Experiment: 3 Date:

Aim: To study and demonstrate Shielded Metal arc welding (SMAW) Process

Objective(s)
1. Become familiar with SMAW welding processes
Student will be introduced to:
2. The SMAW welding equipment, related tools and the essential process safety
considerations
3. Types of work materials, filler rods, shielding gases etc.

1.1 Arc Welding

In this process a joint is established by fusing the material near the region of joint by
means of an electric arc struck between the material to be joined and an electrode. A
high current low voltage electric power supply generates an arc of intense heat
reaching a temperature of approximately 3800OC. The electrode held externally may
act as a filler rod or it is fed independently of the electrode. Due to higher levels of
heat input, joints in thicker materials can be obtained by the arc welding process. It is
extensively used in a variety of structural applications.

There are so many types of the basic arc welding process such as shielded metal arc
welding (SMAW), gas metal arc welding (GMAW), gas tungsten arc welding
(GTAW), submerged arc welding.

1.2 Shielded Metal Arc Welding (SMAW)

One of the most common types of arc welding is shielded metal arc welding
(SMAW), which is also known as manual metal arc welding (MMAW) or stick
welding. An electric current is used to strike an arc between the base material and a
consumable electrode rod or stick. The electrode rod is made of a material that is
compatible with the base material being welded and is covered with a flux that gives
off vapors that serve as a shielding gas and provide a layer of slag, both of which
protect the weld area from atmospheric contamination. The electrode core itself acts
as filler material, making a separate filler unnecessary. The process is very versatile,
requiring little operator training and inexpensive equipment.

Laboratory Manual: <Manufacturing Process – II (20ME303P)> 1

 Fig. 3. 1 Schematic of SMAW

1.3 Equipment’s specifications:

1.4 Results of welding

1.5 Answer the following questions:

1. Write Short Notes on

a) Flux
b) Arc Shielding
c) Welding Distortion
2. What is the difference between AC and DC arc welding?

Laboratory Manual: <Manufacturing Process – II (20ME303P)> 2