Shielded Metal Arc Welding

Process Description
Gaukhar Balkassynova








Introduction to welding particularly to Shielded Metal Arc Welding or What is SMAW?

Welding is a manufacturing process that joins
metals by melting the workpieces to form a
pool of molten metals that cools and creates a
strong joint. There are four major types of
welding, such as Shielded Metal Arc
Welding, Gas Tungsten Arc Welding,
Tungsten Inert Gas and Metallic Inert Gas;
however, the most popular of those four types
of metal-joining methods is Shielded Metal
Arc Welding (SMAW). SMAW, which is also
known as stick welding is a manual arc
welding process. It requires a consumable
electrode that is coated in flux to lay the weld, and an electric current to create an electric arc
between the electrode and the metals that are being welded together. In stick welding, an arc is
struck between the electrode and the metallic work pieces, creating a weld pool and depositing a
consumable metal electrode into the joint.
Working principals of SMAW or How does SMAW work?
The configuration of SMAW can be considered as an electric circuit because it consists of
individual components, and connected
by conductive wires through which
electric current can flow. Hence, the
electrode and the work piece are part of
an electric circuit. This circuit begins
with the electric power supply source
(i.e. welding machine) connected to an
electrode holder/electrode, and a
workpiece through electrode cable, and
work cable respectively.
Welding begins when the tip of
the electrode and the workpiece come
into contact and an electric arc initiates
between them. The intense heat of the arc
melts the tip of the electrode and the surface of the metal piece close to the arc. Small globules of
molten metal rapidly form on the tip of the electrode, then transfer through the arc stream into
the molten weld pool. In this manner, filler metal is deposited as the electrode is progressively
consumed. The arc is moved over the work at an appropriate arc length and travel speed, melting
Figure 1. Shielded Metal Arc Welding
Figure 2. SMAW operating principal
and fusing a portion of the base metal and continuously adding filler metal. While the weld is
being laid, the electrodes flux coating disintegrates. This produces vapors that provide a
shielding gas and a layer of slag. Both the gas and slag protect the weld pool from atmospheric
contamination.
Major techniques used in SMAW or How can SMAW be used?
SMAW is a versatile welding process that can be performed in any position. Although, welding
in the flat position is always preferable, some construction projects require welding in a vertical,
horizontal, or overhead position. There are a couple of techniques that may be used for striking
the arc, and there are several techniques that may be used for depositing the weld metal. Even
though a welder may develop a preference for a certain technique, the technique used usually
depends on the particular job to be done.
Striking the Arc
A welding arc is maintained when the welding current is forced across a gap between the
electrode tip and the base metal. There are two basic methods for striking the arc in stick
welding.
Scratching technique
This method is similar to striking a match. The striking end of
the electrode is dragged across the worksite to get the arc
going. Once contact is made, the electrode is withdrawn to
prevent it from being welded to the work piece. If, by chance,
the electrode does weld itself to the work, a quick twist of the
wrist can free the rod.



Tapping method
When using this technique, the electrode is brought straight
down to make contact with the work piece. Then the
electrode is immediately pulled away from the work to a
point where the arc has reached the desired length.
It takes practice to accurately determine the proper arc
length. An easy guide for determining proper arc length is to
Figure 3. "Scratching" method of arc
starting
Figure 4. "Tapping" method of arc starting
listen to the sound of the arc. When it is at the proper length, there will be a sharp, crackling
sound. Another indication of whether the arc length is accurate is the appearance of the deposited
weld bead.
Depositing the Weld Metal
Welding techniques may vary with the particular electrode used as well as the welding job to be
done. In addition to these, the type of metal to be welded and the welding position may help to
determine which welding technique will better be used.
Common welding methods used with an E6011 electrode(this electrode is used for all position
welding, and produces a deep penetrating weld and works well on dirty, rusted, or painted
metals) include:
Circular pattern
Circular pattern created by moving the electrode in a circular motion. Circular motions work
well for low-hydrogen electrodes. Because low-hydrogen electrodes are high in flux, a whipping
motion could cause the flux to get trapped in the weld, creating a problem called slag inclusion.
Whipping pattern
Whipping pattern is achieved by moving the rod in a back and forth motion. Whipping motion is
desirable when welding thinner metals because it prevents the electrode from burning a hole in
the metal.
Weaving pattern for wider welds created by using a side to side motion
In weaving pattern the electrode is moved or oscillated from side to side in set pattern. The
weaving pattern is preferable for working with thick metals. This method is applied when it is
necessary to weld a wider area in a single pass of the electrode.
Conclusion or Why SMAW is the most popular type of welding?
SMAW or Stick welding is the most versatile welding type, which can be performed with
relatively inexpensive equipment, making it well suited to shop jobs and field work.
Furthermore, an operator/welder can become reasonably proficient with a modest amount of
training and can achieve mastery with experience.



References

Keen Ovens. What are Stick Electrodes? Retrieved on March 18, 2014, from
http://www.keenovens.com/products/stick-electrodes-details.html
Airgas. Welding Help. Stick Welding Basics Retrieved on March 18, 2014, from
http://www.airgas.com/content/details.aspx?id=7000000000137
Wikipedia. Welding Retrieved on March 20, 2014, from http://en.wikipedia.org/wiki/Welding
Shielded Metal Arc Welding/Fundamentals of the Process Retrieved on March 24, 2014, from
http://www.mwsco.com/kb/articles/19990330i.htm
Lincoln Electric. How to Strike and Establish an Arc? Retrieved on March 24, 2014, from
http://www.lincolnelectric.com/en-us/support/welding-how-to/pages/strike-establish-arc-
detail.aspx
Figure 1, 2 Retrieved on March 24, 2014 from
http://dc344.4shared.com/doc/FNTlBr8l/preview.html
Figure 3, 4, Retrieved on March 24, 2014 from http://www.lincolnelectric.com/en-
us/support/welding-how-to/pages/strike-establish-arc-detail.aspx