Shielded Metal Arc Welding

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 What Is Welding ?
• Process of joining metals / alloys

• The process performed by Heat with or without

Pressure

• Filler metal may or may not be used

• The joint will be homogeneous

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 Classification Of Welding
1 Pressure Welding – With Heat & Pressure

2 Fusion Welding – With Heat & mostly

with Filler

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 Pressure Welding Process
• Metal parts heated to forging temperature
• Heating by Oven, Oxy fuel flame or
Electric Resistance
• Pressure applied on heated parts – by
Hammer, Hydraulic Press or Mechanical
liver.
• The Parts remain permanent homogeneous
joint
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 Types Of Pressure Welding

• Forge Welding
• Resistance Butt / Flash Butt / Stud Welding
• Resistance Spot Welding
• Resistance Seam welding

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 Types Of Fusion Welding
• Shielded Metal Arc Welding- SMAW
• Gas Tungsten Arc Welding - GTAW
• Gas Metal Arc Welding - MIG / MAG
• Submerged Arc Welding – SAW
• Gas welding – Oxy Fuel Gas
• Electron Beam Welding - EBW
• Thermit Welding
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 Fusion welding Process
• Metal parts locally heated to melt along the joint.

• Heating by oxy fuel flame or electric Arc.

• Invariably filler metal added to molten pool.

• On cooling, molten puddle solidifies to permanent

homogeneous joint.
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 Shielded Metal Arc Welding
Process Core Wire
• An electric Arc struck between
electrode and base metal joint
• Base metal melts under arc Flux Coating

• Electrode tip melts in drops and

transfers to molten pool of BM

• Electrode with Arc moves along • O ooling

the joint keeping constant arc n pool
length c solidifi
es
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 P
Arc
ool

Bas

Met

al

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 Equipment, Accessories & tools
• Power Source

• Welding Cables, Holder & Earthing Clamp

• Head Screen, Hand gloves, Chipping

Hammer & Wire Brush

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 Types Of Power Source
• Inverter- DC

• Thyrester – DC

• Motor Generator – DC

• Rectifier – DC

• Transformer - AC

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Characteristic Of Power Source
Manual welding Machine welding
Drooping – Cons. A Linear – Cons. V
V V
V1
Vertical
V2
Horizontal
Curve
Curve
V1
V2

A A
A1 A2 A1 A2

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 Electrode
• Consumable

• Metallic Wire Coated with Flux

• Conducts Current and generates Arc

• Wire melts & deposited as filler in joint

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 Flux Coating On Electrode
• Sodium Chloride
• Potassium Chloride
• Titanium Dioxide
• Sodium Silicate
• Ferrosilicon
• Iron Powder
• Alloying Elements
• Binding Material
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 Function Of Flux In welding
• Stabilizes Arc
• Prevents contamination of weld metal
• Cleans the weld from unwanted impurities
• Increases fluidity of molten metal
• Generates inert gas shielding while metal transfers
• Forms slag after melting & covers weld
• Allows deposited metal to cool slowly
• Introduces alloying elements in the weld
• Increases deposition efficiency
• Minimizes the spatter generation
• Helps in even & uniform bead finish
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 CS & LAS Electrode Sizes &
Recommended Currents
Core Wire in mm Time required for
No Gage Current
Dia Length burning in seconds

1 2 300 14 40 – 60 A 50-55

2 2.5 350 12 60 – 85 A 60-65

3 3.15 450 10 100 – 130 A 80 -85

4 4 450 8 130 – 180 A 85-90

5 5 450 6 150 – 210 A 90-95

6 6.3 450 4 240 – 250 A 95-100

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 ASME Classification Of
Electrodes

SFA 5.1
E 7018
E = Electrode
70 = UTS in 1000 psi ( 60/70/80/90/100/ 110)
1 = Position (1= all, 2= 1G, 1F & 2F, 3= 1G & 1F)
8 = Type of coating (0,1,2,3,5,6,8)

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 Baking Of Basic Coated
Electrodes

• Bake the loose electrodes in a baking Oven

• Baking Temperature 250° C to 300° C
• Baking Time 2Hrs to 3 Hrs
• Reduce the temperature to 100 ° C to 150 ° C
• Hold the electrodes at this temperature till use
• Unused / left over electrodes to be re-baked

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 Why Baking

• To remove the moisture (H2O) from

coating to avoid possible cracking of
weld

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 How Does Moist Electrode Generate
Crack Within Weld?

• Moist electrodes introduce atomic hydrogen at high

temperature in weld
• On cooling, atomic hydrogen try to form molecules
• The reaction results in stresses and fine cracks
• Cracks occur within hardened metal - HAZ
• Known as “Hydrogen Embrittlement” or “Under
Bead Crack” or Delayed Crack

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Important Terminology used in Critical
Welding

• Preheating
• Post Heating or Dehydrogenation
• Intermediate Stress leaving
• Inter pass Temperature
• Post Weld Heat Treatment

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 What Is Preheating?
• Heating the base metal along the weld joint to a
predetermined minimum temperature immediately
before starting the weld.
• Heating by Oxy fuel flame or electric resistant
coil
• Heating from opposite side of welding wherever
possible
• Temperature to be verified by thermo chalks prior
to starting the weld

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 Why Preheating?
• Preheating eliminates possible cracking of weld and HAZ
• Applicable to
Hardenable low alloy steels of all thickness
Carbon steels of thickness above 25 mm.
Restrained welds of all thickness

• Preheating temperature vary from 75°C to 200°C

depending on hardenability of material, thickness & joint
restrain

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How does Preheating Eliminate Crack?

• Preheating promotes slow cooling of weld and

HAZ
• Slow cooling softens or prevents hardening of
weld and HAZ
• Soft material not prone to crack even in
restrained condition

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 What Is Post Heating?
• Raising the pre heating temperature of the weld joint to a
predetermined temperature range (250° C to 350° C) for
a minimum period of time (3 Hrs) before the weld cools
down to room temperature.
• Post heating performed when welding is completed or
terminated any time in between.
• Heating by Oxy fuel flame or electric resistant coil
• Heating from opposite side of welding wherever possible
• Temperature verified by thermo chalks during the period

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 Why Post Heating?
• Post heating eliminates possible delayed cracking
of weld and HAZ
• Applicable to
Thicker hardenable low alloy steels
Restrained hardenable welds of all thickness
• Post heating temperature and duration depends on
hardenability of material, thickness & joint
restrain

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 How does Post Heating Eliminate
Crack?
• SMAW introduces hydrogen in weld metal
• Entrapped hydrogen in weld metal induces
delayed cracks unless removed before cooling to
room temperature
• Retaining the weld at a higher temperature for a
longer duration allows the hydrogen to come out
of weld

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What Is Intermediate Stress Relieving?
• Heat treating a subassembly in a furnace to a
predetermined cycle immediately on completion of
critical restrained weld joint / joints without
allowing the welds to go down the pre heat
temperature. Rate of heating, Soaking temperature,
Soaking time and rate of cooling depends on
material quality and thickness
• Applicable to
Highly restrained air hardenable material

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 Why Intermediate Stress Relieving?

• Restrained welds in air hardenable steel highly

prone to crack on cooling to room temperature.

• Cracks due to entrapped hydrogen and built in stress

• Intermediate stress relieving relieves built in stresses

and entrapped hydrogen making the joint free from
crack prone
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 What Is Inter- Pass Temperature?
• The temperature of a previously layed weld bead
immediately before depositing the next bead over
it
• Temperature to be verified by thermo chalk prior
to starting next bead
• Applicable to
Stainless Steel
Carbon Steel & LAS with minimum impact

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 Why Inter Pass Temperature?
• Control on inter pass temperature avoids over
heating, there by
Refines the weld metal with fine grains
Improves the notch toughness properties
Minimize the loss of alloying elements in
welds
Reduces the distortion

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 What Is Post Weld Heat Treatment?
• Heat treating an assembly on completion of all
applicable welding, in an enclosed furnace with
controlled heating/cooling rate and soaking at a
specific temperature for a specific time.
• Rate of heating, Soaking temperature, Soaking time
and rate of cooling depends on material quality and
thickness
• Applicable to
All type of CS & LAS
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 Why Post Weld Heat Treatment?

• Welded joints retain internal stresses within the

structure
• HAZ of welds remains invariably hardened
• Post Weld Heat Treatment relieves internal stresses
and softens HAZ. This reduces the cracking
tendency of the equipment in service

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 Common Defects In SMAW
1. Cracks 2. Lack Of Fusion
3. Slag 4. Porosity
5. Pinhole 6. Piping
7. Undercut 8. Overlap
9. Lack Of Penetration 10. Excess Penetration
11. Spatters 12. Suck Back
13. Under Flush 14. Burn Through
15. Uneven Bead 16.Stray Arcing
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 Crack
Cause Remedy
1) Wrong Consumable 1) Use Right Electrode
2) Wrong Procedure 2) Qualify Procedure
3) Improper Preheat 3) Preheat Uniformly
4) Excessive Restrain 4) Post heating or ISR

crack

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 Lack Of Fusion

Cause Remedy
1) Inadequate Current 1) Use Right Current
2) Wrong Electrode angle 2) Train /Qualify welder
3) Improper bead placement 3) Train/Qualify Welder

Lack Of Fusion

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 Slag
Cause Remedy
1) Inadequate Cleaning 1) Clean each bead
2) Inadequate Current 2) Use Right Current
3) Wrong Electrode angle 3) Train / Qualify welder
4) Improper bead placement 4) Train / Qualify Welder

Slag

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 Porosity
Cause Remedy
1) Damp Electrode 1) Bake the electrodes
2) Damaged coating 2) Replace the electrodes
3) Wet surface of BM 3) Clean & warm the BM
4) Rusted core wire 4) Replace the electrodes

Porosity . .

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 Pinhole

Cause
1) Damp Electrode
2) Damaged coating
3) Wet surface of BM/WM
4) Rusted core wire
Remedy
1) Bake the electrodes
2) Replace the electrodes
3) Clean & warm the BM
4) Replace the electrodes

Pinhole
•

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 Piping
Cause Remedy
1) Damp Electrode 1) Bake the electrodes
2) Damaged coating 2) Replace the electrodes
3) Previous beads wet 3) Clean & warm the weld
4) Rusted core wire 4) Replace the electrodes

Piping
•

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 Undercut

Cause
1) Excess Current
2) Excess Voltage
3) Improper Electrode angle
4) Eccentric Coating
Remedy
1) Reduce the Current
2) Reduce Arc length
3) Train & Qualify the Welder
4) Replace the electrode

Under cut

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 Overlap

Cause Remedy
1) Wrong Electrode Angle 1) Train & Qualify welder

2) Inadequate current 2) Increase the current

Overlap

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 Lack Of Penetration*
Cause Remedy
1) Excess Root Face 1) Reduce Root Face
2) Inadequate Root opening 2) Increase Root Opening
3) Over size electrode 3) Reduce electrode size
4) Wrong Electrode angle 4) Train / Qualify Welder
5) Improper bead placement 5) Train / Qualify Welder
6) Improper weaving technique 6) Train & Qualify Welder

* Applicable to SSFPW

LOP 43
 Excess Penetration*
Cause Remedy

1) Excess root opening 1) Reduce root gap

2) Excess Current 2) Reduce Current
3) Inadequate root face 3) Increase Root face
4) Wrong Electrode angle 4) Train / Qualify Welder
* Applicable to SSFPW

Excess Penetration 43
 Spatters
Cause Remedy
1) Excess Current 1) Reduce to Right Current
2) Excess Voltage 2) Reduce Arc length
3) Wrong Polarity 3) Correct the polarity
4) Wet Electrodes 4) Use Baked electrodes
5) Rusted BM surface 5) Clean BM surface
6) Rusted Core wire 6) Replace the electrodes
7) Eccentrics coating 7)

Spatters
• ••

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 Suck Back*
Cause Remedy

1) Excess weaving in root 1) Reduce weaving

2) Excess Current 2) Reduce Current
3) Inadequate root face 3) Increase Root face
4) Wrong Electrode angle 4) Train / Qualify Welder
* Applicable to SSFPW in 4G, 3G & 2G

Suck Back 45
 Under flush
Cause
1) Inadequate weld beads in
final layer
2) Inadequate understanding on
weld reinforcement requirement
3) Wrong selection of Electrode
size for final layer
Under flush
Remedy
1) Weld some more beads
in final layer
2) Train / Qualify welder
3) Train / Qualify Welder
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 Burn through*
Cause Remedy
1) Excess Current 1) Reduce the Current
2) Excess Root opening 2) Reduce root
3) Inadequate Root face opening
4) Improper weaving 3) Increase root face
4) Train / Qualify
Welder
*Applicable to root pass

Burn trough

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 Uneven Bead Finish
Cause Remedy
1) Improper bead placement 1) Train & Qualify the Welder
2) Excess Voltage 2) Reduce Arc length
3) Excess / inadequate 3) Train & Qualify the Welder
current

Uneven bead finish

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 Stray Arcing
Cause Remedy
1) Wrong Arc Striking Practice 1) Train the Welder
2) inadequate Skill of Welder 2) Train the Welder

Arc Strikes

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Good Engineering Practices in

Shielded Metal Arc Welding

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 Good Engineering Practices In
SMAW
• Do Welding with properly baked electrodes
• Basic coated CS electrodes to be baked to
250° to 300° C for two hours
• Baked electrodes to be directly used on job or
to be retained in a hold over oven at 100° C to
150° C until use
• Unused balance electrodes shall be returned
to baking oven

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 Good Engineering Practices In
SMAW
• Do not weld with damp Electrodes
• Do not try to heat electrodes by touching the
job (Short circuiting)
• Do not use electrodes with damaged coating
• Do not use electrodes with cracked coating
• Do not bend the electrodes after holding it in
the holder

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 Good Engineering Practices In
SMAW
• Do not weld on groove / surface with mill
scale or rusting
• Prior to welding, clean the weld groove with
power wire wheel
• Do not weld with unidentified electrodes
• Do not leave balance electrodes unattended
on shop

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 Good Engineering Practices In
SMAW
• All connections with earthing and welding
cables shall be tight fitted
• Earthing clamp shall always be tightly
connected to the job
• Burn the full length of electrode till 37 mm
stub length

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 Good Engineering Practices In
SMAW
• Earthing cable shall directly connect to the
job with an earthing clamp.
• Tacks for set up shall be minimum 5 times the
electrode diameter
• Weaving shall be limited to three times the
electrode diameter.
• Only trained & qualified welders shall be
employed for welding

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 Good Engineering Practices In
SMAW
• Do not direct fan or blower to welding arc
• Remove paint if any from the area near
welding
• While welding in open, area shall be covered
to protect from rain water & breeze
• Weld edge preparation shall be free from
serrations

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 Good Engineering Practices In
SMAW
• Use poison plates between the job material &
structural supports.
• Do not damage parent metal while removing
temporary supports.
• Locations where from temporary supports are
removed shall be touched up by welding /
grinding and PT checked.

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 Good Engineering Practices In
SMAW
• Remove visible defects from welds before
placing the subsequent beads
• Do not weld over a visible crack
• Electrodes kept out side more than 2 Hrs shall
be returned to baking oven
• Maximum 15 electrodes at a time shall be
taken from oven for welding

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 Good Engineering Practices In
SMAW
• When preheat is required, heat from opposite
side of welding.
• Use temperature indicating crayons for
checking temperature
• Do not Weld more than specified weld size-
Fillet / Reinforcement.

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Safety Precautions in

Shielded Metal Arc Welding

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 Safety Precautions In SMAW
• Welders shall use safety devises – Hand
gloves, Head screen with right glass & Safety
shoes
• Welders shall use full sleeve boiler suit
• Use welding glass-DIN 11/12 up to 250
Amps and 13 above 250 Amps
• Do not look at the arc with naked eyes

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 Safety Precautions In SMAW
• Do not throw Stubs on ground. They shall be
placed in stub collector.
• Do not keep electrode in the holder when
work is not in progress
• Do not touch the electrode held on holder and
the the job when the power source is on
• Keep welding cables duly wound near power
source when no welding is done

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 Safety Precautions In SMAW
• Do not breath welding fumes
• When working in confined area, ensure
adequate ventilation / exhaust
• Gas cutting torch / preheating burner shall not
be taken inside confined area unless the flame
is lit
• When not in use, switch off the the power
source from electric supply

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 Safety Precautions In SMAW
• Acetone / inflammable liquids (Chemical for
dye penetrant test) shall not be brought near
welding
• Gas cutting unit / fuel gas cylinders shall be
away from welding area
• Wet safety Shoes or wet hand gloves shall not
be worn while welding

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Thank You

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