SHIELDED METAL

ARC WELDING
(SMAW)
ESSENTIALS
OF
WELDING
 Shielded metal arc welding
(SMAW)
also known as manual metal arc
welding (MMA or MMAW), or
informally as stick welding
is a manual arc welding process that
uses a consumable electrode coated
in flux to lay the weld.
An electric current, in the form of
either alternating current or direct
current from a welding power
supply, is used to form an electric arc
between the electrode and the
metals to be joined.
The work piece and the electrode
melts forming the weld pool that
cools to form a strong joint.
THE FIVE ESSENTIAL VARIABLES OF
SMAW WELDING
1.Current Setting
2.Length of Arc
3.Angle of Electrode
4.Speed of Travel
5.Selection of Electrode
 1. CURRENT SETTING
 The welding current or amperage is essential to producing welds
with good appearance and the required strength characteristics.
 Amperage may be referred to as the heat by some welders.
 Amperage variables is controlled by setting the amperage on the
welding machine prior to welding.
 Amperage is set from recommended ranges according to the
following:
• Size of electrode
• The type of electrode
• The type of the current use such as AC(alternating
current) or DC(direct current) which can be set for DCEN
(Direct Current Electrode Negative) with Straight Polarity
or DCEP (DirectCurrent Electrode Positive) with Reverse
Polarity.
The picture below gives an idea of
the evaluation process:
 2. LENGTH OF ARC
 The ARC is the term used to describe the distance from the tip of
the electrode to the base metal and can be varied from lightly
touching the metal at an angle sufficient to maintain an arc to a
distance far enough from the base metal to extinguish the arc.
 Drag technique is applied when the electrode is held in contact
with the work using the slight angle to maintain the arc.
 Another method to employ is to allow a slight gap between the
electrode tip and the base metal. The length of the arc gap affects
the appearance of the weld.
 3. ANGLE OF ELECTRODE
 In SMAW process there are TWO ELECTRODE ANGLES that
welder must control:
 WORK ANGLE: the angle formed between the electrode
are the base metal
 TRAVEL ANGLE: the angle of the electrode is held at
relative to the direction of travel
 4. SPEED OF TRAVEL
 The rate of travel across the joint is controlled by the welder
during welding and greatly affects the appearance and strength
characteristics of the weld.
 The amount of weld metal deposited (weld deposited rate)and
the travel speed may vary with the type and size of electrode
being used.
 A weld speed that is too fast will results in a thin stringy weld
with poor strength.
 A weld bead that is too slow a speed will result in a heavy weld
that has too much convexity.
 5. SELECTION OF ELECTRODE
 There are variety of electrodes available for welding a wide
range of metals. In general, the electrode weld metal must be
matched to the type and composition of the base metal being
weld.
 The following is a brief description of the most commonly used
electrodes for welding Carbon Steel. The electrodes are classified
by a letter and numbering as follows:

E – 60 1 0
 The TENSILE STRENGTH is defined as the ability of the weld
metal to withstand forces acting to pull it apart.
 INTERNATIONAL
WELDING CODES AND
STANDARDS
INTERNATIONAL ORGANIZATION FOR STANDARDIZATION(ISO)
 has developed over 18500 standards and over 1100 new
standards for welding are published every year.

WELDING CODES
 are documents establishing legal obligations spelled out
through laws and rules to be complied with whenever
engaging in the manufacture of certain constructions
regulated by the appointed authority.

WELDING SPECIFICATIONS
 cover requirements for voluntary adoption and no
enforcement is meant unless they are agreed upon between
procuring agency and contractor as spelled out in a purchase
order.
WELDING STANDARDS
 Cover industry agreed upon conventions like definitions of
terms and of symbols used in the industry for conveying
information

WELDING RECOMMENDED PRACTICES

 reflect the recommendations of some of the most
knowledgeable professionals in the field with the purpose
o0f helping people improve the practical implementation of
different techniques and procedures and obtain best results.
ACCEPTABLE WELD
PROFILE
FILLET WELDING PROFILE
GROVE WELDING PROFILE
 VISUAL WELD INSPECTION
ACCEPTANCE CRITERIA
 The weld shall have no cracks.
 Thorough fusion shall exist between adjacent layers of weld
metal and between weld metal and base metal.
 All craters shall be filled to the full cross section of the weld.
 When the weld is transverse to the primary tensile stress in the
part that is undercut, the undercut shall be no more than
0.010inch (0.25mm) deep.
 When the weld is parallel to the primary tensile stress in the part
that is undercut , the undercut shall be no more than 1/32inch
(0.80mm) deep.
 VISUAL WELD INSPECTION
ACCEPTANCE CRITERIA
 The sum of the diameters of visible porosity shall not exceed
3/8inch (9.5mm) in any linear inch of weld nor shall the sum
exceed 3/4inch (19.0 mm) in any 12 inches (305mm) length of
weld.
 Any single continuous fillet weld shall be permitted to under run
the nominal fillet weld size specified by 1/16inch (1.6mm).
 Visual inspections of welds in all steels may begin immediately
after the completed welds have cooled to ambient temperature.
 Arc strikes outside the weld groove or area are prohibited.
TACK WELDS
WELD DEFECTS,
CAUSES
AND REMEDIES
SPATTER
DEFORMATION
LONGITUDINAL CRACKS IN THE
HEAT AFFECTED ZONE
ARC STRIKING DIFFICULTIES
ARC BLOW
UNDERCUT
SOLIDIFICATION CRACKS
LACK OF ROOT PENETRATION
LACK OF FUSION DEFECTS
CRATER CRACKS
POROSITY
SLAG INCLUSIONS
SAFE WELDING
PRACTICES
FACE PROTECTION
 Always wear a welding mask with the proper tinting for the
type of welding you are doing

BODY PROTECTION
 Select clothing that provides good manoeuvrability while
protecting from sparks, burns and radiation.

SHOCK PROTECTION
 Welding involves a great deal of electricity. Never weld in wet
conditions or around water.

PROTECTING AGAINST FUMES

 Always keep your head out of the fume plume, and only weld
in places with good ventilation.
FIRE SAFETY
 Be sure not to weld near combustible materials, and pay
attention to where the sparks are landing.

WELDING’s SPECIAL CONCERN

 The very nature of welding requires that workers be exposed
to certain risks. Sparks can ignite fires, ultraviolet radiation
can produce serious burns, electrical currents can produce
shocks and the melting of welding rods can create fumes that
are dangerous for workers to breathe.
Thank you