SELF-LEARNING HOME TASK (SLHT)

Subject: Shielded Metal Arc Welding (SMAW) Grade Level : 10

Quarter: Q3 Week: LHT 12 (Q3-W3)
MELC: shows an understanding of the different ESSENTIALS OF WELDING and on how to apply them during
welding process.
Competency Code: TLE_IAAW10FC-IIIaIVj-2
School: Buanoy National High School District: Balamban II

Readings:

5 ESSENTIALS OF SHIELDED METAL ARC WELDING

Essentials of welding. When we talk about essentials, it means necessary or important things that we have to
know or to do. In welding, it is not just tacking and weld the piece of metals is enough. There are things that we
have also to consider like good weld profile and welding technique. In order to have a good weld profile, we have
to consider the 5 essentials variables of welding which are: Correct Electrode size, Correct Current Setting,
Correct Arc Length, Correct Travel Speed and Correct Electrode Angle.

If these five essentials are NOT FOLLOWED nor done even just one of it, there will be some weld
discontinuities or defects will occur such as; porosities, overlap, undercut, incomplete fusion, incomplete
penetration, insufficient throat, cracks porosity, insufficient leg size, excessive convexity, excessive spatters,
slag inclusions and poor fusion

WELDING is a practical skill that requires continual practice and careful attention to the variables that the
welder controls to improve. The old golden rule “practice makes perfect” (practice correctly makes PERFECT)
applies to welding in that the more you do, as long as you or someone evaluates your welds, the better you
become. Essentials of welding are very important in producing a quality weld and the term variable as used in
this text means that the welder has to control of either before welding or during welding. There are five (5)
essentials of welding. it includes the use of the correct electrodes size, correct current setting, correct arc length
or voltage, correct travel peed and correct electrode angles.

1. CORRECT ELECTRODE SIZE

Electrodes for shielded metal arc welding range in diameter from 3/32 to
3/16 of an inch. You may also come across some ¼ inch electrodes. They are
commonly found in 9, 14 and 18-inch lengths. Electrode diameter is based on
the thickness of the base metal, the welding position and the type of joint to be
welded. Larger diameter electrodes are used on thicker metals and for flat
position welding because they offer higher deposition rates.

Smaller diameter electrodes are used for horizontal, vertical and overhead
welding, because they produce a smaller weld puddle that is easier to control
than the bigger puddle produced by larger diameter electrodes. Joint design
also affects electrode diameter. On groove welds for example, the electrode
has to be small enough to access the root of the joint. he welder’s skill also
has a bearing on electrode diameter because a more capable welder can
control a larger, more fluid weld puddle.

As a general rule, when there is no welding procedure specification, use the

largest diameter electrode possible. Larger diameter electrodes produce welds of
the required dimensions in the least amount of time and at lower cost, because they have higher deposition
rates and allow faster travel speeds.

1
The correct choice of electrode size involves consideration of a variety of factors, such as the type, position,
and preparation of the joint, the ability of the electrode to carry high current values without injury to the weld
metal or loss of deposition efficiency, the mass of work metal and its ability to maintain its original properties
after welding, the characteristics of the assembly with reference to effect of stresses set up by heat application,
the practicability of heat treatment before and/or after welding, the specific requirements as to welding quality
and the cost of achieving the desired results.

8 FACTORS to be considered IN SELECTING arc welding ELECTRODES

1.1. BASE METAL STRENGTH PROPERTIES=Know and match mechanical properties. Mild steel-generally E-
60XX or E-70XX electrodes match base metal. Low alloy steel-select electrodes that match base metal
properties.
1.2. BASE METAL COMPOSITION=Know and match composition. Mild steel –any E-60XX or E-70XX electrode
is satisfactory. Low alloy steel – select electrode that most closely matches base metal composition.
1.3. WELDING POSITION=Match electrode to welding position encountered.
1.4. WELDING CURRENT=Match power supply available. Some electrodes are designed for direct current (DC);
other, alternating current (AC); some, either. Observe correct polarity.
1.5. JOINT DESIGN AND FIT UP =Select for penetration characteristic- digging, medium, or light. No beveling
of tight fit- up – use digging. Thin material or wide root opening – light, soft arc.
1.6. THICKNESS AND SHAPE OF BASE METAL =To avoid weld cracking on thick and heavy material of
complicated design, select electrode with maximum ductility. Low hydrogen processes or electrodes are
recommended.
1.7. SERVICE CONDITION AND/ OR SPECIFICATIONS =Determine service conditions – low temperature, high
temperature, shock loading – match base metal composition, ductility and impact resistance. Use low hydrogen
process. Also, check welding procedure or specification for electrode type.
1.8. PRODUCTION EFFICIENCY AND JOB CONDITIONS =For high deposition and most efficient production
under flat position requirements, select high iron powder type of large diameter wires; for other conditions, you
may need to experiment with various electrodes and sizes.

2. CORRECT CURRENT SETTING

AWS ELECTRODE DIAMETER (INCH) AND AMPERAGE RANGE
CLASSIFICATIO 3/32” 1/8” 5/32”
N
E6010 40–80 70–130 110–165
E6011 50–70 85–125 130–160
E6012 40–90 75–130 120–200
E6013 40–85 70–120 130–160
E6027 (3/16”)=225-300 amps. (7/32”)=275-375 amps. (¼”)=350-450 amps.
E7014 80-110 110-150 140-190
E7016 75–105 100–150 140–190
E7018 70–110 90–165 125–220
E7024 90-120 120-150 180-230
E7028 (5/32”)=175-250 amps. (3/16”)=250-325 amps. (¼”)=375-475 amps.
Table 1: Welding Amperage Range for Common Electrode Types and Sizes
Current is measured in amperes, or amps. Each type of electrode has
recommended amperage ranges for optimum performance. Amperage ranges

2
are usually specified in the welding procedure or in the manufacturers’ data sheets. If the amperage is set
above the suggested operating range, the electrode melts too fast. This increases deposition and the weld
puddle becomes too large to control. It could also cause the electrode coating to overheat and break down.

Appropriate welding current is based on the diameter of the coated electrode.  When operated within the
suggested current ranges, the electrodes should exhibit good arcing characteristics with minimum spatter.   The
use of excessive current can lead to overheating of the electrode, reduced arc stability, spalling of the electrode
coating, and weld metal porosity.

Amperage too high – The weld bead is wide and flat with excessive penetration and spatter, and undercutting
frequently occurs along the toes. If the amperage is set below the designated rang e, there is insufficient heat to
melt the base metal, and the weld puddle is too small for proper control. The droplets forming on the end of the
electrode may bridge to the weld puddle periodically
extinguishing the arc. The weld bead will be irregular with
a crowned appearance and insufficient penetration.

Amperage too low - there is not enough heat to melt the

base metal and your molten pool will be too small, will pile
up. The weld bead will be irregular with a crowned
appearance and insufficient penetration.

3. CORRECT ARC LENGTH

Arc length is the distance from the tip of the electrode core wire to
the weld puddle. Arc length can be deceiving, because the core wire is
recessed inside a cup that forms at the tip of the electrode. You have
to take this into consideration when gauging arc length.

Excessive spatter is an indication that arc length is too long, welding

current is too high, polarity is not reversed, or there has been
absorption of moisture by the electrode coating. 

The correct arc length varies according to the electrode

classification, diameter and composition of the flux coating, as well as
the amperage and welding position. As a general rule, when amperage
is set within the specified range, arc length should not exceed the
diameter of the core wire. Increasing the arc length increases the arc
voltage, and reduces the amperage slightly.

If the arc is too long, the metal core melts off in large globules
that wobble from side to side and drop onto the work as spatter,
rather than forming useful weld metal. The weld bead is wide
with excessive spatter and undercut. The base metal is not
properly melted, so the weld metal is deposited on top of the
plate with incomplete penetration, and slag inclusions will
probably occur. Long arcing is often used to preheat the base
metal directly after striking the arc. Shortening the arc length
reduces the arc voltage and increases the amperage slightly.

NOTE: The arc may jump to the closest metal, reducing root penetration .

If the arc length is too short, the arc has a tendency to short out and the electrode freezes to the work.

4. CORRECT TRAVEL SPEED

Travel speed is the rate at which the electrode moves along the work. The key to correct travel speed is
“reading” the weld puddle, because the weld puddle is a liquid version of the weld bead.

A properly formed weld bead has an oval shape with an oval crater and uniform ripple pattern. Travel speed is
influenced by the type of welding current (DCEN, DCEP or AC), amperage, welding position, electrode melt rate,
material thickness, surface condition of the base metal, type of joint, joint fit up and electrode manipulation.

If you travel too fast, the puddle cools too quickly trapping gasses and slag. The ripples are pointed and narrow
with irregular penetration and undercut along the toes.
If you travel too slowly, the weld metal piles up forming a high, wide weld-bead with too much reinforcement
that may result in overlap. So read the puddle, and keep the arc on the leading edge. The suggested travel
3
speed for SMAW is 3 to 6 inches per minute (ipm) / 75 to 150 mm/min.

5. CORRECT ELECTRODE ANGLE

The electrode angle is measured from the electrode to the surface of the metal. The term used to identify the
electrode angle is affected by the direction of travel, generally leading or trailing. The relative angle is important
because there is a jetting force blowing the metal and flux from the end of the electrode to the plate.

In shielded metal arc welding, the work and travel angles are used to control the shape of the weld puddle and
the amount of penetration. The travel angle is the angle between the joint and the electrode along the axis of
the weld. Travel angle has

Direction of travel and electrode angle.

Leading Electrode Angle

A leading electrode angle pushes
molten metal and slag ahead of the
weld, Figure 9-11. When welding in
the flat position, caution must be
taken to prevent cold lap and slag
inclusions. The solid metal ahead of
the weld cools and solidifies the
molten filler metal and slag before
they can melt the solid metal. This
rapid cooling prevents the metals
from fusing together, Figure 9-
12. As the weld passes over this area,
heat from the arc may not melt it. As
a result, some cold lap and slag inclusions are left.

The following are suggestions for preventing

cold lap and slag inclusions:
 Use as little leading electrode angle as
possible.
 Ensure that the arc melts the base metal
completely, Figure 9-13.
 Use a penetrating-class electrode that
causes little buildup.
 Move the arc back and forth across the
molten weld pool to fuse both edges. A
leading angle can be used to minimize penetration or to help
hold molten metal in place for vertical welds, Figure 9-14.

Trailing Electrode Angle

A trailing electrode angle pushes the molten metal away from the
leading edge of the molten weld pool toward the back where it
solidifies, Figure 9-15. As the molten metal is forced away from the
bottom of the weld, the arc melts more of the base metal, which
results in deeper penetration. The molten metal pushed to the back
of the weld solidifies and forms reinforcement for the weld, Figure 9-
16.

4
A push angle exists when the electrode points in the direction of travel. And a  drag angle points away the
direction of travel.
When all other essentials are under control, a change in the direction of travel changes the heat input to the
puddle. A drag travel angle increases heat input because the arc is pointing into the puddle. A push travel angle
reduces heat input because the arc is pointing away from the puddle.

The work angle is pointing between the electrode and the work surface along the work plane, which runs
perpendicular to the axis of the weld. An incorrect work angle can cause you to favor one side of the joint more
than another. The result is undercut and lack of fusion.

Exercise 01: MULTIPLE CHOICE

Directions: Choose the LETTER of the right answer and write it on your answer SHEET (1 whole SHEET of
PAPER).
1. Which of the following is a practical skill that requires continual practice and careful attention to the
variables that the welder controls to improve?
A. Carpentry B. Plumbing C. Welding
2. What are the very important or the most necessary factors to be considered in producing a high-quality
weld?
A. Essentials of welding B. Welding Parameter C. Welding Guide
3. Which of the following welding essential is based on the diameter of the coated electrode?
A. Welding Current B. Travel Speed C. Arc Length
4. Which of the following correct/proper amperage setting for an E6011 welding electrode with 1/8”
diameter?
A. 85-125 amps. B. 130-230 amps. C. 250- 350 amps.
5. Which of the following correct/proper amperage setting for an E6012 welding electrode with 1/8”
diameter?
A. 75-130 amps. B. 150 250 amps. C. 300-350 amps.
6. Which of the following is the correct definition of a term Work Angle?
A. It is pointing between the electrode and the work surface along the work plane, which runs
perpendicular to the axis of the weld.
B. It is pointing away the direction of travel
C. It pushes the molten metal away from the leading edge of the molten weld pool toward the back
where it solidifies.
7. Which of the following welding essentials is measured from the electrode to the surface of the metal?
A. Correct Arc Length B. Correct Electrode Angle C. Correct Current Setting
8. Which of the following electrode angle pushes molten metal and slag ahead of the weld?
A. Leading Angle B. Trailing Angle C. Weaving Angle
9. Which of the following statement is right and true about the trailing angle?
A. It pushes the molten metal ahead to the leading edge of the molten weld pool toward the back where
it solidifies.
B. It pushes the molten metal away from the leading edge of the molten weld pool toward the back
where it solidifies
C. It pushes the molten metal away from the leading edge of the molten weld pool toward the side of the
metal where it solidifies
10. What is the suggested travel speed for SMAW welding process?
A. 60-120 mm/min B. 3-6 ipm C. 1-2 ipm

C. Assessment/Application/Outputs
Directions: Copy the table below in your bond paper and define the following WELDING TERMINOLOGIES.
(2-3 sentences only) (your score will be X2/10 x 2=20).
5
 Welding Terminology Definition
1. Essentials of
Welding

2. Correct Current
Setting

3. Correct Electrode
Angle

4. Correct Arc Length

5. Correct Travel Speed

6. Correct Electrode
Angle

7. Leading Angle

8. Trailing Angle

9. Work Angle

10. Travel Angle

References:
-https://www.keenovens.com/products/stick-electrodes-details.html#:~:text=Welding%20electrodes%20are
%20metal%20wires,arc%2C%20and%20improves%20the%20weld.
-WELDING SKILLS/WELDING CHAP 7-21.pdf

Prepared by: JUDY C. SINGIT

Checked By: Verified by:

ROMMEL C. MELGAR SUSAN C. TRIBUNALO
TLE Dept. Coordinator School Principal I