1.introduction To SMAW

Introduction to
Shielded Metal Arc Welding

(SMAW)
Yeong-Do Park, PhD
Associate Professor, Director of Center for Education of
Welding Engineering
Department of Advanced Materials Engineering
Dong-Eui University
Content
Introduction
Types of Welding
Shielded Metal Arc Welding (SMAW)
How is metal prepared for welding?

Striking an arc and making a weld
Electrode classifications
Welding techniques
Advantages and limitations
Safety and Precautions
Introduction
Welding is joining two pieces of metal by:
Heating to temperature high enough to cause softening or
melting
With or without application of pressure
With or without use of filler metal
Melting point same as metals beginning joined or melting
point below metals but about 800 F
New methods, applications and systems
Tremendous progress in short time
Usually best method to use when fastening metal
Applications: Aerospace, Automotive, Shipbuilding, Construction,
Steel industries
Types of Welding
Fusion Welding Processes

Consumable Electrode
SMAW Shielded Metal Arc Welding
GMAW Gas Metal Arc Welding
SAW Submerged Arc Welding
GMAW
SMAW
Non-Consumable Electrode
SAW
GTAW Gas Tungsten Arc Welding

PAW Plasma Arc Welding
GTAW
Fusion Welding Processes

Radiant Energy Beam
Electron Beam Welding
Laser Beam Welding
EBW
LBW
Solid State Welding Processes

Friction Welding
Diffusion Welding
Ultrasonic Welding
Resistance Welding
Friction welding
Ultrasonic welding
Diffusion bonding
Resistance spot welding
Arc Welding Types-Summary

(SMAW)

Shielded or Heavy Coating Flow
Electrode Core Wire

Shielding Gas
Fusion or Molten Weld Metal
Solidified Slag
Weld Metal
Base Metal
Schematic View of SMA welding Process

During this overview, we will
discuss the following topics:
SMAW Basics
Equipment Set-Up
Welding Techniques
Process Advantages and
Limitations
Safety and precautions
The SMAW process is great for

maintenance and repair work

Upon successful completion of the
SMAW Unit of Study, you will have
learned to:
Properly protect yourself and others
while welding
Set up and operate SMAW equipment
Strike and maintain an arc
Make welds in four positions using
different electrodes
Understand a weld inspection process
Apply the AWS electrode classification
system
Take the next step to becoming a
certified welder
Most structural steel welders are

required to be certified

Process Capability
Shielded metal arc welding one of most used of various
electric arc welding processes
9%
2%
13%
42%
34%
SMAW
GMAW/FCAW
GTAW
SAW
Others

Principles
The American Welding Society
defines SMAW as Shielded Metal
Arc Welding
SMAW:
Is commonly known as Stick
welding or manual arc welding
Is the most widely used arc
welding process in the world
Can be used to weld most
common metals and alloys

Circuit
Current flows through the electrode cable, to the electrode
holder, through the electrode, and across the arc
On the work side of the arc, the current flows through the
base material to the work clamp and back to the welding
machine

Process
Lets take a little closer look at the SMAW process
Electrode
1
Travel direction
Shielding Gas
4
6
6
Slag
Slag
Weld Puddle 3
3
Weld Puddle
Solidified Weld Metal
Solidified Weld Metal
2
2
Arc
Arc

The Electrode
Is a consumable - it gets melted
during the welding process
Is composed of two parts
Core Rod (Metal Filler)
Carries welding current
Becomes part of the weld
Flux Coating
Produces a shielding gas
Can provide additional filler
Forms a slag

The Arc
An arc occurs when the
electrode comes in contact with
the work-piece and completes
the circuit like turning on a
light!
The electric arc is established in
the space between the end of the
electrode and the work
The arc reaches temperatures of
10,000F which melts the
electrode and base material
Can you identify the weld joint and

position being used?

Weld Puddle
As the core rod, flux coating,
and work pieces heat up and
melt, they form a pool of molten
material called a weld puddle
Weld puddle
The weld puddle is what a

welder watches and
manipulates while welding
Electrode
1/8 E6013 at 125 Amps AC

Shielding Gas
A shielding gas is formed when
the flux coating melts
Shielding Gas
4
This protects the weld puddle

from the atmosphere
preventing contamination
during the molten state
3
2
The shielding gas protects the molten

puddle from the atmosphere while
stabilizing the arc

Solidified weld Metal
As the molten weld puddle
solidifies, it forms a joint or
connection between two pieces
of base material
Weld bead
When done properly on steel,
it results in a weld stronger
than the surrounding base
metal

Slag
Slag is a combination of the flux
coating and impurities from the
base metal that float to the
surface of the weld
Slag quickly solidifies to form a
solid coating
The slag also slows the cooling
rate of the weld
Electrode
The slag can be chipped away and This welder chips the slag
off of a weld during
cleaned with a wire brush when
the repair of railroad tracks
hard

Slag
Combination of melted flux & base metal impurities

Quickly solidifies to form a shell
Slows the cooling rate of weld
Chip and clean with hammer & brush
If proper technique is used it should come off easy
Never weld over slag!!
ALWAYS SIDE CHIP SLAG, DONT HIT

IT LIKE A HAMMER
Slag

Equipment Setup
1. Turn power supply on
2. Connect work clamp
3. Select electrode
a. Type
b. Diameter
4. Adjust output
a. Polarity
b. Amperage
5. Insert electrode into electrode holder

Process Variables
Settings on the machine
Polarity : AC, DC+, DC Amperage Output
Operator Controlled
Variables
Work Angle
Travel Angle
Arc Length
Travel Speed
A straight AC machine will not have a

polarity switch like this AC/DC machine
How is metal prepared for

welding?

Preparing the correct type of joint for each kind of metal is
crucial to securing strong welded structures.
The basic types of joints are the
1.
2.
3.
4.
5.
Butt
Lap
Tee
Corner
Edge
These joints may be applied to the different types of welds:

(1) Fillet (2) Groove (3) Plug (4) Slot and (5) Surface

There are five basic types of welding joints, with each having a number of variations in order to meet different needs
A butt weld, or a square-groove, is the most common and easiest to use.
Tee joints, considered a fillet type of weld, form when two members intersect at 90
resulting in the edges coming together in the middle of a component or plate
A corner weld is a type of joint that is between two metal parts and is located at
right angles to one another in the form of a L.
This is formed when two pieces are placed atop each other while
also over lapping each other for a certain distance along the edge.
Edge welding joints, a groove type of weld, are placed side by side
and welded on the same edge.

(1) Fillet
A tee weld is a type of fillet weld. The fillet weld has two
surfaces at right angles, and the bead is triangular in shape
(2) Groove
Fillet
The groove weld is a weld made in a groove

between the two pieces of metal to be joined.
(3) Plug and (4) Slot

The plug and slot welds are used to join
pieces that overlap.
Groove
The welds are placed in plug or slot holes.

These types of welds commonly take the
place of rivets in welded structures.
Plug
Slot
Used quite often on light gauge metal to

prevent warping and heat distortion
(5) Surface welds

The Surfacing weld is not for joining parts
The purpose is to increase the thickness of the plate or
provide a protective coating on the surface
Surface
Striking an Arc and Making a Weld

Striking an arc
To begin the SMAW Process, you must first strike an arc.
This can be done using one of the following techniques:
Scratch start scratch the electrode on the base metal
like a match
Tap Start tap the rod against the base metal

Work angle
The work angle is the
angle between the
electrode and the work as
depicted on the left
Work angles can vary
depending on the position
the weld is being made in

Work angle
Work angles can vary depending on the position the weld is
being made in
700
300
450

Travel angle
Also commonly called Lead
Angle
The travel (lead) angle is
the angle between the
electrode and the plane
perpendicular to the weld
axis
20-30

Arc Length
After striking the arc, maintain a 1/8 distance between
the electrode and the workpiece
If the arc length becomes too short, the electrode will get
stuck to the workpiece or short out
If the arc length becomes too long; spatter, undercut,
and porosity can occur
Arc Length = 1/8

Travel Speed
The travel speed is the speed
at which the electrode moves
along the base material while
welding
Too fast of a travel speed results
in a ropey or convex weld
Too slow of a travel speed results
in a wide weld with an excessive
metal deposit
The travel speed impacts the

shape of the bead

Filling the Crater
At the end of the weld, the operator breaks the arc which
creates a crater
Use a short pause or slight back step at the end of the weld to
fill the crater
Large craters can cause weld cracking
Back stepping is a short move in the opposite direction of weld travel

Restarting a Bead
Here is the proper technique for restarting a weld:
1. Strike arc here

Troubleshooting Welds
A
These welds were cut and etched with nitric acid to show penetration

Troubleshooting Welds
A Good Weld: Proper Current, Speed and Arc Length

B Current low: Ropey, convex bead appearance
C Current too High: Excess spatter & burn-through
D Arc Length too short: Poor wet-in at toes
E Arc Length too Long: Spatter, undercut and porosity
F Travel Speed too slow: Wide weld with excess deposit
G Travel Speed too high: Ropey and convex bead
Electrode Classifications

AWS Electrode Classification
E70XX
Electrode
Tensile in 70,000 psi
Welding Position:
1 = All Position, 2 = Flat & Horizontal, 4 = Vertical down
Type of Current and Coating

Electrode Selection
What type of welder do I have, AC or DC?

What am I welding, steel, cast, stainless, etc?
What is the metal condition, dirty or clean?
Is it a root or cover pass?
How strong does it have to be?
What electrodes do I have to chose from?

Electrode Selection

Amperage Chart
Amperage is dependent on electrode diameter, electrode

type, and metal thickness
Reference charts whenever possible.

Electrode care
Electrodes must be kept dry
Dampness will introduce hydrogen
into the weld causing cracking or brittleness
Damp electrodes may cause the flux to blow away &
cause porosity
Bake questionable electrodes for several hours.
6010 & 6011 (fast freeze) are exempt
Our electrodes are stored in a dry oven

Electrode care
Burn electrodes down to numbers!

Place stubs in stub box
Put unused electrodes back in oven
Only grab several electrodes at a time
Electrodes are not cheap
Welding Techniques

Techniques Electrode Movement
Stringer (drag) (whip)
Weave
Circles
Crescent
zig zag
box weave
double J

Weld Bead
A weld resulting from a pass
Weave Bead
Stringer Bead

Weld Pass
Weld Pass - A single progression of welding along a joint.
The result of a pass is a weld bead or layer
1. Single Pass
2. Multi pass

Multipass
Ability to make multipass welds
such as this one, on plate and pipe,
led to growth of industry. Welds are
sound and have uniform appearance.
Cover Pass
Fill Pass
Root Pass
Pass 1
Pass 2
Hot Pass
Pass 3

There are four positions used when welding:
1. Flat
Position
The flat position produces welds that are stronger than in any
other position

2. Vertical

3. Horizontal
Fillet/Groove - stringers (small weave may be used in tight place)

Bead Placement - bottom to top

4. Overhead
Same as horizontal for Fillets

6010 open root whip for flat face and keyhole control
7018s stringers
Over head Butt Joints can be stringers or weaves
Advantages and Limitations

Advantages
Low initial cost

Portable
Easy to use outdoors
All position capabilities
Easy to change between
many base materials
What safety precautions should be

taken by these welders?

Limitations
Lower consumable
efficiency
Difficult to weld very thin
materials
Frequent restarts
Lower operating factor
Higher operator skill
required for SMAW than
some other processes
Building a barge in a large shipyard

Quality Issues
Discontinuities associated with
manual welding process that
utilize flux for pool shielding
Slag inclusions
Lack of fusion
Other possible effects on quality
are porosity, and hydrogen
cracking
Safety and Precautions

Safety - Hand and Head Shields
Brilliant light caused by electric arc contains two kinds of
invisible rays which injure eyes and skin
Ultraviolet
Infrared
Rays affect eyes within 50 feet;
and skin any distance within
20 feet
Fibre-Metal Products Co.
Hand shield so person may hold

shield in front of face

Safety - Hand and Head Shields
Also called hood or helmet
Attached to adjustable headband
Allows it to be moved up or down as wearer desires
Dependable protection
Both hands free to grasp electrode holder
Partial protection
Must also wear leather or
nonflammable cap for adequate protection

Safety - Glasses
Should be worn
Also behind hood to prevent severe
arc flash reaching eyes
Can Absorb more than 99.9% harmful
ultraviolet rays
Worn by others who work with welders
Light in weight, well ventilated, and
comfortable
Lenses have light tint (Not dark!) and
tented side shields
RobCrandall/The Image Works

Safety Protective Clothing
Gloves to protect hands
Made of leather or some other type of fire-resistant
material
Leather capes, sleeves, shoulder
garments with detachable bibs,
aprons
Split-type apron if sitting down
No place to collect hot particles
High-top shoes
Leggings and spats
Department of Labor

Safety Protective Clothing
100% cotton or wool
Thick enough to prevent
injurious ultraviolet rays from
penetrating to skin
Long sleeves
Shirts buttoned to neck
Shirttails tucked
Cuffless pants long enough to
cover top of leather boots

Safety Further Protection
Ear Protection
Full ear muffs that cover entire ear or ear plugs
Dangers
Noise
Hot weld spatter or slag entering ear canal
Flume Protection
Always use proper ventilation to keep head out of fume
plume

Safety- Further Protection
SMAW Safety is supplemental

and does not replace the
information found in Arc Welding
Basics
Understand and follow all safety
precautions listed in Safety in
Welding, Cutting, and Allied
Processes (ANSI Z49.1) and Arc
Welding Safety (E205)
Understand and follow all warning
labels found:
On welding equipment
With all consumable packaging
Within instruction manuals
Read Material Safety Data Sheets
(MSDS)
IfIfyou
youever
everhave
haveaaquestion
questionabout
aboutyour
yoursafety
safetyororthose
those
around
you,
PLEASE
ASK
YOUR
INSTRUCTOR!
around you, PLEASE ASK YOUR INSTRUCTOR!

Safety- Further Protection
Fumes and Gases can be dangerous

Keep your head out of the fumes
Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases from
your breathing zone and the general area
The SMAW process can withstand wind and exhaust near the arc from
ventilation equipment
Electric Shock can kill to receive a shock your body must touch the electrode and
work or ground at the same time
Do not touch the electrode or metal parts of the electrode holder with skin or wet
clothing
Keep dry insulation between your body and the metal being welded or ground
Arc Rays can injure eyes and skin - Choose correct filter shade (See chart below)
** Information taken from ANSI Z49.1:2005**

Safety Working Conditions
Indoors or outdoors
Noisy
Hearing protection needed
Awkward positions
Spacious surroundings or
cramped quarters
High off ground in scaffolds with
safety harness

Safety Job Hazards
Fire danger
Burns (including "sunburn" from electric arcs)
Noxious fumes from materials vaporized at high
temperatures
Eye strain
Welders flash
Electric shock
Hazards can be minimized
or eliminated by use
of proper protective
clothing and equipment.

Safety Way to Stay Current
1.
2.
3.
4.
Read trade journals, service manuals, text books, and

trade catalogs
Join associations such as the American Welding Society
Research topics on the Internet
Trade trips with your peers
Questions and Answers
Thank
You!
Dong-Eui University
Center for Education of Welding Engineer

1.introduction To SMAW

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1.introduction To SMAW

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Introduction to

Shielded Metal Arc Welding

How is metal prepared for welding?

Fusion Welding Processes

GTAW Gas Tungsten Arc Welding

Fusion Welding Processes

Solid State Welding Processes

Resistance spot welding

Arc Welding Types-Summary

Shielded Metal Arc Welding

Shielded Metal Arc Welding

Electrode Core Wire

Fusion or Molten Weld Metal

Schematic View of SMA welding Process

Shielded Metal Arc Welding

The SMAW process is great for

Shielded Metal Arc Welding

Most structural steel welders are

Shielded Metal Arc Welding

Shielded Metal Arc Welding

Shielded Metal Arc Welding

Shielded Metal Arc Welding

Solidified Weld Metal

Solidified Weld Metal

Shielded Metal Arc Welding

Shielded Metal Arc Welding

Can you identify the weld joint and

Shielded Metal Arc Welding

The weld puddle is what a

1/8 E6013 at 125 Amps AC

Shielded Metal Arc Welding

This protects the weld puddle

The shielding gas protects the molten

Shielded Metal Arc Welding

Shielded Metal Arc Welding

Shielded Metal Arc Welding

Combination of melted flux & base metal impurities

ALWAYS SIDE CHIP SLAG, DONT HIT

Shielded Metal Arc Welding

Shielded Metal Arc Welding

A straight AC machine will not have a

Shielded Metal Arc Welding

How is metal prepared for

Shielded Metal Arc Welding

These joints may be applied to the different types of welds:

Shielded Metal Arc Welding

Shielded Metal Arc Welding

The groove weld is a weld made in a groove

(3) Plug and (4) Slot

The welds are placed in plug or slot holes.

Used quite often on light gauge metal to

(5) Surface welds

Shielded Metal Arc Welding

Striking an Arc and Making a Weld

Shielded Metal Arc Welding

Shielded Metal Arc Welding

Shielded Metal Arc Welding

Shielded Metal Arc Welding

Shielded Metal Arc Welding

Arc Length = 1/8

Shielded Metal Arc Welding

The travel speed impacts the

Shielded Metal Arc Welding

Information taken from ANSI Z49.1:2005