Mc Eli Dorupan
Shielded metal arc welding
Shielded metal arc welding (SMAW) is a welding process in which
coalescence of metals is produced by heat from an electric arc
maintained between the tip of a consumable electrode and the surface
of the base material in the joint being welded. Stainless steel, carbon
steel, alloy steel and cast steels are generally welded using SMAW.
Shielded metal arc welding (SMAW), also known as manual metal arc
welding (MMA or MMAW), flux shielded arc welding[1] or informally
as stick welding, is a manual arc welding process that uses a
consumable electrode covered with a flux to lay the weld.
HOW SMAW WORKS ?
1. Arc Initiation: An electric current (AC or DC) creates an arc between
the electrode and the workpiece. This arc's intense heat melts both the
electrode and the base metal, forming a weld pool.
2. Flux Decomposition: The electrode's flux coating decomposes, releasing
shielding gases (like carbon dioxide) and forming slag. These protect the
molten weld pool from atmospheric gases (like oxygen and nitrogen) that
could weaken the weld.
3. Weld Formation: Molten metal from the electrode transfers into the
weld pool, filling the joint. As the electrode melts, the welder feeds it into
the weld pool, continuously adding filler metal.
4. Slag Removal: Once the weld cools and solidifies, a layer of slag covers
the weld bead. This slag must be removed using a chipping hammer to
reveal the finished weld.
SAFETY PRECAUTIONS
A. Personal Safety
B. Workshop Safety
A. PERSONAL SAFETY
Welding Helmet: A welding helmet with a sufficiently dark shade lens
(the appropriate shade depends on the welding process and
amperage) is essential to protect eyes from intense UV radiation and
the arc’s brightness. Auto-darkening helmets offer added convenience
and safety.
Welding Gloves: Heavy-duty leather gloves provide protection
against burns from hot metal and sparks. The type of glove (e.g.,
leather, aluminized, Kevlar) should be selected based on the specific
welding process and intensity.
Protective Clothing: Long-sleeved, flame-resistant clothing (jackets,
pants) and high-top boots made of durable, flame-resistant materials
protect the body from sparks, molten metal splatter, and burns. Avoid
synthetic materials, which can melt onto the skin.
Training: Proper training from a qualified instructor is crucial before
attempting SMAW.
First Aid: Have a well-stocked first aid kit nearby and know how to
respond to common welding-related injuries.
B. WORKSHOP SAFETY
Proper Ventilation: Ensure adequate ventilation to remove fumes
and gases. This could involve using a fume extractor or ensuring
sufficient airflow in the work area.
Grounding: Ensure proper grounding of the welding machine and
workpiece to prevent electrical shocks.
Fire Safety: Keep a fire extinguisher readily available and
maintain a clean work area free of flammable materials.
Safe Work Practices: Follow established safety procedures and
never weld alone.
Regular Equipment Inspection: Check all equipment for damage
before use. This includes the welding machine, cables, electrode
holder, and ground clamp.
Follow Manufacturer’s Instructions: Always follow the
manufacturer’s instructions for the welding equipment and
procedures.
Stay a Safe Distance Away from the Arc: Do not stand too
close to the arc, as this can expose you to intense heat and
radiation.
Maintain a safe work environment: Keep your work
environment free of clutter to avoid falls or other accidents. Do not
work in wet areas or areas which are too cramped. Ensure that all
workers know the safety rules and are following them.
WELDING TERMS
1. Base metal – Base metal (also known as the parent metal) is
the primary metal or alloy that is being welded, or the metal
that is being joined by the welding process.
2. Welding arc – A welding process that is used to join metal to
metal by using electricity to create enough heat to melt
metal, and the melted metals, when cool, result in a joining of
the metals.
3. Covered electrode - A filler metal electrode used in shielded
metal-arc welding, consisting of a metal-wire core with a flux covering.
4. Core Wire – Core wire, also known as flux-cored wire, is a
type of welding wire that is consumed during the welding
process, meaning it melts and contributes to the weld
puddle.
5. Flux – Material used to prevent, dissolve, or facilitate removal of
oxides and other undesirable surface substances.
6. Molten pool – Refers to the part of the base metal that is
melted into a pool due to the heat of the welding arc. The
geometrical liquid metal part formed on the weldment during
welding is called the molten pool.
7. Shielding gas – Protective gas used to prevent atmospheric
contamination.
8. Slag – Welding slag is produced as a by-product of some arc
welding processes, most commonly shielded metal arc welding (also
known as stick welding or SMAW), electroslag welding, submerged
arc welding, and flux-cored arc welding (also known as FCAW). Slag
forms as a hardened layer of material on top of welds made using
these processes and is created from the melted flux they use.
9. Weld metal – The portion of a fusion weld that has been completely
melted during welding.
10. Heat affected zone – The “heat-affected zone” (HAZ) is
the area of metal that hasn’t been melted but has undergone
changes in properties due to exposure to high temperatures
during welding, located between the weld and the unaffected
base metal.
