Shielded Metal Arc Welding (SMAW)

Arc welding
Heat for welding generated by electric arc established between flux-covered consumable metal rod (electrode) and work

Called stick electrode welding Combustion and decomposition of electrode creases gaseous shield (Gases given off)
Protects electrode tip, weld puddle, arc, and highly heated work from atmospheric contamination
Additional shielding provided by covering of molten slag (flux)
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What is an Electric Arc?

An electric arc is a discharge of electric current across a gap in a circuit It is sustained by an ionized column of gas (plasma) through which the current flows To initiate the arc in AW, electrode is brought into contact with work and then quickly separated from it by a short distance

Arc Welding
A pool of molten metal is formed near electrode tip, and as electrode is moved along joint, molten weld pool solidifies in its wake

SMAW

American Welding Society

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SMAW Advantages
Equipment less complex, more portable and less costly Can be done indoors or outdoors, in any location and any position Electrodes available to match properties and strength of most base metals
Not used for welding softer metals

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SMAW Operating Principles

Sets up electric circuit
Includes welding machine, work, electric cables, electrode holder and electrodes, and a work clamp

Heat of electric arc brings work to be welded and consumable electrode to molten state
Heat intense: as high at 9,000F at center

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SMAW Operating Principle

American Welding Society

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

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Welding Power Sources

Each type of power source has fundamental electrical differences that best suit particular processes Welding machine
Must meet changing arc load and environmental conditions instantly Must deliver exact amount of electric current precisely at right time to welding arc

Available in wide variety of types and sizes

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Four Types of Power Source

Engine-driven generators
Powered by gas or diesel combustion engine Can be found with a.c. or d.c. electric motor
No longer being manufactured and rarely found

Inverters
Increases frequency of incoming primary power Constant current, constant voltage, or both Produce a.c. or d.c. welding current
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Four Types of Power Source

A.C. transformers
Used to step down a.c. line power voltage to a.c. welding voltage

Transformer-rectifiers
Use basic electrical transformer to step down a.c. line power voltage to a.c. welding voltage Welding voltage then passed through rectifier to convert a.c. output to d.c. welding current May be either d.c. or a.c.-d.c. machines
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Bridge Rectifier

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Output Slope
Two basic types
Constant current Constant voltage

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Current Controls
Amperage
Quantity of current (flow) Determines amount of heat produced at weld

Voltage
Measure of force of current (push) Determines ability to strike an arc and maintain its consistency

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Constant Current Welding Machines

Used for shielded metal arc welding and gas tungsten arc welding
Available in both d.c. and a.c. welding current Current remains fairly constant regardless of changes in arc length Total Wattage stays the same Voltage drops as amps increase (dropping arc voltage (DAV) machine)

Enables welder to control welding current in specific range by changing length of arc
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Open Circuit and Arc Voltage

Open circuit voltage runs between 50-100 volts (no welding being done, volts high, no amps)
Drops to arc voltage when arc struck

Arc voltages (Voltage generated between electrode and work during

welding, voltage lower, amps higher)

Range: 36 volts (long arc) to 18 volts (short arc) Determined by arc length held by welder and type of electrode used

Arc lengthened, arc voltage increases and current decreases

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Polarity
Electrode negative and electrode positive used in d.c. welding DCEN (d.c. electrode negative)
Electrode connected to negative terminal of power source and work connected to positive terminal (current flows from neg to pos) flow from electrode to work = more electrode consumption.

DCEP (d.c. electrode positive)

Electrode connected to positive terminal of power source and work connected to negative terminal
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D.C. Transformer-Rectifier Welding Machines

Have many designs and purposes Flexibility one reason for wide acceptance
Deliver either DCEN or DCEP

May be used for:

Stick electrode welding Gas tungsten arc welding Submerged arc welding Multi-operator systems Stud welding

Miller Electric Mfg. Co. The Lincoln Electric Co.

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

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Transformer-Rectifier Machines
Have two basic parts
Transformer for producing and regulating alternating current that enters machine rectifier that converts a.c. to d.c.

Third important part is ventilating fan

Keeps rectifier from overheating

Design improves arc stability and makes it easy to hold short arc which is soft and steady No major rotating parts so consume little power
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A.C. Transformer Welding Machines

Most popular a.c. welding machine Function of transformer
Step down high voltage of input current to high amperage, low voltage current required for welding

Especially suited for heavy work

Miller Electric Mfg. Co

The Lincoln Electric Co.

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

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Advantages of a.c. Power Sources

Reduces tendency to arc blow Can use larger electrodes
Resulting in faster speeds on heavy materials

Lower cost Decreased power consumption High overall electrical efficiency Noiseless operation Reduced maintenance
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D.C. and A.C.-D.C. Inverter Welding Machines

Portable, lightweight, and versatile May be either constant current, constant voltage or both Can perform several different processes

Miller electric Mfg. Co.

The Lincoln Electric Co.

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

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Duty Cycle
Percentage of any given 10-minute period that machine can operate at rated current without overheating or breaking down
Rating of 100% means machine can be used at rated amperage on continuous basis
Required by continuous, automatic machine welding

Rating of 60% means machine can be used at its capacity 6 out of every 10 minutes without damage
Satisfactory for heavy SMAW and GTAW
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3. Arc Length
Arc length is the distance from the tip of the bare end of the electrode to the base metal. Arc length is equal to the diameter of the bare end of the electrode.

Fill Pass
Root Pass

Cover Pass
Hot Pass

Techniques
Stringer (drag) (whip) Weave Circles crescent zig zag box weave double J

Penetration Comparisons

Arc voltage too high for travel speed.

Proper arc voltage for speed

Arc voltage too slow for travel speed

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Successful Arc Welding depends upon:

Correct metal identification
Metal properties vary

Correct electrode selection

Depends on metal type, thickness and position of weld

Correct amperage
Depends upon electrode type, size, position, and metal thickness Influence burn off rate and affect arc length and speed of travel

Successful Arc Welding depends upon:

Proper Arc length
Influences the amount of heat during the weld

Correct speed of travel

Determines the width of bead and indirectly the strength of the weld

Angle of electrode
Determines the bead shape and controls slag and gas inclusions