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Definition
Shield Metal Arc Welding is an arc welding process that uses a consumable electrode to initiate the arc and provide the filler material.
SMAW Process
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 power source. As the weld cools slag forms on top of the weld puddle.
Equipment
A. Polarity switch B. Power cord
C. Electrode holder
D. Electrode E. Base metal F. Ground clamp G. Electrode lead H. Ground lead I. Amperage scale J. Amperage adjustment K. On/Off switch L. Welder case
Type
Transformer Transformer with rectifier Generator Alternator Alternator with rectifier Inverter
Current
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.
Why?
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 and then lift it 1/8 inch.
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What are the characteristics of insufficient heat when completing a SMAW weld?
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1. Protection from atmospheric contamination & slag formers 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
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Fill-freeze
General purpose electrodes Characteristics of fast-freeze and fast-fill
Low hydrogen
Welding characteristics of fillfreeze Designed for medium carbon and alloy steels
Fast-fill
Highest deposition rate Stable arc Thick flux Flat position and horizontal laps only
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Is it permissible to use more than one diameter of electrode to complete the same joint?
Yes. Explain!
ROT: the diameter of the electrode should not exceed the thickness of the metal.
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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 (H 2 O). Moisture in the flux also causes excessive gasses to develop in the weld pool and causes a defect in the weld caused worm holes.
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The travel angle is the angle of the electrode parallel to the joint.
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Can you think of a situation where the travel angle should be modified?
What are the characteristics of a weld completed with insufficient arc length?
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Step one: determine the area of the weld. (Assuming 1/16 inch penetration.)
Step Two: knowing the deposition rate of the electrode, determine the welding speed. (Deposition rate = 2.5 in3/min.)
in 2.5 in3 = min min x 1 0.0625 in2 = 40 in min
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SMAW Joints
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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.
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What determines that amount of joint preparation that must be done before welding?
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T-Joints
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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
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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.
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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.
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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.
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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.
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Weld Defects
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Hot cracks
Caused by excessive contraction of the metal as it cools. Excessive bead size May also be found at the root of the weld.
Undercutting
improper welding parameters; particularly the travel speed and arc voltage.
Slag inclusions
Long arc Incomplete removal of slag on multipass welds.
Porosity
Atmospheric contamination or excess gas in the weld pool.
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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.
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