MANUAL METAL ARC WELDING (MMAW)

• Manual metal arc welding (MMAW)

 Refer to the fusion welding process which
provides a permanent joint of metals in which a
coalescence of metal is archived by the heat of
an electric arc between electrode and the base
metal.
manual arc welding process
Manual arc welding process uses an electrical power supply
and maintain an electric arc between
electrode and the base metal to melt metals at the welding
point.
Manual metal arc welding can use either alternating current
(AC) or direct current (DC) and either consumable
electrode or non consumable electrode.

manual metal arc welding process

the welding region/molten pool is protected from
atmospheric contaminations by a liquid slag from
flux materials which melt together with electrode.
During the manual metal arc welding polarity can considered,
polarity is the matter of direction of current during the
process, in welding a positively charged anode will have a
greater heat concentration and as a result changing the
polarity of electrode has an impact on weld properties.
There is two types of polarity which are
a. Straight polarity in which a work piece is positive
and electrode is negative this result into shallow
penetration and it can be suitable to work
piece with wide gaps.
b. Reverse polarity in which work piece is negative
and electrode is positive and this result into deep
penetration and increasing welding speed
because the metal will melt more quickly

• Note: when using direct current and non consumable

electrode when the work piece is negative and the
electrode is positive will result in shallow penetration
because the electrode will produce only an electric
arc.

EQUIPMENT USED IN MANUAL

METAL ARC WELDING
• This equipment are categorized into two category
which are
 Equipment for the welding process which are as
follows
 i. Welding power supply
ii. Cables
iii. Electrode holder
iv. Electrode
v. Filler material
vi. Chipping hammer
vii. Wire brush

 Equipment for safety

i. Gloves
ii. Safety boot
iii. Goggles
iv. Long hand overall
v. Face mask

MANUAL ARC WELDING SETUP

The welding machine is connected to the main power source then
the two cables from a welding machine, one will connect to the
electrode and the other will connect a work piece
But the arc will not start until the electrode touches the work,
this is what completes the circuit .
When the electrode is lifted away slightly and a gap
appears once more, electricity passes across the gap
using the lined-up atoms of ionized air as a conductor.
The arc stopped or broken by moving the electrode
further away.

• Advantages of manual metal arc welding

i. Is the simplest of all the arc welding process
ii. The equipment can be portable and the cost is
fairly low
iii. It can use either alternating current(AC) or direct
current (DC)
iv. Welding can be carried out in any position with
highest weld quality
v. A wide range of metal and their alloys can be
welded

MANUAL METAL ARC WELDING DEFECTS

i. Lack of penetration
 Incomplete Penetration occurs when
therootoftheweldbeaddoesnotreachthero
ot of the joint to weld the opposite surface
in the part. To correct this discontinuity,
you can increase the current, decrease the
welding speed, or change the joint
geometry.

ii. Lack of fusion

Incomplete Fusion occurs with. localized
lack of fusion, either at the joint edge or at
the face of the previously deposited
strand. To correct this discontinuity, you
can increase the current, decrease the
welding speed, change the joint geometry
 or use some artifice to avoid magnetic
blowing.

iii. Porosity
It This defect is produced when the gas
that could not escape before the
solidification of molten metal collects to
form spherical cavities inside the bead. If
these gas cavities solidified on the bead
surface and left holes, they become the
surface defect known as pits (open
defect).ccurs with the formation of gas
bubbles retained within the melt zone. It
can occur internally and also surfacing on
 the surface. To correct this discontinuity, it
is possible to correct the flow of the
protection gas and to use gases of better
quality (with greater purity in its
composition).

iv. Slag inclusion

It occurs with the retention of solid
materials, metallic or not, within the weld
metal. Causes are inadequate cleaning of
weld surface between passes. It can also
occur in single pass welds when slag gets
trapped in the root and toes of the weld.
v. Under cut
It occurs with a depression, as a notch, at
the foot of the cord. To correct this
discontinuity, you can reduce the current
or reduce the welding speed.

vi. Cracking
Among the discontinuities of metallurgical
origin, one can mention cracks, which may
 appear in the zone affected by the weld
(Fused Zone or Heat Affected Zone) due to
several factors, such as the contraction of
the solidifying metal and the growth of
grains, and can be classified as cold cracks,
solidification cracks and reheating cracks.

vii. Blowholes
This defect is produced when the gas that
could not escape before the solidification
of molten metal collects to form spherical
cavities inside the bead. If these gas
cavities solidified on the bead surface and
 left holes, they become the surface defect
known as pits (open defect).

SAFETY PRECAUTION ASSOCIATED WITH

MMAW
• Ensure that there is no area of exposed skin as
ultra-violet rays from the weld arc will burn the
skin.
• Face masks are designed to deflect fumes and should
therefore be held close to the face.
• Ensure your surroundings are dry and where
possible stand on a timber to prevent from
electric short.
• Ensure the suitable fire extinguisher and fire blanket a
ready available in case of small fire.
• Keep the welding screen in front of the eyes until the
arc is broken.
• Ensure adequate ventilation at source when welding
inside buildings.