FUNDAMENTALS OF

SHIELDED METAL
ARC WELDING

Julian Niko A. Dela Cruz

Table of Contents

Chapter 1 INTRODUCTION TO SHIELDED METAL ARC WELDING

a. Parts of a Welding Machine
b. Different kinds of Welding
c. Parts of a Flux Covered Electrode
d. Different types of Electrode

Chapter 2 OCCUPATIONAL HEALTH AND SAFETY

a. Personal Protection Equipment
b. Parts of the Fire Extinguisher
c. How to use the Fire Extinguisher
d. What to do in case of emergency
e. Hazzard and Disease caused by Welding

Chapter 3 TOOLS AND EQUIPMENT

1. IDENTIFYING THE TOOLS AND EQUIPMENT
2. PERFORMING INDUSTRY CALCULATION
A. English System
B. Metric System

Chapter 4 WELDING APPLICATION AND TECHNIC

1. 5 Essentials of Welding
2. Types of Welding Application
a. Tack Welding
b. Stringer
c. Weaving
3. Welding Manipulation
4. 5 types of Joints in Welding
5. Weld Deposits and Position

A. Different types of Grove

B. Fillet Weld in Plate
C. Grove weld in Pipe

6. Weld Defects and Remedies

7. Interpret Drawings
A. Welding Symbols

8. Housekeeping
Chapter 1

WHAT IS SHIELDED METAL ARC WELDING (SMAW)

Shielded Metal Arc Welding, or manual metal arc welding/flux shielded arc welding, is a
process that uses a flux-covered electrode to form the weld. As the electricity passes through
the electrode, the flux forms a gas, which shields the electric arc in the space between the
electrode and the metal being welded. A process of joining two pieces of metal through fusion.
 PERSONAL PROTECTIVE EQUIPMENT

WELDING MASK One of the most

common accessories in welding - you can't weld
without one or a type of protective eye shield.
Many people mistakenly think that the lens shade
number corresponds to the amount of protection
that is provided to the eyes and hence the higher
the number, the better the protection. But in
reality, all well-constructed quality welding lenses,
have a screen that filters out 100 percent of the
harmful ultraviolet (UV) and infrared (IR)
wavelengths and provides protection to the eyes.
The number just denotes the amount of darkness
provided by that particular lens and should be used
by operators as a guide to select the one that is
most comfortable and yet provides good visibility
for the particular application.

SAFETY SHOES - A steel-toe boot

(also known as a safety boot, steel-capped boot
or safety shoe) is a durable boot or shoe that has
a protective reinforcement in the toe which
protects the foot from falling objects or
compression, usually combined with a mid-sole
plate to protect against punctures from below.
The applicable standard for protective footwear is
ASTM (American) standards F 2412-05, Standard
Test Methods for Foot Protection and ASTMF
2413-05, Standard Specification for Performance
Requirements for Foot Protection. The
International Organization for Standardization
provides the European standard for Safety
footwear. The current one is ISO 20345:2011[5] -
previously ISO 20345:2004
 WELDING GLOVES are personal
protective equipment (PPE) that protects the hands
of welders from the hazards of welding. These
gloves allow digit articulation while protecting the
operator from electrical shock, extreme heat, and
ultraviolet and infrared radiation, and also provide
abrasion resistance and enhanced grip. Gloves
should be: Dry and moisture resistant., In good
condition, no holes or tears., Flame resistant,
Comfortable--proper fit and size. Electrically and
thermally insulated to suit the process, Flexible--
allow easy movement and full range of motion.
Made with materials, seams, and edges that do not
affect the health or safety of the user. Durable,
tough, and long lasting, Cut, scrape, tear, and
puncture resistant

SAFETY GOGGLES - are

forms of protective eyewear that usually
enclose or protect the area surrounding
the eye in order to prevent particulates,
water or chemicals from striking the eyes.
They are used in chemistry laboratories
and in woodworking. They are often used
in snow sports as well, and in swimming.
Goggles are often worn when using
power tools such as drills or chainsaws to
prevent flying particles from damaging
the eyes.
 WELDING APRON is a heat resistant
leather which protects welder from
hot metal slag and burns. Normally
made of cows skin or goat skin.

RESPIRATOR MASKS designed to protect the welder

From inhaling harmful fumes.
Welding - Personal Protective Equipment
Body Part Equipment Illustration Reason
Eyes and face Welding Protects from:
helmet, hand
shield, or radiation
goggles hot slag, sparks
intense light
irritation and
chemical burns

Wear fire resistant head

coverings under the helmet
where appropriate

Lungs Respirators Protects against:

(breathing)
fumes and oxides

Exposed skin Fire/Flame Protects against:

(other than resistant
feet, hands, clothing and heat, fires
and head) aprons burns

Notes: pants should not

have cuffs, shirts should
have flaps over pockets
or be taped closed
Ears - hearing Ear muffs, ear Protects against:
plugs
noise

Use fire resistant ear plugs

where sparks or splatter
may enter the ear.

Feet and hands Boots, gloves Protects against:

electric shock
heat
burns
fires
PARTS OF A WELDING MACHINE
CHAPTER 2
IDENTIFIYING TOOLS AND EQUIPMENT

Anvil is a block with a hard surface

on which another object is struck. The
block is as massive as is practical,
because the higher the inertia of the
anvil, the more efficiently it causes the
energy of the striking tool to be
transferred to the work piece. On a
quality anvil the smith's hammer should
rebound with almost as much energy as
the smith puts into the downward
stroke, ultimately making the smith's
job easier and less physically strenuous.
In most cases the anvil is used as a
forging tool. Before the advent of
modern welding technology, it was a
primary tool of metal workers

ELECTRODE BAKING OVEN

are designed to recondition and
rebake welding electrodes that have
been damaged by harmful moisture
exposure. Coatings on welding
electrodes rapidly absorb atmospheric
moisture once they are removed from
cans. When a moisture-contaminated
electrode is used in the welding
process, hydrogen is released into the
metal when heat is applied. When the
weld cools it can become brittle, crack
and/or develop pinholes.
 ENGINEERS VICE,
. also known as a
metalworking vice or machinist's vice, is used to
clamp metal. It is used to hold metal when filing or
cutting. It is sometimes made of cast steel or
malleable cast iron, but most are made of cast iron.
However, most heavy duty vices are 55,000 psi cast
steel or 65,000 psi ductile iron. Some vices have a
cast iron body but a steel channel bar. Cast iron is
popular because it is typically 30 ksi grey iron which
is rigid, strong and inexpensive. The jaws are often
separate and replaceable, usually engraved with
serrated or diamond teeth. Soft jaw covers made of
aluminum, copper, wood (for woodworking) or
plastic may be used to protect delicate work. The
jaw opening of an engineer's vice is almost always
the same size as the jaw width, if not bigger

C CLAMP or G CLAMP - a type of

clamp device typically used to hold a wood
or metal workpiece, and often used in, but
are not limited to, carpentry and welding.
These clamps are called "C" clamps
because of their C shaped frame, but are
otherwise often called G-clamps or G-
cramps because including the screw part
they are shaped like an uppercase letter G
C-clamps or G-clamps are typically made
of steel or cast iron, though smaller clamps
may be made of pot metal. At the top of the
"C" is usually a small flat edge. At the
bottom is a threaded hole through which a
large threaded screw protrudes. One end
of this screw contains a flat edge of similar
size to the one at the top of the frame, and
the other end usually a small metal bar,
perpendicular to the screw itself, which is
used to gain leverage when tightening the
clamp. When the clamp is completely
closed, the flat end of the screw is in
contact with the flat end on the frame,
Hacksaw is a fine-toothed saw, originally and principally made for cutting metal. They
can also cut various other materials, such as plastic and wood; for example, plumbers and
electricians often cut plastic pipe and plastic conduit with them. There are hand saw versions
and powered versions (power hacksaws).

SHEAR also known as Tin Snip, are hand tools used to cut sheet metal and other tough
webs. There are two broad categories: tinner's snips, which are similar to common scissors, and
compound-action snips, which use a compound leverage handle system to increase the
mechanical advantage
 TAPE MEASURE or measuring
tape is a flexible ruler. It consists of a ribbon
of cloth, plastic, fibre glass, or metal strip
with linear-measurement markings. It is a
common measuring tool. Its design allows
for a measure of great length to be easily
carried in pocket or toolkit and permits one
to measure around curves or corners.

SPIRIT LEVEL, bubble level

or simply a level is an instrument
designed to indicate whether a surface
is horizontal (level) or vertical (plumb).
Different types of spirit levels may be
used by carpenters, stonemasons,
bricklayers, other building trades
workers, surveyors, millwrights and
other metalworkers, and in some
photographic or videographic work.

VENIER CALIPER is a precision instrument that measures internal dimensions,

outside dimensions, and depth. It can measure to an accuracy of one thousandth of an inch and
one hundredth of a millimeter. The caliper has two sets of jaws, one each on the upper and
lower portions. Each set has a fixed jaw and a movable jaw. The upper set is designed to
measure inside dimensions, while the lower is designed for outside dimensions. It also has a
depth probe at the base or on the rear part, which functions as a depth measuring tool.
 STEEL SQUARE of L square is a
tool used in carpentry. Carpenters use
various tools to lay out structures that are
square (that is, built at accurately measured
right angles), many of which are made of
steel, but the name steel square refers to a
specific long-armed square that has
additional uses for measurement, especially
of various angles. Today the steel square is
more commonly referred to as the framing
square or carpenter's square. It consists of a
long arm and a shorter arm, which meet at
an angle of 90 degrees (a right angle). It can
also be made of aluminum or polymers,
which are light and resistant to rust.

ABRASIVE SAW, also

known as a cut-off saw or chop
saw, is a power tool which is
typically used to cut hard
materials, such as metals, tile, and
concrete. The cutting action is
performed by an abrasive disc,
similar to a thin grinding wheel.
GRINDING MACHINE
often shortened to grinder, is any of various
power tools or machine tools used for
grinding, which is a type of machining using
an abrasive wheel as the cutting tool. Each
grain of abrasive on the wheel's surface
cuts a small chip from the workpiece via
shear deformation
.

A disc cutter is a specialised, often hand-

held, power tool used for cutting hard
materials, for example ceramic tile. This
tool is very similar to an angle grinder, with
main difference being cutting disc itself
(circular diamond blade for disc cutter vs.
abrasive grinding wheel for angle grinder)

WHEEL BRUSH is a tool consisting

of a brush whose bristles are made of wire,
most often steel wire. The steel used is
generally a medium- to high-carbon variety
and very hard and springy. Other wire
brushes feature bristles made from brass or
stainless steel, depending on application.
Wires in a wire brush can be held together
by epoxy, staples, or other binding. Wire
brushes usually either have a handle of
wood or plastic (for handheld use) or are
formed into a wheel for use on angle
grinders, bench grinders, pistol-grip drill
motors, or other power tools
 ELECTRIC HAND DRILL is a
tool fitted with a cutting tool attachment or
driving tool attachment, usually a drill bit or
driver bit, used for boring holes in various
materials or fastening various materials
together. The attachment is gripped by a
chuck at one end of the drill and rotated
while pressed against the target material.

DRILL BIT are cutting tools

used to remove material to create
holes, almost always of circular cross-
section. Drill bits come in many sizes
and shape and can create different
kinds of holes in many different
materials. In order to create holes drill
bits are attached to a drill, which powers
them to cut through the workpiece,
typically by rotation. The drill will grasp
the upper end of a bit called
the shank in the chuck.
 OXYACETYLENE
WRENCH is a multi-tool use
in opening or closing the cylinder

CHIPPING HAMMER is
a tool used to remove welding slag
from a weld and welding spatter
from along side welds. Used by
carefully swinging and hitting the
weld to shatter the slag. To remove
spatter, use the wide flat part of the
chipping hammer and slide along
the surface of the job.

HAMMER is a tool or device

that delivers a blow (a sudden impact)
to an object. Most hammers are hand
tools used to drive nails, fit parts,
forge metal, and break apart objects.
Hammers vary in shape, size, and
structure, depending on their
purposes. Hammers are basic tools in
many trades. The usual features are a
head (most often made of steel) and a
handle (also called a helve or haft).
A rivet gun, also known as a pneumatic hammer, is a type of tool used to drive rivets. The rivet
gun is used on the manufactured head side of the rivet and a bucking bar is used on the buck-
tail side of the rivet.

screwdriver is a tool, manual or powered, for turning (driving or removing) screws. A typical
simple screwdriver has a handle and a shaft, and a tip that the user inserts into the screw head
to turn it. The shaft is usually made of tough steel to resist bending or twisting. The tip may be
hardened to resist wear, treated with a dark tip coating for improved visual contrast between
tip and screwor ridged or treated for additional 'grip'. The two most common are the simple
'blade'-type for slotted screws, and Phillips, generically referred to as "cross-recess".
Locking pliers, mole grips (mole wrench) or vise-grips are pliers that can be locked into position,
using an over-center action. One side of the handle includes a bolt that is used to adjust the
spacing of the jaws, the other side of the handle (especially in larger models) often includes a
lever to push the two sides of the handles apart to unlock the pliers. "Mole" and "Vise-Grip" are
trade names of different brands of locking pliers.

Locking pliers are available in many different configurations, such as needle-nose locking pliers,
locking wrenches, locking clamps and various shapes to fix metal parts for welding.

Pliers are a hand tool used to hold objects firmly, possibly developed from tongs used to handle
hot metal in Bronze Age Europe.[1] They are also useful for bending and compressing a wide
range of materials. Generally, pliers consist of a pair of metal first-class levers joined at a
fulcrum positioned closer to one end of the levers, creating short jaws on one side of the
fulcrum, and longer handles on the other side.
PERFORMING INDUSTRY CALCULATION