Shielded Metal Arc
Welding (SMAW)
Learning Outcomes
Students can understand the working principle and design
steps for joining products using shield metal arc welding
(SMAW) and oxy-acetylene gas welding (OAW)
Introduction
▪ What is the basic difference between ECM, EDM dan
SMAW
The Basic Principle of
SMAW
▪ An electric arc is created between
the electrode and the base metal
▪ An electric arc will generate heat
to melt the electrode and base
metal.
▪ Molten metal will be protected by
solidified slag and fumes from
flux coating.
SMAW
SMAW
The Basic Component of SMAW
• Power supply can be AC or
DC
• Electrode holder
• Accessories (helmets, jackets,
gloves, shoes etc.)
Typical Fusion Weld Join
Heat Affected Zone (HAZ)
Solidification of the Weld
Metal
Deep penetration Shallow penetration
The grain structure and size depend on
1. Specific alloy
2. Welding process
3. The type of Filler metal
Residual Stresses
Developed During Welding
Advantage of AC vs. DC
Welding
No AC Welding DC Welding
1 Lower equipment and maintenance The electric arc produced is stable for
cost small currents and small electrode
diameters.
2 Wires of workpiece and electrodes Can use all types of electrodes, a
can be exchanged, but it does not positive electrode for deep penetration
affect the weld result. and a negative electrode for shallow
penetration
3 Small arc flame to reduce the Can be used for welding thin plates.
incidence of porous on the weld
ribs.
4 Arc blow is rare in this machine The electric arc is easy to initiate, and a
short arc is easy to maintain.
5 Medium deep penetration (between Less weld spatter was generated for
positive and negative electrode) the DCRP type.
Advantage of AC vs. DC
Welding
No AC Welding DC Welding
6 Heat is evenly distributed Heat is uniformly distributed
between the electrode and the
working material.
The welding DC machine is classified into:
1. DCSP (Direct Current Straight Polarity) / DCEN (Direct Current Electrode
Negative) ➔ Workpiece(+) electrode (-), 1/3 heat occurs at the electrode and
2/3 heat occurs in the workpiece
2. DCRP (Direct Current Reverse Polarity) / DCEP (Direct Current Electrode
Positive) ➔ Workpiece(-) electrode (+), 2/3 heat occurs at the electrode and
1/3 heat occurs in the workpiece
DCEP vs. DCEN
Direct Current Straight
Polarity (DCSP/DCEN)
No Advantage Disadvantage
1 Elimination of insufficient melting Need arc cleaning action
(lack of penetration, high
reinforcement, etc.)
2 Suitable for material with high High distortion
melting point
3 Suitable for certain electrode High residual stress
(EXXX2 and E6012)
4 Cutting action in thin plate, not joining
5 Not suitable for metal with low metal
point
6 Low-rate of metal deposition
Direct Current Reverse
Polarity (DCRP/ DCEP)
No Advantage Disadvantage
1 Better arc cleaning action Life of electrode reduces
2 High volume deposition rate High reinforcement ➔ causes wastage
of filler metal
3 Preferred for thin plate joining Insufficient melting and Lack
penetration
4 Suitable for joining metal having Not suitable for metal with high metal
lower melting point point
Main Equipment of SMAW
The function of electrode in
SMAW
1. As a protective arc welding from the influence of the atmosphere, such as
oxygen, nitrogen, and air.
2. Prevents ionization at the tip of an electrode.
3. Keeping the bow steady
4. Produce slag and slag
5. As a blending element
6. To control the electrode fluid
7. To control the penetration of welded joints
8. To control the profile or contour of the weld, especially in the welding process
that uses added materials (filler metal).
Parts of Electrode
▪ The axis of the electrode is a filler metal that melts in an electric arc
together with the working piece material and then solidifies to form a
weld seam.
▪ The electrode cover (flux) decomposes within the electric arc. It
produces a CO2 gas shield and a solid layer. It protects the weld seam
being formed against the damaging effects of the surrounding air
Weld Slag
Electrode characteristic
Choosing electrode
Arc shielding
▪ Metals are chemically significantly reactive
to oxygen, nitrogen, hydrogen, and air at
high temperatures.
▪ If this happens, the mechanical properties
of the connection will be degraded.
▪ Therefore, we need arc shielding in gas,
flux (such as argon), helium, and other inert
gases.
▪ In addition, arc shielding serves to stabilize
the arc and reduce spattering
Electrode Holder & work
clamp
▪ The electrode holder holds the end of the
electrode (not covered part) to control the
electrode's motion, and the electric current
flows smoothly.
▪ The mouth must be clean so that the
resistance is small and the current flows
easily.
▪ Clamping pliers are used to connect the
workpiece to a power source.
Supporting Equipment of
SMAW (1/2)
▪ The welding hammer serves to remove the "weld spatter" on the
surface of the workpiece.
▪ Wire brush to clean the workpiece to be welded from the slug.
Remove Wels Spatter
Supporting Equipment of
SMAW (2/2)
Clamping pliers move hot workpieces after welding
Safety Equipment
Filter Lenses
Welding Procedure : Turn on and
off the welding arc (1/2)
▪ scratching method
Welding Procedure : Turn on and
off the welding arc (2/2)
▪ Tapping method
Welding Procedure: Joining
process
▪ Cleaning slag/weld spatter The electric arc is ignited at
approximately 1/2 inch from the target.
▪ The electrode is moved to the weld crater. The seam is
filled at the same volume at each point.
Welding Procedure: movement
of electrode
Welding Pattern Training
(1/2)
Welding Pattern Training
(2/2)
Welding Procedure:
connection planning
Welding Procedure: welding
position (angle)
Fillet Welds Angle
Welding Procedure: welding
position (groove)
Groove Welds Angle
Advantages of SMAW
▪ Can be used anywhere, outside, workshop & in the water
▪ Can weld various types of materials
▪ Quick set-up and very easy to set up
▪ Can be used to weld all positions
▪ Electrodes are easily available in many sizes and diameters
▪ The equipment used is simple, inexpensive and easy to carry anywhere.
▪ Low noise (rectifier)Less sensitive to corrosion, oil & grease
Disadvantages of SMAW
▪ (Consumable electrode) Welding is limited to the length of the
electrode and must make connections when it runs out
▪ Every time you do the next welding, the slag must be cleaned.
▪ Cannot be used for welding non-ferrous steel materials.
▪ Oxidation is easy due to molten metal shielding only the welding arc
from the flux.
▪ The diameter of the electrode depends on the plate thickness and
the welding position.
Electrode Angel
Arc Length and Travel
Speed
Arc Welding
Poor Weld Characteristic
Good Weld Characteristic
Defects on SMAW
Defects on SMAW
Incomplete Fusion
Defects on SMAW
Defects on SMAW
Defects on SMAW
Undercutting
Crack On Welding
Welding Test: Destructive
Techniques – Tension shear test
Welding Test: Destructive
Techniques – Bending test 1
Welding Test: Destructive
Techniques – Bending test 2
Using 3 points transverse bending
Welding Test - Fracture
Toughness Test
▪ Fracture toughness tests commonly utilize the impact
testing techniques.
▪ Charpy V-notch specimens are prepared and tested for
toughness.
▪ Other toughness tests include the drop-weight test in
which the energy is supplied by a falling weight.
Welding Test – Corrosion
and Creep Test
▪ Because of the difference in the composition and
microstructure of the materials in the weld zone,
preferential corrosion may take place in it.
▪ Creep tests are important in determining the behavior of
welded joints at elevated temperatures.
▪ Testing weld hardness may also be used to indicate weld
strength and microstructural changes in the weld zone.
Spot Welding Test
Welding Test –
Nondestructive Test
▪ Radiographic,
▪ Magnetic particle,
▪ Liquid penetrant,
▪ Ultrasonic testing methods.
General Guide Line For
Welding (1/2)
General guidelines for weld design and weld process selection
1. The design should minimize the number of welds to avoid excessive
stress and stress concentration in the structure.
2. The edge of the part to be welded must be completely prepared,
especially the workpiece resulting from sawing, shearing, flame
cutting etc.
3. The size of the weld bead should be kept to a minimum to avoid
interference with further processing
General Guide Line For
Welding (2/2)
Standard Identification and
Symbol For Welding
