SHIELDED METAL ARC

WELDING (SMAW)

KRISTIANA PASAU, ST., MT

 SMAW PROCES

• The arc temperature over 9,000 oF melts the base

metal, the wire core and the coating on the
electrode.
• The high temperature causes some of the
ingredients in the flux to form a gaseous shield.
• The electric energy is provided by a special power
source.
• As the weld cools slag forms on top of the weld
puddle.

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 SMAW POWER SUPPLIES
 SMAW requires a constant current
(CC) of either DC or AC.
 Some power supplies will supply both
DC and AC.
 Power supply capacity determines the
maximum diameter of electrode that
can be used.
 Equipment

Polarity Switch
Power Supply Power Cord

Electrode Holder
Power Switch
Electrode

Amperage
Adjustment

Amperage
Scale

Base Metal
(work Piece)
Ground Cable Ground Clamp
Electrode Cable

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 Open Circuit Voltage (OCV)
 Open circuit voltage is the potential between the
welding electrode and the base metal when the
machine is on, but there is no arc.
 The higher the OCV a machine has, the easier it
will be to strike an arc.
 Only adjustable of dual control machines.

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 Arc Voltage
 Arc voltage is the potential between the electrode
and the base metal when the arc is present.
 Arc voltage is less than OCV.
 Adjustable on dual control machines.

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 POLARITY

1. The polarity of an object is its physical

alignment of atoms.
2. The term is often used to describe the
positive and negative ends of batteries and
magnets.
 The negative end has an excess of electrons
 The positive end has a deficiency of electrons.

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 Five (5) Common Power Supplies
1.Transformer
 AC only

2.Rectifier
 DC only

3.Transformer/rectifier
 AC or DC

4.Generator
 DC and/or AC

5.Inverter
 AC and DC

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Comparison of A.C. and D.C. arc welding
Alternating current ( From Transformer )

1. More efficiency
2. Power consumption less
3. Cost of equipment is less
4. Higher voltage – hence not safe
5. Not suitable for welding non ferrous metals
6. Not preferred for welding thin sections
7. Any terminal can be connected to the work or
electrode
 Striking The Arc

 Select the best electrode

 Set the welder
 Turn on welder
 Warn bystanders
 Lower helmet
 Start arc (two methods):
Brushing and Tapping

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 Brushing Method

 Hold end of electrode about 1/4 -

1/2 inch above the surface.
 Lower helmet
 Gently brush surface of the metal
with the end of the electrode.
 When arc starts, lift electrode 1/8
inch.
 If electrode sticks, twist it back and forth. If it does not break
loose, release electrode from electrode holder. Do not shut off
the welder with the electrode stuck to the metal.

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 Tapping Method
 Set up welder
 Hold the electrode at
the travel angle and
1/4 - 1/2 inch above
the metal.
 Quickly lower the
electrode until it
touches the metal
More difficult method to learn and then lift it 1/8
inch.

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Arc Welding Bead Nomenclature

Flux Electrode
Gas
Slag shield Electrode
metal

Molten Penetration
Base metal Bead
puddle

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 Running Beads

 Practice running stringer beads

 Speed used should result in a bead
2-3 times wider than the diameter
of the electrode.
 Cool metal between beads.
 Practice holding a long arc for a
couple of seconds after striking the
arc.
 Practice filling in the crater.

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Five (5) Factors of Arc Welding

1. Heat
2. Electrode
3. Electrode angle
4. Arc length
5. Speed of travel
 Factors : Heat
 The arc welder must produce sufficient heat (electric
arc) to melt the electrode and the base metal to the
desired depth.
 The amount of heat produced is determined by the
amperage.
 The amount of heat needed to complete the weld is
determined by several factors:

 Thickness of the  Excessive heat.  Insufficient heat.

metal  Electrode easier to  Hard to start
 Type of joint, start
 Reduced
 Electrode type  Excessive penetration
penetration
 Electrode (burn through)
 Excessive bead width  Narrow bead
diameter
 Excessive splatter  Coarse ripples
 Weld position
 Electrode overheating
 Factors : Electrodes
 The SMAW process
uses a consumable
electrode,Electrode
must be compatible
with base metal.
 Electrodes are
available for different
metals.
 Carbon steels
 Low alloy steels
 Corrosion resisting
steels
 Cast irons
 Aluminum and alloys
 Nickel and alloys
American Welding Society (AWS)
Classification System
 The AWS system
distinguishes the tensile
strength, weld position
and, coating and current.

 Manufactures may and do

use there own numbering
system and produce
electrodes that do not fit
in the AWS system.
 Welding Currents

 Not all electrodes are designed to

work with all currents.
 Common SMAW currents.
 Alternating Current (AC)
 Direct Current straight polarity (DCSP) or (DCEN)
 Direct Current Reverse polarity (DCRP) or (DCEP)
 Arc Welding Electrode Flux
 Flux : A material used during arc welding, brazing or
braze welding to clean the surfaces of the joint
chemically, to prevent atmospheric oxidation and to
and/or float them to the surface.
 Seven (7) Classifications of Flux constituents
1. Protection from atmospheric contamination
2. Fluxing agents
3. Arc initiators and stabilizers
4. Deoxidizes
5. Physical properties of the flux
6. Fillers and metallic additions
7. Binders and flux strength improvers
 Electrode Grouping
 Electrodes are also grouped - Fill-freeze
according to there performance
characteristics. • General purpose
electrodes
 Fast-freeze
• Characteristics of fast-
• Mild steel
freeze and fast-fill
• Quick solidification of weld pool
 Low hydrogen
• Deep penetrating
• Welding
• Recommended for out of
characteristics of fill-
position welds
freeze
• Deep penetrating arc
• Designed for medium
 Fast-fill carbon and alloy
• Highest deposition rate steels
• Stable arc
• Thick flux
• Flat position and horizontal laps
only
 Selecting Electrode Size

The optimum electrode diameter is determined by

the thickness of the base metal, the welding position
and the capacity of the welding power supply.

 A smaller diameter is usually recommended for out of position

welding.
 When completing root passes in V-joints, a smaller diameter
maybe used and then a larger diameter is used for the filler
passes.
 ROT: the diameter of the electrode should not exceed the
thickness of the metal.
 Electrode Storage
 Electrodes are damaged by rough treatment,
temperature extremes and moisture.
 The should be kept in their original container until
used.
 They should be stored in a heated cabinet that
maintains them at a constant temperature.
 The storage of low hydrogen electrodes is very
critical.
 Designed to reduce underbead cracking in alloy and medium
carbon steels by reducing the the amount of hydrogen in the
weld pool.
 The flux is hydroscopic--attracts moisture (H2O).
 Moisture in the flux also causes excessive gasses to develop in
the weld pool and causes a defect in the weld caused worm
holes.
 Factors : Electrode Angle
 The electrode angle influences
the placement of the heat.
 Two angles are important:
 Travel
 Work

 The is the angle of the electrode parallel to the joint.

 The correct travel angle must be used for each joint.
 Beads = 15o from vertical or 75o from the work.
 Butt joint = 15o from vertical or 75o from the work.
 Lap joint = 45o.
 T joint = 45o.
 Corner = 15o from vertical or 75o from the work.
 Five (5) Factors
Electrode Angle-cont.
 The is the angle of the electrode
perpendicular to the joint.
 The appropriate angle must be used for
each joint.
 Beads = 90o
 Butt joint = 90o
 Lap joint = 45o
 T joint = 45o
 Corner = 90o
 The work angle may need to be
modified for some situations.
 For example, a butt joint with two
different thickness of metal.
 Factors : Arc Lenght
 The arc length is the distance from the metal part of the
electrode to the weld puddle.
 The best arc length is not a fixed distance, but should be
approximately equal to the diameter of the electrode.

 Arc length can be adjusted slightly to

change the welding process.
 Excessive length
 Excessive spatter
 Reduced penetration
 Poor quality weld
 Insufficient length
 Electrode sticks
 Narrow weld
 Poor quality weld
 Factors : Speed of Travel
 The speed of travel (inches per minute) is
an important factor when arc welding.
 The best speed of travel (welding speed) is
determined by several factors:
 The size of the joint,
 The type of electrode
 The size of the electrode
 The amperage setting on the machine
 Deposition rate of the electrode (cubic inches per minute)
 The deposition rate of an electrode will
change with the welding amperage.
 Five (5) Factors
Speed-cont.
The ideal speed can be calculated using
the volume of the joint and the
deposition rate of the electrode.
 Five (5) Factors : Speed-cont.
The correct welding speed is indicated by
the shape of the ripples.

Too slow = excessive width,

1
excessive penetration

Too fast = narrower width,

2 elongated ripple pattern,
shallow penetration.

Recommended = width 2-3

3 times diameter of electrode,
uniform ripple pattern, full
penetration.
Joints, Welds & Positions

Flat
Horizontal

Vertical Up Vertical Down

Overhead
 Square Groove

 A butt joint can be completed with a groove

welded on metal up to 1/8 inch thick with a single
pass on one side, with no root opening.
 Electrode manipulation should only be used to
prevent burning through.
 Square Groove Thicker Metal
 A groove weld on metal up to 1/4 inch thick can
be welded with a single pass on one side but, if
possible, it should be completed with a single
pass on both sides.
 Metal this thick requires a root opening to achieve
adequate penetration.
 Electrode manipulation will reduce penetration.
 Single V Groove Weld
 Butt joints on metal greater than 1/4 inch thick require
joint preparation.
 Note that the groove does not extend all the way. A
short distance, called the root face, is left undisturbed.
 The amount of joint preparation is dependent on the
diameter of the electrode and the amperage capacity of
the power supply.
 Several different combinations of passes can be used to
complete this joint.

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 Information
 In a T-joint the two welding surfaces are at
an angle close to 90 degrees from each
other.
 The welding side and number of passes uses
depends on the thickness of the metal, the
welding access and capacity of the power
supply.
 Common joints include.
 Plane T
 T with joint gap
 Single preparation
 Double preparation
 Plane T-Joint

 The plane T joint is very useful for thin metal.

 Can be completed at angles other than 90
degrees.
 Can be completed with metal of different
thickness. The work angle must be changed to
direct more heat to the thicker piece.
 T-joint--Thicker Metal
 When the metal thickness exceeds 1/8 inch the
recommendation is to gap the joint.
 Improves penetration
 May not be necessary if larger diameter electrode is used and sufficient
amperage is available.
 The need for a joint gap varies with the type of
electrode, but should not exceed 1/8 inch.
 T-joint Single Single Bevel

 As with other joints,

thicker metal must
have joint preparation
to achieve full
penetration with
smaller diameter
electrodes.

 Several different preparations can be used. A popular one is

the bevel, a bevel can be completed by grinding or cutting.
 The bevel joint can be completed with electrode manipulation
or no electrode manipulation.
 When when electrode manipulation is used to fill the joint, the
first pass should be a straight bead with no manipulation.
 T-joint Double Bevel

 The double bevel T-joint is recommended for

metal 1/2 inch thick and thicker.
 The root passes should be with not manipulation,
but the filler passes can be completed with either
straight beads or patterns beads.
 Alternating sides reduces distortion.
 COMMON SMAW DEFECT

Under Cutting Porosity

Hot Cracks
Slag Inclusions

 Hot cracks
 Caused by excessive  Undercutting
contraction of the metal as it
 improper welding
cools.
parameters; particularly
 Excessive bead size the travel speed and arc
 May also be found at the root of voltage.
the weld.
 Porosity
 Slag inclusions
 Atmospheric
 Long arc contamination or excess
 Incomplete removal of slag on gas in the weld pool.
multipass welds.
 SMAW Weld Defects-cont.

Incomplete fusion

Microcracks Toe cracks

Underbead cracks

 Toe Cracks
 Excessive heat and rapid cooling.
 Underbead cracks
 Excessive hydrogen in weld pool
 Microcracks
 Caused by stresses as weld cools.
 Incomplete fusion
 Incorrect welding parameters or welding techniques.
Weld Nomenclature-cont

Cover Pass
Filler Pass
Root Pass

Tack Weld
Weld Nomenclature
Penetration Bead

Base metal

Joint Angle Reinforcement

Bead

Root Face Excessive

Penetration
Root Opening