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Section
apt
er 5
C ha
h ap
ptt er
SMAW:
Equipment
and Supplies
Chapter 5:
SMAW: Equipment and Supplies
Chapter 6:
SMAW: Equipment Assembly and
Adjustment
Chapter 7:
SMAW: Electrodes
Chapter 8:
SMAW: Flat Welding Position
Learning
Chapter 9:
SMAW: Horizontal, Vertical, and
Overhead Welding Positions
Chapter 10:
Surfacing
bjectives
Technical
Terms
alternating current (ac)
bridge rectifier
chipping hammer
constant current (CC)
constant voltage (CV)
cover plate
cycle
diode
direct current (dc)
droopers
duty cycle
electrode holder
electrode lead
filter lens
flash goggles
frequency
gauntlet gloves
helmet
hertz
input power
inverter
lug
open circuit voltage (OCV)
polarity
primary current
Direction
of travel
Flux
covering
Shielding
gas
Arc flame
Slag
Electrode
holder
Base metal
Welding arc
Electrode
()
Weld pool
Depth of
penetration
Figure 5-1. In shielded metal arc welding, slag covers the weld
bead while it cools. Shielding gas is formed as the flux covering
is burned.
Arc
gap
Workpiece
(+)
Direct Current
Alternating Current
Electrode
holder
Electrode
(+)
Arc
gap
SMAW Outfit
SMAW requires the use of proper protective
clothing and various tools, supplies, and equipment.
The welding outfit includes equipment required to
actually create a weld. The welding station includes
tools, supplies, and other items required to make
welding safe and comfortable. A complete SMAW
outfit includes the following:
Welding machine/power source (dc, ac, or ac/dc).
Electrode holder.
Maximum
Current
Electrode
wire
Maximum
Workpiece
()
1/120 sec
1/60 sec
One cycle or hertz (Hz)
Time
1/120 sec + 1/120 sec = 2/120 sec = 1/60 sec
Selects alternating
current
Figure 5-4. This polarity switch has positions for DCEP, AC,
and DCEN.
Chapter 5 SMAW: Equipment and Supplies
Welding table.
Covered electrodes.
Current range
selector
Current adjustment
dial
Generator
engine
AC/DC
polarity
switch
70
60
Volts
50
40
30
20
10
0
0
54
80
25
50
75 100 125
Amperes
150
175 200
SCR
SCR
SCR
SCR
Controls
Inductor
Transformer
Duty cycle.
Welding Leads
300
250
Welding Amperes
200
150
100
15
20
30
40
50
60 70 80 90 100
% Duty Cycle
Input bridge
rectifier
Transformer
Inverter
Output bridge
rectifier
1- or 3-phase
primary
Inverter
control
circuit
Figure 5-14. This arc welding lead shows the large number of
fine copper wires used. When twisted into larger bundles,
these fine wires give the lead its flexibility. The lead is then
covered with insulating material, cord reinforcement, and an
outer layer of rubber or plastic.
Figure 5-11. An inverter power supply takes a number of steps to change the supplied power into power used for welding. The
different steps and the resulting waveform are illustrated.
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57
Welding leads are available in a variety of diameters. The diameter is referred to by number size. These
number sizes and their actual diameters are shown in
Figure 5-15. Figure 5-15 also shows what size lead
should be used to carry a given amperage to the weldment and back. The amperages shown are the maximum that can be carried in the various leads over the
stated distances.
Lead Connections
Welding leads are connected to the welding
machine and base metal with lugs, clamps, or special
terminals. Figure 5-16 shows several lugs that may be
used on the machine end of the workpiece and electrode leads. Lug connections can also be used to connect the workpiece lead to the welding table. Special
push-and-turn connectors are shown in Figure 5-17.
These quick-connect terminals may be used on both
welding leads.
Various other types of clamps or special connectors may be used to connect the workpiece lead to the
base metal. The workpiece lead may be clamped to
the base metal using a spring-loaded clamp, as shown
in Figure 5-18. Occasionally, a part must be welded
while it is being rotated. A special rotating workpiece
clamp is used for this application, Figure 5-19. Lugs,
spring clamps, or other special connectors are
mechanically connected or soldered to the bare end of
the leads.
Electrode Holder
The electrode holder is held by the welder during
the welding operation. The well-insulated handle of
the electrode holder protects the welder from electrical shock. An electrode is clamped in the copper alloy
jaws of the electrode holder. The jaws provide a good
electrical contact for the electrode. See Figure 5-20.
The electrode lead is clamped into the electrode holder.
The cable clamp is under the insulated handle.
Protective Clothing
Pockets on shirts, pants, or coveralls should be
covered to prevent sparks from being caught in
them. The top collar button should be fastened,
especially when welding out of position. Pant legs
should not have cuffs.
A cap should be worn to protect your hair. Leather
gloves should be worn. Gauntlet gloves, leather gloves
with long cuffs, are the type preferred for out-of-position
welding. High-top shoes offer added safety from sparks.
Steel-toed shoes are recommended when working
around heavy metal parts.
Figure 5-16. These lugs are for arc welding leads. They are
usually connected to the lead by means of a mechanical crimp.
(Lenco)
E
4/0
3/0
2/0
1/0
1
2
3
4
Lead Diameter
Length
0 50 ft.
0 15.2 m
Length
50 100 ft.
15.4 30.5 m
Length
100 250 ft.
30.5 76.2 m
in.
mm
Amperage
Amperage
Amperage
.959
.827
.754
.720
.644
.604
.568
.531
24.4
21.0
19.2
18.3
16.4
15.3
14.4
13.5
600
500
400
300
250
200
150
125
600
400
350
300
200
195
150
100
400
300
300
200
175
150
100
75
Note: Lengths given are for the total combined length of the electrode and work leads.
Figure 5-15. Welding lead size recommendations. Lead sizes range from 4/0 to 4. If the work is 100 (30.5 m) from the machine,
200 (61 m) of leads are needed: 100 (30.5 m) for the workpiece lead and 100 (30.5 m) for the electrode lead. Size 1/0 leads are
required to carry 200A through 200 (61 m) of leads.
58
Release lever
Handle
Jaws
Figure 5-17. ACThese are all examples of European connectors called DIN connectors. Each connector has a small
raised square on the round shaft. DIN connectors are most
often used for making lead connections. DThis DIN connector also has a gas connection. EThis is an American-type
connector, which has a split round shaft. FAn American to
DIN adapter. (Lenco)
Chapter 5 SMAW: Equipment and Supplies
Setscrew secures
lead in place
Application
10
12
14
11
Ventilation
Adequate ventilation must be provided when
performing any type of welding. The size or capacity
of the ventilation system for a given area should be
calculated by a safety engineer.
Exhaust fumes from an arc welding area can be
toxic to a welder. A flexible exhaust pickup tube is
often used to remove the fumes. The welder positions the pickup tube for maximum performance.
Fumes should be picked up and exhausted before
they cross the welders face. See Figure 5-23.
Figure 5-25. The curtains in this work area are a filtered, transparent plastic. Note also the flexible fume exhaust system.
(Nederman, Inc.)
12
10 to 14
Figure 5-21. The suggested filter lens shade numbers for various
arc welding applications.
60
Lens Shade
Number
Figure 5-23. This welder is using a welding fume exhaust system. The flexible duct allows the welder to position the pickup
vent close to the weld area. (Nederman, Inc.)
61
Review
Questions
Write your answers on a separate sheet of paper. Please do not write in this book.
1. Identify the parts of this SMAW in progress.
Direction
Figure 5-27. A wire brush is used to clean the weld after slag
has been removed.
of travel
Summary
Shielded metal arc welding (SMAW) is a welding process in which the base metals are heated to fusion
or melting temperature by an electric arc. The arc is created between a covered metal electrode and the
base metal. The shielding gas is created as the flux covering on the electrode melts. The flux solidifies
and forms a slag that protects the weld metal while it cools. The melting electrode wire furnishes filler
metal to the weld.
D
H
When direct current flows from the electrode to the base metal, it is referred to as direct current electrode
negative or direct current straight polarity.
When direct current flows from the base metal to the electrode, it is referred to as direct current electrode
positive or direct current reverse polarity.
Direct current flows in only one direction. Alternating current reverses direction at a set frequency,
usually 60 cycles per second.
A welding outfit consists of the equipment required to actually create a weld. A welding station also
includes tools, supplies, and other items required to make welding safe and comfortable.
Arc welding machines used for SMAW produce a constant current (CC).
The electrical cable that connects the electrode holder to a welding machine is the electrode lead. The
workpiece lead (ground) is the electrical cable that connects the base metal to the welding machine.
A #10#14 filter lens should be used for SMAW. A darker lens is required when using larger diameter
electrodes.
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2.
3.
4.
5.
6.
7.
8.
63
A welder using the SMAW process on a large weldment. Note how the flexible exhaust
tube is positioned to effectively remove fumes. (Nederman, Inc.)
64