DC machines, this is important. When the electrode is negative and the work
piece is positive, this is called Straight Polarity. The opposite of this is Reverse
Polarity.

DCSP or direct current straight polarity is characterized by faster melting of the

electrode, the weld puddle being broad and penetration into the base metal is
relatively shallow. This is used when fast welding speeds and high deposition
rates are required.

DCRP or direct current reversed polarity results in a hotter arc, making deeper,
narrower weld puddle. This is used for structural welding, multi pass welds, and
applications requiring deep penetrations.

Most electrodes are designed to be used with only one polarity.

Power Sources
Most AC power sources contain a transformer that steps down line voltage to the
level required for welding (normally less than 100V)

Welding Machines
Many types and sizes of welding machines are used for shielded metal-arc
welding. The current of a Constant-Current type does not change significantly in
variations in arc length. This is preferred for manual welding operations.

The Constant-Potential type of welding machine adjusts the current according to

the arc length. If used in a manual operation, the unavoidable variations in arc
length will produce large fluctuations in the current, resulting in an unstable, non-
uniform arc. For automatic operations, the constant electrode feed rate
establishes a stable arc and uniform arc length.

The current rating of the machine is its maximum current output. A current rating
of 400 amp means the machine can deliver up to 400 amps of welding current.

The duty cycle rating of the machine is the safe operating capacity for non-stop
welding. This is expressed as a percentage over a 10-minute period over which a
machine can deliver its rated maximum welding current output without damage or
overheating. An 80 percent 400-amp machine is one, which can deliver 400
amps of welding current for a total of 8 minutes out of every 10, and must idle at
least, 2 minutes out of every 10 for cooling.

Tools and Accessories

The tools for SMAW are: cables, holders, clamps, chipping hammer, wire brush.
The protective equipment are face shield, goggles, apron, gloves, shoes, long
sleeved shirt. The protective equipment is to avoid eye injuries, and burns. Also
there is a need to prevent electric shocks, especially in wet areas.

Selecting an Electrode
Electrodes are classified by their core material: mild steel, high-carbon steel,
special alloy steel, cast iron, and non-ferrous. Mild steel electrodes are the most
commonly used. In general, the electrode core material is matched as closely as
possible with the composition of the base metal. Electrode size varies with the
thickness of the base metal.

The size and characteristics of the selected electrode determine the arc current
settings on the welding machine. Normally, the range of recommended
amperage for the electrode is given by the manufacturer.

Set up and Operation

Observe fire precautions before starting to weld. No combustible should be near
the work area. 

With the electrical power still off; clamp the earth wire to the work piece and the
electrode on the holder. Turn on the power. To strike an arc, position the end of
the electrode about 1 inch above the weld start point. Lower your face shield and
with a rapid tapping of scratching motion, touch the electrode to the base of the
metal. Immediately after the contact, raise the end of the electrode slightly to
establish an arc whose length is approximately equal to the electrode diameter.

If you do not raise the electrode fast enough, it will stick to the work. Twist or
bend the electrode to break it free. If the electrode does not break free, quickly
release it from the holder. With a little practice, you can learn to strike an arc
without the electrode sticking.

When the current settings and a proper arc length is maintained, a continuous
cracking sound is heard while welding. A humming sound indicates that the arc
length is too long or the current is too high. Arcs too short make a popping sound
and may flash on and off, indicating the electrode is sticking and short circuiting
to the base metal.