Shielded Metal Arc Welding (SMAW)

FUNDAMENTALS OF THE PROCESS

SMAW “stick welding.” This process operates by heating the metal with an electric arc between
a covered metal electrode and the metals to be joined.

Shielded metal arc welding electrodes:

It is made up of a metal core wire covered with a layer of granular flux held in place by some
type of bonding agent.
All carbon and low alloy steel electrodes use essentially the same type of steel core wire.

The electrode coating Importance:

1. Shielding—some of the coating decomposes to form a gaseous shield for the molten metal.
2. Deoxidation—the coating provides a fluxing action to remove impurities and oxygen and
other atmospheric gases.
3. Alloying—the coating provides additional alloying elements for the weld deposit.
4. Ionizing—when the flux coating becomes molten it improves electrical characteristics to
increase arc stability.
5. Insulating—the solidified slag provides an insulating blanket to slow down the weld metal
cooling rate.
The thickness of the slag will have an effect on the weld bead appearance. Heavier slag will
produce beads that are smooth and have a good appearance. Thin slag will produce deposits that
have rougher surfaces.
AWS Shielded Metal Arc Covered Electrode Classification System

“E,” which stands for electrode.

The first two, or three, numbers refer to the minimum tensile strength (in thousands of pounds
per square inch) of the deposited weld metal.
The next number refers to the positions in which the electrode can be used.
“1” All position.
“2” Flat and horizontal position for fillet welds only.
“4” Downhill progression.
The last number in the designation describes composition of the coating and operating
characteristics.

Electrode Classification According F-No:

F-1 High Deposition Group (Exx20, Exx24, Exx27, Exx28)
F-2 Mild Penetration Group (Exxx2, Exxx3, Exxx4)
F-3 Deep Penetration Group (Exx10, Exx11) Cellulosic electrode
F-4 Low Hydrogen Group (Exxx5, Exxx6, Exxx8)
It is important to note that those electrodes ending in “5,” “6,” or “8” are classified as “low
hydrogen” types. To maintain this low hydrogen (moisture) content, they must be stored in their
original factory-sealed metal container or an acceptable storage oven.
This oven should be heated electrically and have a temperature control capability in the range of
150°F to 350°F. Since this device will assist in the maintenance of a low moisture content (less
than 0.2%), it must be suitably vented.
Any low hydrogen electrodes which are not to be used immediately should be placed into the
holding oven as soon as their airtight container is opened. Most codes require that low hydrogen
electrodes be held at a minimum oven temperature of 250°F [120°C] after removal from their
sealed container.
Those SMAW electrodes used for joining low alloy steels may also have an alpha-numeric suffix
which is added to the standard designation after a hyphen.

Stainless Steel Electrodes Classification

EXXX(X)-XX
“E,” which stands for electrode.
The first three, numbers refer to type of Stainless Steel.
These may be followed by the symbol of a chemical element and either the letters “L” or “H.”
The letter “R” may be added to indicate a modification to the all-weld-metal chemistry of the
parent class.
“L” Low Carbon Content (0.04% Max.).
“H” High Carbon Content.
“R” signifies that detrimental residuals are restricted to low levels.
Classification suffix -XX may be -15, -16, -17, or -26.

EQUIPMENT
The equipment for shielded metal arc welding is relatively simple and Consist of the power
source, welding cable, workpiece connector and electrode holder.
Power Source Selection
Several factors should be considered when selecting a power source for shielded metal arc
welding:
1. The type of welding current required,
2. The output characteristics of the power source,
3. The amperage range required,
4. The positions in which welding will be done, and
5. The primary type of power available at the workstation.
For dc welding, the choice is between a transformer-rectifier or motor-generator power source.
When both ac and dc are to be used, a single-phase transformer-rectifier or an alternator-rectifier
power source can be used.

Type of Output Current

Either ac or dc (DCEP,DCEN) can be employed for shielded metal arc welding.

Instances of Excessive Voltage Drop.

The voltage drop in the welding cables is lower with ac; therefore, if the welding is to be done at
a long distance from the power supply ac is more efficient.
Significance of the Volt-Ampere Curve

Electrode moved closer, Arc V falls, Arc A rises

Electrode moved away, Arc V rises, Arc A drops
Arc current directly related to heat input and deposition rate.
Flatter response at low current settings on the power source can assist the welder in several ways:
(1) maintaining a constant arc length,
(2) making an instantaneous adjustment to deposition rate, and
(3) improving arc starting by preventing the electrode from sticking to the workpiece in the weld
pool.

Open-circuit voltage (OCV)

is defined as the voltage between the output terminals generated by the welding machine when
no welding is being done(Current is Zero).
WELDING VARIABLES
The welding variables that must be considered are the type and size of the electrode and its
orientation during welding, the type and magnitude of current, arc length, and travel speed.
ELECTRODE DIAMETER
In general, larger electrodes will be selected for applications involving thicker materials and for
welding in the flat position in order to take advantage of the higher deposition rates of these
electrodes.
For welding in the horizontal, uphill, and overhead positions, the bead shape is an important
consideration.In these positions the small-diameter electrodes will be selected.

WELDING CURRENT
Most covered electrodes operate better on direct current electrode positive, also referred to as
reverse polarity, although some electrodes are designed for use with direct current electrode
negative, also referred to as straight polarity. Direct current electrode positive produces deeper
penetration, but direct current electrode negative produces a higher electrode melting rate.

ARC LENGTH
Arc length is the distance from the molten tip of the electrode core wire to the surface of the
weld pool.
The correct arc length varies according to the electrode classification, diameter, and covering
composition as well as the amperage and welding position.
Too short an arc length will lead to erratic operation as the metal droplets short-circuit during
metal transfer, causing increased spatter.
Too long an arc will lead the spatter may be heavy and hence the deposition efficiency will be
low. In addition, the gas and flux generated by the electrode covering are not as concentrated, so
they may not effectively shield the arc and the weld metal and that causes porosity.

TRAVEL SPEED
Travel speed is the rate at which the electrode moves along the joint.
Travel speed is influenced by several factors:
1. Type of welding current, amperage, and polarity;
2. Position of welding;
3. Melting rate of the electrode;
4. Thickness of base metal;
5. Surface condition of the base metal;
6. Type of joint;
7. Joint fit-up; and
8. Electrode manipulation.
Up to a point, increasing the travel speed will narrow the weld bead and increase penetration. Beyond this point,
higher travel speeds can decrease penetration, cause the surface of the bead to deteriorate and cause undercut at the
edges of the weld. It will also make slag removal difficult and entrap gas (causing porosity) in the weld metal.
With low travel speed, the weld bead will be wide and tend to be convex with shallow penetration.
Low travel speed increases heat input and this, in turn, increases the size of the heat affected zone and reduces the
cooling rate of the weld.
Higher travel speed reduces the size of the heat-affected zone and increases the cooling rate of the weld.
Arc Blow
arc blow is used to describe the undesirable deflection of the arc by magnetic forces.
To reduce the effects of arc blow, several alternatives can be tried. They include:
1. Change from DC to AC.
2. Hold as short an arc as possible.
3. Reduce welding current.
4. Angle the electrode in the direction opposite the arc blow.
5. Use heavy tack welds at either end of a joint, with intermittent tack welds along the length of
the joint.
6. Weld toward a heavy tack or toward a completed weld.
7. Use a backstep technique.
8. Weld away from the work connection to reduce back blow; weld toward the work connection
to reduce forward blow.
9. Attach the work cable to both ends of the joint to be welded.
10. Wrap work cable around the workpiece and pass work current through it in such a direction
that the magnetic field set up will tend to neutralize the magnetic field causing the arc blow.
11. Extend the end of the joint by attaching runoff plates.
In addition to porosity, arc blow can also cause spatter, undercut, improper weld contour, and
decreased penetration.

DISCONTINUITIES
The following discontinuities are sometimes encountered in welds made by the shielded metal
arc welding process:
1. Porosity,
2. Slag inclusions,
3. Incomplete fusion,
4. Undercut ,
5. Cracks,
6. Arc Strike, and Incomplete joint penetration.
SMAW Advantages
1. Field or shop use
2. Inexpensive power supply
3. Very portable
4. All positions
5. Welds most alloys

SMAW Limitations
1. High welder skill required
2. Rate deposition is very low
3. Slag removal
4. Electrode storage considerations
5. Arc blow