Shielded Metal Arc Welding

1. SMAW Basic Principles

 SMAW Principles
• The American Welding Society defines SMAW
as Shielded Metal Arc Welding
• SMAW:
– Is commonly known as ‘Stick’ welding or manual arc
welding
– Is the most widely used arc welding process in the world
– Can be used to weld most common metals and alloys
 SMAW Definitions
An arc welding process with an arc between a covered
electrode and the weld pool. The process is used with
shielding from the decomposition of the electrode
covering,
without the
application of
pressure
and with filler
metal from
the electrode.
 SMAW Process
Electrode

1
Travel direction

Shielding Gas
4

Slag
6 Slag
6
Weld Puddle 3
3 Weld Puddle Arc
2
2 Arc

5 Solidified Weld Metal

5 Solidified Weld Metal
 Welding Arc
• An arc occurs when the electrode comes in
contact with the work-piece and completes
the circuit … like turning on a light!
• The electric arc is established in the space
between the end of the electrode and the
work
• The arc reaches temperatures of 10,000°F
which melts the electrode and base material
 Weld puddle/pool
• As the core rod, flux
coating, and work
pieces heat up and
melt, they form a pool
of molten material
called a weld puddle

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 the molten state
puddle 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

• Low Start Up Costs • All Position Welding

• Portability • Variety of Materials

• Mechanical
• Outdoor Weldability
Properties
 Limitations

• Low Efficiency (65%) • Amperage Limit

• Operating Factor
• Slag
• Operator Skill
• Spatter
• Restarts
 2. SMAW Equipment Setup

1. Turn power supply on 4. Select electrode

2. Connect work clamp a. Type
3. Adjust output b. Diameter
a. Polarity 5. Insert electrode into electrode holder
b. Amperage
Lincoln 405-S Lincoln DC-400
 SMAW Equipment Setup

Upper Jaw Insulation Electrode Cable

Electrode Jaw Arm Insulation

Lower Jaw Connector Pin Grip Handle

Cable Coupling
Lower Jaw Insulation
SMAW Equipment Setup

Tighten Lug To Ground Secure Lug to Cable

Clamp
 SMAW Equipment Components

• Constant Current (CC)

Power Source
• Electrode Cable and Holder
• Work Cable and Clamp
• Flux Covered Filler Metal
• Welding Arc Is Established
When Tip of Electrode Strikes
the Work Piece
 Constant Current Power Source
Constant Current (CC) Power Source:
An arc welding power source with a volt-ampere relationship
yielding a small welding current change from
a large arc voltage change.
Arc Length

In arc welding, the voltage is directly related to the length

of the arc, and the current is related to the amount of heat input
 Direct Current Electrode Negative
(DCEN)
The arrangement of direct current arc welding
cables/leads in which the electrode is the negative
pole and the workpiece is the positive pole of the
welding arc.
 Direct Current Electrode Positive
(DCEP)
The arrangement of direct current arc welding
cables/leads in which the electrode is the positive
pole and the workpiece is the negative pole of the
welding arc.
 3. SMAW Welding Technique
• SMAW Variable
• Electrode Angle
• Arc length
• Travel Speed
• Starting – restarting bead
• Bead Quality
 SMAW Process Variable
• Settings on the machine
– Polarity : AC, DC+, DC-
– Amperage Output
• Operator Controlled
Variables
– Work Angle
– Travel Angle
– Arc Length
– Ampere
– Voltage
– Travel Speed
Electrode Angle

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

Arc Length = 1/8” (3mm)

 Travel Speed
• The travel speed is the speed
at which the electrode moves
along the base material while
welding
– Too fast of a travel speed
results in a ropey or convex
weld
– Too slow of a travel speed The travel speed impacts the
shape of the bead.
results in a wide weld with
an excessive metal deposit
 Starting the Arc
Scratch (gores) start – scratch the electrode on the base metal like a
match
Tap (ketuk) Start – tap the rod against the base metal
 Restarting the Bead
1. Strike Arc Here

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

Back stepping is a short

move in the opposite
direction of weld travel
Arc Blow
 A B
Bead
C
Type Problem
A Good Weld
B Current too low
C Current too High
D Arc Length too short
E Arc Length too Long
F Travel Speed too slow
G Travel Speed too high
Quality
D E F G
Cause
Proper Current, Travel Speed and Arc Length
Ropey convex bead appearance
Excess spatter and possible burn through of base materials
Poor wet in at toes, electrode can ‘short’ to base material
Excess spatter, undercut and porosity
Wide weld with excess metal deposit
Ropey and convex bead
 4. SMAW Electrode
• Electrode is a consumable - it
gets melted during the
welding process
• Electrode is composed of two
parts
– Core Rod (Metal Filler)
– Carries welding current
– Becomes part of the weld
– Flux Coating
– Produces a shielding gas
– Can provide additional filler
– Forms a slag
 Flux Function
Why you need an electrode coating ?

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 :

1. Electrode Size Diameter & length

Cracks, chips & concentricity

2. Electrode Condition

3. Electrode Spesification Correct specification/code

AWS E 7018
 Electrodes Identification
 Lincoln Fleetweld 5P AWS A5.1 E6010

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

 Kobelco LB-52 AWS A5.1 E7016 ???

Electrode Classification (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

Issue in heated Quiver at

temperature 750C
Need to rebake after
finish working hour or if
more than 4 hours Used in welding
exposure in open field
 5. Welding Safety

Welding Helmet and Head Protection

Eye & Ear Protection

Welding Gloves & Optional Covering

Proper Attire
Welding Helmet & Head Protection

Gas mask Welding Helmet

Head Protection
 Eye, Ear Protector & Welding Covering

Safety Glasses Ear Plugs

Ear Muff

Safety Shoes
 GTAW Hand gloves

Coverall SMAW Hand gloves

Proper Atribut
 Safety on Workplace

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

• Electrical Shock Can Kill

– Do Not Touch Electrode With Skin or Wet Clothing
– Insulate Yourself From Work and Ground
 Fumes & Gasses

• Welding May Produce Hazardous

Fumes And Gases
• Shielding Gases Can Displace Air and May Cause
Injury or Death
• Use Ventilation To Keep Air Breathing Zone Clear
• Do Not Weld Near Chlorinated Hydrocarbons
 Arc Radiation
• Electric Arc Welding Rays Can
Burn Eyes and Skin

• Always Use a Helmet When Arc Welding

• Select Appropriate Filter Lens

• Wear Appropriate Clothing

• Provide Non-Flammable Shielding to Protect Others

 Fire or Explosion

• Remove Flammable Materials From

The Welding Area

• Keep a Fire Extinguisher in the Welding Area

• Wear Fire Retardant Clothing

• Do Not Weld on Containers Which Have Held

Combustible Materials
 General Safety on Workplace

• Keep Power Source Cables, Welding

Materials and Tools Neatly Organized
• Connect Work Cable as Close as Possible to the Weld Area
• Do Not Allow Alternative Circuits Through Scaffold Cables,
Hoist Chains, or Ground Leads
• Use Only Properly Grounded Equipment
• Always Disconnect Power to Arc Welding Equipment Before
Servicing