CSWIP 3.

1 Welding Inspection

Manual Metal Arc Welding

or
Shielded Metal Arc Welding
TWI Training & Examination Services
Course Reference WIS 5

MMA - Principle of operation

MMA welding
Main features:

Shielding provided by decomposition of flux covering

Electrode consumable
Manual process

Welder controls:

Arc length
Angle of electrode
Speed of travel
Amperage settings

Manual Metal Arc Basic Equipment

Control panel
(amps, volts)
Electrode
oven
Electrodes
Return lead
Welding visor
filter glass

Power source
Holding oven
Inverter power
source
Electrode holder
Power cables

MMA Welding Plant

Transformer:
Changes mains supply voltage to a voltage suitable for welding.
Has no moving parts and is often termed static plant.
Rectifier:
Changes a.c. to d.c., can be mechanically or statically achieved.
Generator:
Produces welding current. The generator consists of an armature
rotating in a magnetic field, the armature must be rotated at a
constant speed either by a motor unit or, in the absence of
electrical power, by an internal combustion engine.
Inverter:
An inverter changes d.c. to a.c. at a higher frequency.

Constant Current Power Source

(Drooping Characteristic)
100

O.C.V. Striking voltage (typical) for

arc initiation

90
80

Required for: MMA, TIG, Plasma

arc and SAW > 1000 AMPS

Voltage

70
60
50
40

Large voltage variation, e.g. +

10v (due to changes in arc
length)

Normal Operating
Voltage Range

30

Small amperage change

resulting in virtually constant
current e.g. + 5A.

20
10
20

40

60

80

100

120

Amperage

130

140

160

180

200

Constant Current Power Source

(Drooping Characteristic)

Factors to be considered when selecting a MMA power source:

type of current
required

Voltage (V)
High OCV

amperage range
required
the primary type of
power available
the position in
which welding will
be done

Greater change in current

improves arc starting and
avoid stubbing for low
amperage applications

Low
OCV
Long arc
Normal arc
Short length
arc

Arc
voltage

15
40

Current (A)

MMA Welding Variables

Voltage
The arc voltage in the MMA process is measured as close to the
arc as possible. It is variable with a change in arc length
O.C.V.
The open circuit voltage is the voltage required to initiate, or reignite the electrical arc and will change with the type of electrode
being used e.g 70-90 volts
Current
The current used will be determined by the choice of electrode,
electrode diameter and material type and thickness. Current has
the most effect on penetration.
Polarity
Polarity is generally determined by operation and electrode type
e.g DC +ve, DC ve or AC

MMA Welding Checks

The welding equipment
A visual check should be made on the equipment to ensure it is in
good working order
The electrodes
Checks should be made to ensure that the correct specification of
electrode is being used, the electrode is the correct diameter and
in good condition.
Basic fluxed electrodes ensure the correct heat treatment is being
carried out before use
Rutile electrodes do not require pre-baking but should be stored in
a dry condition.
Cellulosic electrodes should not be dried

MMA electrode holder

Collet or twist type

Tongs type with

spring-loaded jaws

MMA welding parameters

Welding current
approx. 35 A/mm of diameter
governed by thickness, type of joint and welding position

Too low
poor starting
slag inclusions
weld bead contour too
high
lack of
fusion/penetration

Welding
current

Too high
spatter
excess
penetration
undercut
burn-through

MMA welding parameters

Arc length = arc voltage
Too low

Arc
voltage

arc can be extinguished

stubbing

Too high
spatter
porosity
excess
penetration
undercut
burn-through

Polarity: DCEP generally gives deeper penetration

MMA welding parameters

Travel speed

Too low
wide weld bead contour
lack of penetration
burn-through

Travel
speed

Too high
lack of root fusion
incomplete root
penetration
undercut
poor bead profile,
difficult slag removal

MMA welding parameters

Type of current:

voltage drop in welding cables is lower with AC

inductive looses can appear with AC if cables are coiled
cheaper power source for AC
no problems with arc blow with AC
DC provides a more stable and easy to strike arc, especially
with low current better positional weld, thin sheet applications
welding with a short arc length (low arc voltage) is easier with
DC better mechanical properties
DC provides a smoother metal transfer less spatter

MMA - Troubleshooting

MMA quality (left to right) - current, arc length and travel speed
normal; current too low; current too high; arc length too short; arc
length too long; travel speed too slow; travel speed too high

MMA welding typical defects

Most welding defects in MMA are caused by a lack of welder skill
(not an easily controlled process), the incorrect settings of the
equipment, or the incorrect use, and treatment of electrodes

Typical Welding Defects:

Slag inclusions
Arc strikes
Porosity
Undercut
Shape defects (overlap, excessive root penetration, etc.)

Manual Metal Arc Welding (MMA)

Advantages:

Field or shop use

Range of consumables

All positions

Portable

Simple equipment

Disadvantages:

High welder skill required

High levels of fume

Hydrogen control (flux)

Stop/start problems

Comparatively uneconomic when compared with

other processes i.e MAG, SAW and FCAW

some

Any Questions