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WP1.1
Basic Shielded Metal Arc Welding
Objectives
After completing this learning unit you should be able to:
Describe the principles of the process and the equipment used
Explain the functions of the electrode wire, coating and slag
Identify electrodes and the materials used in the coating
Explain the classification system for welding electrodes
Identify the usability characteristics of different types of electrodes
Describe the requirements for storage and conditioning of electrodes
Outline the advantages, limitations and applications of the process
Identify the welding process variables controlling the process
Describe the influence of the process variables on weld quality
Terminology
Standard terminology:
SMAW – Shielded Metal Arc Welding
(CSA, AWS, ASME)
MMAW ‐ Manual Metal Arc Welding
Non‐standard terminology:
Manual Welding
“Stick” (electrode) welding
WP1.1
Basic Shielded Metal Arc Welding Copyright © 2014 CWB Group Industry Services
SMAW Principles
FIG. 1 The shielded metal arc welding process.
WP1.1
Basic Shielded Metal Arc Welding Copyright © 2014 CWB Group Industry Services
SMAW Principles
FIG. 2 SMAW Equipment and set‐up.
WP1.1
Basic Shielded Metal Arc Welding Copyright © 2014 CWB Group Industry Services
Power Sources
Power output is constant current (CC) type – it has a drooping volt‐amp curve
With a change in the arc voltage, the accompanying change in current and
therefore melt‐off rate are small
Power sources may have a different slope
Some machines allow adjustment
Adjustment of the slope allows the welder to better control the weld pool and
penetration for applications such as:
Out‐of‐ position welding
Root passes in a pipe with varying gap
WP1.1
Basic Shielded Metal Arc Welding Copyright © 2014 CWB Group Industry Services
Power Sources
FIG. 3 Constant current power source slope.
WP1.1
Basic Shielded Metal Arc Welding Copyright © 2014 CWB Group Industry Services
Power Sources
Direct current (DC) or Alternating
current (AC)
Transformer or alternator type
used for AC
Transformer/rectifier or motor
generator used for DC
Some power sources can be used
for DC and AC
Inverters are becoming popular
FIG. 4 Typical power sources.
WP1.1
Basic Shielded Metal Arc Welding Copyright © 2014 CWB Group Industry Services
Arc Force Control
WP1.1
Basic Shielded Metal Arc Welding Copyright © 2014 CWB Group Industry Services
Current and Voltage
Depending on the size and type
of electrode, the current can be
AC or DC
Open circuit voltage (OCV): 50 ‐
70V for AC
Arc voltage: 16 ‐ 40 volts ‐
depends on the arc length
Welding current: 30 ‐ 550 amps.
FIG. 7 Current and polarity.
WP1.1
Basic Shielded Metal Arc Welding Copyright © 2014 CWB Group Industry Services
This is a sample instructor
presentation, some pages
have been removed
WP1.1
Basic Shielded Metal Arc Welding Copyright © 2014 CWB Group Industry Services