Arc Welding

Processes
 1. SHIELD
METAL ARC
WELDING
(SMAW)
 1.1 INTRODUCTION
Shielded metal arc welding (SMAW), also known as manual metal arc
(MMA) welding 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. As the weld is laid, the
flux coating of the electrode disintegrates, giving off vapors that serve as a
shielding gas and providing a layer of slag, both of which protect the weld
area from atmospheric contamination.

Because of the versatility of the process and the simplicity of its equipment
and operation, shielded metal arc welding is one of the world's most
popular welding processes. It dominates other welding processes in the
maintenance and repair industry, and though flux-cored arc welding is
growing in popularity, SMAW continues to be used extensively in the
construction of steel structures and in industrial fabrication. The process is
used primarily to weld iron and steels (including stainless steel) but
aluminum, nickel and copper alloys can also be welded with this method
 1.2 OPERATION
To strike the electric arc, the electrode is brought into contact with the
workpiece in a short sweeping motion and then pulled away slightly. This
initiates the arc and thus the melting of the workpiece and the consumable
electrode, and causes droplets of the electrode to be passed from the
electrode to the weld pool.

As the electrode melts, the flux covering disintegrates, giving off vapors that
protect the weld area from oxygen and other atmospheric gases. In addition,
the flux provides molten slag which covers the filler metal as it travels from the
electrode to the weld pool. Once part of the weld pool, the slag floats to the
surface and protects the weld from contamination as it solidifies.
Once hardened, it must be chipped away to reveal the finished weld.
As welding progresses and the electrode melts, the welder must
periodically stop welding to remove the remaining electrode stub and
insert a new electrode into the electrode holder. This activity,
combined with chipping away the slag, reduce the amount of time
that the welder can spend laying the weld, making SMAW one of the
least efficient welding processes.

SMAW weld area

The actual welding technique utilized depends on the electrode, the
composition of the workpiece, and the position of the joint being
welded. The choice of electrode and welding position also determine
the welding speed. Flat welds require the least operator skill, and can
be done with electrodes that melt quickly but solidify slowly. This
permits higher welding speeds. Sloped, vertical or upside-down
welding requires more operator skill, and often necessitates the use of
an electrode that solidifies quickly to prevent the molten metal from
flowing out of the weld pool. However, this generally means that the
electrode melts less quickly, thus increasing the time required to lay the
weld.
 1.3 QUALITY
The most common quality problems associated with SMAW include weld
spatter, porosity, poor fusion, shallow penetration, and cracking. Weld
spatter damages its appearance and increases cleaning costs. It can be
caused by excessively high current, a long arc, or arc blow, a condition
associated with direct current characterized by the electric arc being
deflected away from the weld pool by magnetic forces.

Arc blow can also cause porosity in the weld, as can joint contamination,
high welding speed, and a long welding arc, especially when low-hydrogen
electrodes are used.

Porosity, often not visible without the use of advanced nondestructive

testing methods, is a serious concern because it can potentially weaken
the weld.

Another defect affecting the strength of the weld is poor fusion, though it
is often easily visible. It is caused by low current, contaminated joint
surfaces, or the use of an improper electrode.
Shallow penetration, another detriment to weld strength, can be
addressed by decreasing welding speed, increasing the current or using a
smaller electrode.

Any of these weld-strength-related defects can make the weld prone to

cracking, but other factors are involved as well. High carbon, alloy or sulfur
content in the base material can lead to cracking, especially if
low-hydrogen electrodes and preheating are not employed. Furthermore,
the workpieces should not be excessively restrained, as this introduces
residual stresses into the weld and can cause cracking as the weld cools.
 1.4 APPLICATION
Shielded metal arc welding is one of world's most popular welding processes. Because of
its versatility and simplicity, it is particularly dominant in the maintenance and repair
industry, and is heavily used in the construction of steel structures and in industrial
fabrication.

In recent years its use has declined as flux-cored arc welding has expanded in the
construction industry and gas metal arc welding has become more popular in industrial
environments. However, because of the low equipment cost and wide applicability, the
process will likely remain popular, especially among amateurs and small businesses where
specialized welding processes are uneconomical and unnecessary.

SMAW is often used to weld carbon steel, low and high alloy steel, stainless steel, cast iron,
and ductile iron. While less popular for nonferrous materials, it can be used on nickel and
copper and their alloys and, in rare cases, on aluminum. The thickness of the material
being welded is bounded on the low end primarily by the skill of the welder, but rarely
does it drop below 0.05 in (1.5 mm). No upper bound exists: with proper joint preparation
and use of multiple passes, materials of virtually unlimited thicknesses can be joined.
Furthermore, depending on the electrode used and the skill of the welder, SMAW can be
used in any position.
 1.5 EQUIPMENT
Shielded metal arc welding equipment typically consists of a constant
current welding power supply and an electrode, with an electrode holder,
a work clamp, and welding cables (also known as welding leads)
connecting the two.

Schematic illustration of
SMAW.
Also known as stick
welding, because the
electrode is in the
shape of a stick.
 1.5 ELECTRODES
The choice of electrode for SMAW depends on a number of factors,
including the weld material, welding position and the desired weld
properties. The electrode is coated in a metal mixture called flux.

Electrode coating has the following basic functions:

- to improve the arc stability.
- to generate gases to act as a shield against the surrounding
atmosphere in order to prevent weld contamination.
- to control the rate at which the electrode melts.
- to act as a flux to protect the weld against the formation of
oxides, nitrides and other inclusion and to protect molten –
weld pool.
- to add alloying elements to the weld zone to enhance the
properties of the joint.