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Shielded Metal Arc Welding
Shielded Metal Arc Welding
1
Travel direction
Shielding Gas
4
Slag
6 Slag
6
Weld Puddle 3
3 Weld Puddle
Arc
2
2 Arc
1/8” E6013 at
125 Amps AC
Shielding Gas
• A shielding gas is
Shielding Gas
4 formed when the flux
coating melts.
3 • This protects the weld
2 puddle from the
atmosphere preventing
contamination during
The shielding gas protects the molten puddle the molten state
from the atmosphere while stabilizing the
arc
Slag
• Slag is a combination of the flux
coating and impurities from the base
metal that float to the surface of the
weld.
• The slag also slows the cooling rate of
the weld
• The slag can be chipped away and
cleaned with a wire brush when hard
Advantages
• Operating Factor
• Slag
• Operator Skill
• Spatter
• Restarts
2. SMAW Equipment Setup
20-30°
Arc Length
• After striking the arc, maintain a 1/8” distance between
the electrode and the workpiece
– If the arc length becomes too short, the electrode will get
stuck to the workpiece or ‘short out’
– If the arc length becomes too long; spatter, undercut, and
porosity can occur
2. Move Electrode to
Crown/Circle of Crater
3. Resume Travel
Forward
Bead Initiation
After the arc is ignited, hold for 1-2 seconds till
weld puddle/pool is created, then travel along
weld direction
Bead Formation
Move eelctrode while observing the weld pool
smoothly. Keep travel speed constant
End of Bead
• At the end of the weld, the operator breaks the arc which
creates a ‘crater’
• Use a short pause or slight back step at the end of the weld
to fill the crater
• Large craters can cause weld cracking
1. Shielding
→ decomposed/burnt to form gasses. The substances usually are
cellulose, fluorspar, and limestone (carbonate)
2. De-oxidation
→ remove oxygen, nitrogen, and other gasses. The gass in weld
pool can cause porosity. Addition of manganese or silicon can
react to oxygen, and aluminium can react to nitrogen. Hence
those can reduce oxygen and nitrogen in weld pool.
Flux Function
3. Alloying
• → provides additional alloying element into molten base metal. Alloying
elements are added to improve mechanical properties of weld metal
such as strength, ductility, hardness and toughness. The usual alloying
element are molybdenum, chromium, carbon, manganese, nickel, and
vanadium.
4. Ionizing
• → improves electrical characteristics to stabilize/smooth arc and
reduce spatter. The usual added substances are potassium and sodium
5. Insulating
• → forms slag as insulating blanket to aid good weld bead shape and
reduce cooling rate. The added substances are oxides of calcium,
potassium, silicon or sodium
Core Wire (Filler Metal)
• Can conducts current
• Primarily Steel
• Major Component of Weld Deposit
• Additional Elements Contained in the Core Wire:
–C
– Mn
– Si
– P and S are Additional Elements
Electrode Inspection
Inspection Points :
AWS E 7018
Electrodes Identification
Trade name
AWS Standard (Specification for
Carbon Steel Electrodes for SMAW)
Electrode Classification
E 60 1 0
Electrode
Filler metal tensile strength
60.000 psi (60 ksi)
Position (1: all position)
Cellulose flux & DCEP polarity
E7018
AWS
E XX X X
Type of Coating
Welding Position
Strength of Electrode (ksi)
Electrode
Table 1
Low Hydrogen Electrode Storage
• Low hydrogen electrode shall be wrapped in
plastic and only opened prior use.
• After opening, the electrode shall be stored in
hold oven at 120°C
Rebaking Low Hydrogen Electrode
Baking in Oven at temp
3500C for 2.5 hours
Rebaking is normaly
two times depend on
Store in holding oven at
manufacturing
temperature 1500C
recomendation
Proper Attire
Welding Helmet & Head Protection
Head Protection
Eye, Ear Protector & Welding Covering
Safety Shoes
GTAW Hand gloves
Electrical Hazards
Fumes and Gases
Arc Radiation
Fire or Explosion
Hazards in the Work Area
Compressed Gas Hazards
Electrical Hazard
• High Voltage Can Kill
– Do Not Operate With Covers Removed
– Disconnect Input Power Before Servicing
– Do Not Touch Electrically Live Parts