Chapter 2

Worker Education
For a person to be an arc welder or have a career in arc welding he/she must posses the following
educational background:
 At least be a high school or vocational graduate.
 Several months of training.
 Must have a certificate given by the employer.
 Obtain an outside construction license.

Equipment
Listed below are the equipment used in SMAW and their classification.
a. Hand Tools

Fig 2.1: Center Punch Fig 2.2: Tape Measure

Fig 2.3: Metal Brush Fig 2.4: Ball Peen Hammer

Fig 2.5: Metal File Fig 2.6: Hack Saw

Fig 2.7: Welding Pliers Fig 2.8: Try Square

Fig 2.9: Lubricant Fig 2.10: Vernier Caliper

 Fig 2.11: Dividers Fig 2.12: Adjustable Wrench

b. Power Supplies

Fig 2.13: Generator Fig 2.14: Transformer

Fig 2.15: Rectifier Fig 2.16: Inverter

 c. Clamping Tools

Fig 2.17: C-Clamp Fig 2.18: Vice Grip

d. Marking tools

Fig 2.19: Welding Magnets Fig 2.20: Scribe

Fig 2.21: Permanent Marker Fig 2.22: Soapstone

Testing Method
There are two types of testing method used in SMAW namely: Radiographic Testing (RT) and
Ultrasonic Testing (UT). These two are the best know and widely used non-destructive test (NDT)
weld tests to detect discontinuities within the internal structure of the welds. Their advantage is
that they help strengthen the weld without destroying it.
Radiographic Testing (RT) makes use of x-rays or gamma rays produced by radioactive isotopes
to test the welding process. This process is the same as radiography (medical x-ray procedure on
a human being), radiation passes through a solid object then a result of that is printed into a
photographic film thus giving us an image of the internal structure of the object. The discontinuities
are detected by viewing the shape and variation in density of the object in the processed film.
Advantages:
 It can provide a permanent film record of weld quality that is relatively easy to interpret by
trained personnel.
 usually suited to having access to both sides of the welded joint.
 This method is great for detecting porosity, inclusions, cracks, and voids in the interior of
welds.
Disadvantages:
 Serious health and safety implications.
 Deals with x-ray and gamma radiation.
 When done poorly it affects the productivity.
 Slow weld inspection method.
 Expensive weld inspection method.
Ultrasonic Testing (UT) this method uses mechanical vibrations similar to that of sound waves but
with higher frequencies, it is done by directing an ultrasonic energy to the object to be tested. To
detected a discontinuity just check for a loss of the beam, this is called the ultrasonic contact pulse
reflection technique. This method uses a transducer, the transducer is excited by a high-frequency
voltage, which causes a crystal to vibrate mechanically. The crystal probe becomes the source of
ultrasonic mechanical vibration. The transducer now serves as a receiver for the reflected energy.
After performing the steps, the detection, location, and evaluation of the discontinuity is possible.
Advantages:
 Its ability to determine the exact position of a discontinuity in a weld.
 Suited for testing thicker sections accessible from one side only.
 Can often detect finer lines or plainer defects that RT can detect.
 Can be used in ferrous or non-ferrous materials.
Disadvantages:
 Requires a high level of operator training and competence (needs additional workers)
 Dependent on the establishment.

Value welding
The current used in each electrode is determined on its size, the normal operating range and current
are given in the packaging it is recommended by the manufacturers. As a rule of thumb when
selecting a suitable current level, an electrode will require about 40A per millimeter (diameter).
The electrical stick-out tolerance allowed for most SMAW projects is +- 1/8 inches.

Best Practices
 Angle of travel
In stick welding you must hold the electrode perpendicular to the joint when it’s a
horizontal position, and then tilt the top in the direction of the travel approximately 5 to 15
degrees. When vertical tilt it 0 to 15 degrees away from the direction of travel.

 Length of arc
There is no certain arclength, it changes depending on the electrode’s size. But a good
practice is it must not exceed the diameter of the metal portion of the electrode.
 Current setting
The electrode you select will determine whether your machine should be set up in DC
positive, DC negative or AC. Make sure you have it set correctly for your application.
 Manipulation of electrode
The manipulation of the electrode depends on the welder, it is their own specific technique
in which they are comfortable in, perfect your own style and call it your own.

 Speed of travel
Your travel speed should allow you to keep the arc in the leading one-third of the weld
pool.
Safety
According to the Labor code of the Philippines, RULE 1100: GAS AND ELECTRIC WELDING
AND CUTTING OPERATIONS a welder must follow these guidelines:
1. Welding or cutting operations shall not be permitted in rooms or areas containing
combustible materials or in proximity to explosives or flammable liquids, dusts, gases or
vapors, until all fire and explosion hazards are eliminated.
2. Welding or cutting operations on containers filled with explosives or flammable substance
is prohibited. Welding closed containers that have held explosive or flammable substance
shall only be undertaken after the containers have been thoroughly cleaned and found
completely free of combustible gases or vapors or the containers are filled with inert gas
or with water.
3. Welding and cutting operations carried out or done in places where persons other than the
welders work or pass shall be enclosed by means of suitable stationary or portable screens.
Screens shall be opaque, of sturdy construction to withstand rough usage of a material
which will not readily be set on fire by sparks or hot metal, at least 2 m. (6.5 ft.) high, and
preferably painted with light flat paint.
4. A portable fire extinguisher shall be provided at the place where welding and cutting
operations are being undertaken.
5. Authorization, before welding and cutting operations are allowed in large establishments,
the area shall be inspected by the safetyman. He shall issue a written permit or authorization
for welding and cutting, indicating therein the precautions to be followed to avoid fire or
accidents.
6. All workers or persons directly engaged in welding or cutting operations shall be provided
with the following personal protective equipment:

Fig 6.1: Welding Gloves Fig 6.2: Welding Mask Fig 6.3: Welding Suit
 Fig 6.4: Welding Googles

References:
http://www.wermac.org/others/welding_electrode_manual-metal-arc-welding-
process_smaw.html
Labor code of the Philippines
Group #1’s PowerPoint presentation
Gellerman, M. (1995). Welding Fundamentals, First Edition. Albany, New York: Delmar
Publishers
https://www.esabna.com/us/en/education/blog/radiographic-and-ultrasonic-testing-of-welds.cfm
Miller welds. Five steps to improve your stick welding techniques
https://www.millerwelds.com/resources/article-library/five-steps-to-improving-your-stick-
welding-technique