Module 11 Quarter II WEEK 5

Republic of the Philippines
DEPARTMENT OF EDUCATION
Region I
Pangasinan Division II
Luciano Millan National High School
Asingan,Pangasinan
MODULE 11
IN
SHIELDED METAL ARC WELDING NC II
Grade 12
Set-up Welding Equipment
Common Competencies
Quarter II Week 5
OBJECTIVES:
1. Identify welding machine parts based on manufacturer’s
Manual.
2. Perform proper setting of welding machine according to
manufacturer’s manual.
PREPARED BY:
WILMER J. DIRECTO
SHS-TEACHER
1
PRE TEST
Multiple Choice: Read and analyze the statement carefully. Choose
the best answer and write the letter only in your answer sheet.
1. Is a process which melts and joins metals by heating them with an

arc between a coated metal electrode and the work piece.
a.GTAW b. SAW c. GMAW d. SMAW
2. The electrode outer coating is called.
a. Flux b. Filer metal c. Core d. Arc
3. When the electrode is moved along the workpiece at
the correct speed the metal deposits in a uniform layer
called a.
a. Bead b. Weaving c. Core d. Arc
4. The arc that is produced during SMAW is current that
jumps across the gap from the tip of the electrode to
the surface of the work piece.
a. Welding Current b. AC Welding Current
c. DC Welding Current d. Polarity
5. Is derived from either a transformer-type machine or
an alternator-type machine.
6. Is derived from either a transformer-rectifier type system or
from a generator
7. Is determined by the way the welding leads are
connected to the welding machine.
8. They use a voltage step-down transformer, which converts high-
voltage, low-amperage current from commercial power lines to low-
voltage, high-amperage welding current.
2
a. Transformer Welding Machines
b. Transformer-Rectifier Welding machine
c. Inverter Power Source
d. Engine Driven Generator and Alternator Machines
9. A rectifier is a device that converts AC current to DC
current.
10. This provides a smaller, lighter power source.
INTRODUCTION:
PRINCIPLES OF SHIELDED METAL ARC WELDING (SMAW)
Shielded Metal Arc Welding (SMAW) or Stick welding is a process
which melts and joins metals by heating them with an arc between
a coated metal electrode and the workpiece.
The electrode outer coating, called flux, assists in creating the
arc and provides the shielding gas and slag covering to protect the
weld from contamination.
The electrode core provides most of the weld filler metal.
When the electrode is moved along the workpiece at the correct
speed the metal deposits in a uniform layer called a bead.
The Stick welding power source provides constant current (CC)
and may be either alternating current (AC) or direct current (DC),
depending on the electrode being used. The best welding
characteristics are usually obtained using DC power sources.
The power in a welding circuit is measured in voltage and
current. The voltage (Volts) is governed by the arc length between
3
the electrode and the workpiece and is influenced by electrode
diameter.
Current is a more practical measure of the power in a weld
circuit and is measured in amperes (Amps).
The amperage needed to weld depends on electrode diameter,
the size and thickness of the pieces to be welded, and the position
of the welding.
Thin metals require less current than thick metals, and a small
electrode requires less amperage than a large one. It is preferable
to weld on work in the flat or horizontal position. However, when
forced to weld in vertical or overhead positions it is helpful to
reduce the amperage from that used when welding horizontally.
Best welding results are achieved by maintaining a short arc,
moving the electrode at a uniform speed, and feeding the electrode
downward at a constant speed as it melts.
Welding Current
 The arc that is produced during SMAW is current that
jumps across the gap from the tip of the electrode to the
surface of the workpiece.
 If the electrode tip is touched and held against the
workpiece instead of allowing for a gap between the two,
the electrode will pass the electricity directly to the
workpiece without creating an arc.
Types of Welding current
 SMAW welding machines are designed to produce an
output of constant current (cc).
 The current may be AC or DC.
 The type of current used depends on the type of welding
being done and/or the equipment being used.
AC Welding Current
 Alternating current (AC) in welding machines is derived
from either a transformer-type machine or an alternator-
type machine.
4
 The transformer changes high-voltage, low current AC
power to low voltage, high-current power for welding.
 The alternator uses an electric or fuel driven motor to turn a
rotor inside a number of electromagnets to produce the
welding current.
DC Welding Current
 Direct welding current (DC) has no frequency.
 Direct current in welding is derived either from a
transformer-rectifier type system or from a generator.
 In a transformer-rectifier type system, AC voltage first is
reduced (transformed) to lower voltage level through the
application of a transformer and then converted (rectified)
into DC voltage
 Most engine driven SMAW welding machines produce DC
current through a generator.
Polarity
 Polarity only applies to DC current.
 Polarity in welding is determined by the way the welding
leads are connected to the welding machine.
 The universally accepted theory is that DC current always
travels from the negative to the positive pole.
 The plus marked terminal on the welding machine is the
positive terminal.
 The minus marked terminal on the welding machine is the
negative terminal
 DCEN generates more heat in the work piece than at the
electrode and is used for GTAW
 DCEP puts more heat at the electrode than at the work
piece.
Characteristics of Welding Current
 The voltage in a welding machine, whether the machine is
connected to commercial power or driven by an engine, is
5
reduced or stepped down by a transformer called a step-
down transformer.
 The step-down transformer reduces the voltage level and
raises the current level.
Voltage
 Operating voltage, or arc voltage, is the voltage measured
after the arc is struck.
 The higher open-circuit voltage is required to establish the
arc because the air gap between the electrode and the work
has higher resistance to current flow.
 Once the arc is established, less voltage is needed.
Amperage
 Amperage is a measurement of the electric current flowing
in a circuit.
 The unit of measurement for current is the ampere (amp or
A).
 The number of amps produced by the welding machine
determines the amount of heat available to melt the
electrode.
 The current is increased or decreased according to the size
of the electrode being used and the position in which the
welding is being performed.
SMAW Machine Classifications
 SMAW machines are classified by the type of welding
current they produce: AC, DC, or AC/DC
 Welding machines that produce only DC welding voltage
and current can be further classified by the characteristics
of the welding current they produce.
SMAW Machine Types
 Several different type of basic SMAW welding machines
are available.
 They include:
• Transformers
6
• Transformer-rectifiers
• Inverter
• Engine driven generators
 Transformer, transformer-rectifiers, and electric motor
generators all require electrical power from commercial
power lines to operate called the primary current.
 The primary power required for this type machine is 240-
volt single-phase or 480-volt three-phase.
Transformer Welding Machines
 Transformer welding machines without rectifiers produce
AC welding current.
 They use a voltage step-down transformer, which converts
high-voltage, low-amperage current from commercial
power lines to low-voltage, high-amperage welding current.
 Special light-duty transformer welding machine s used for
sheet metal work are designed to be plugged into 120-volt
outlet.
 However, most light-duty transformer welding machines
operate more efficiently on 240V primary power.
 A transformer welder called a buzz box has an ON/OFF
switch, an amperage control and weld lead terminals.
Transformer-Rectifier Welding machine

 A rectifier is a device that converts AC current to DC
current.
7
 Depending on their size, transformer-rectifier machines
require 240-volt three-phase or 480-volt three-phase.
 Multiple transformer rectifiers are available grouped into a
single cabinet called a pack.
Inverter Power Source

 Inverter power sources increase the frequency of the
incoming primary power.
 This provides a smaller, lighter power source.
 An inverter supports both GTAW and SMAW processes
Engine Driven Generator and Alternator Machines

 Engine-driven generators often have an auxiliary power
unit to produce 120-volt current for power tools and
lighting.
8
 When 120-volt current is required the engine must run at
welding speed.
 Engine-driven weld machines have engine control and
welding current controls.
 Some of the basic controls are:
 Starter
 Voltage gauge
 Temperature gauge
 Fuel gauge
 Hour meter
 Many engine-driven machines are mounted on trailers,
which makes them portable so they can be used in the
field.
SMAW Machine Ratings

 The size of a welding machine is determined by the
amperage output of the machine at a given duty cycle.
 The duty cycle of a welding machine is based on a ten-
minute period.
 It is the percentage of ten minutes that the machine can
continuously produce its rated amperage without
overheating.
 For example:
9
A machine with a rated output of 300A at 60% duty cycle can deliver
300A of welding current for six minutes out of ten without
overheating.
 The duty cycle of a welding machine will be 10%, 20%, 30%,
40%, 60%, or 100%.
 If the amperage is set below the rated amperage, the duty
cycle will increase.
POST TEST
Multiple Choice: Read and analyze the statement carefully. Choose
the best answer and write the letter only in your answer sheet.
s
1. Is a process which melts and joins metals by heating them with an
arc between a coated metal electrode and the work piece.
a.GTAW b. SAW c. GMAW d. SMAW
2. The electrode outer coating is called.
a. Flux b. Filer metal c. Core d. Arc
3. When the electrode is moved along the workpiece at
the correct speed the metal deposits in a uniform layer
called a.
a. Bead b. Weaving c. Core d. Arc
4. The arc that is produced during SMAW is current that
jumps across the gap from the tip of the electrode to
the surface of the work piece.
5. Is derived from either a transformer-type machine or
an alternator-type machine.
6. Is derived from either a transformer-rectifier type system or
from a generator
10
7. Is determined by the way the welding leads are
connected to the welding machine.
8. They use a voltage step-down transformer, which converts high-
voltage, low-amperage current from commercial power lines to low-
voltage, high-amperage welding current.
9. A rectifier is a device that converts AC current to DC
current.
10. This provides a smaller, lighter power source.
REFERENCES:
1.CBLM, TESDA
2.Welding Technology, Second Edition by Gower A. Kennedy
3. Welding Inspection Technology, Education Department, American
welding Society
4.Welding Principles and Application by Larry Jeffus and
Harold V. Johnson
11

Module 11 Quarter II WEEK 5

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Republic of the Philippines

1. Is a process which melts and joins metals by heating them with an

Transformer-Rectifier Welding machine

Inverter Power Source

Engine Driven Generator and Alternator Machines

SMAW Machine Ratings

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