Principles in
Shielded Metal Arc
Welding (SMAW)
Shielded Metal Arc Welding (SMAW) or Stick
welding is a process which melts and joins metals
by heating them with an arc between a coated
metal electrode and the workpiece. The electrode
outer coating, called flux, assists in creating the arc
and provides the shielding gas and slag covering to
protect the weld from contamination. The electrode
core provides most of the weld filler metal.
When the electrode is moved along the workpiece
at the correct speed the metal deposits in a uniform
layer called a bead.
The Stick welding power source provides constant
current (CC) and may be either alternating current
(AC) or direct current (DC), depending on the
electrode being used. The best welding
characteristics are usually obtained using DC
power sources.
The power in a welding circuit is measured in
voltage and current. The voltage (Volts) is governed
by the arc length between the electrode and the
workpiece and is influenced by electrode diameter.
Current is a more practical measure of the power in
a weld circuit and is measured in amperes (Amps).
The amperage needed to weld depends on
electrode diameter, the size and thickness of the
pieces to be welded, and the position of the
[Link] metals require less current than thick
metals, and a small electrode requires less
amperage than a large one.
It is preferable to weld on work in the flat or
horizontal position. However, when forced to weld
in vertical or overhead positions it is helpful to
reduce the amperage from that used when welding
horizontally. Best welding results are achieved by
maintaining a short arc, moving the electrode at a
uniform speed, and feeding the electrode
downward at a constant speed as it melts. More
specific information on the Stick welding procedure
is provided in the following sections.
Typical stick welding Set-Up
Welding current starts as soon as electrode touches
the workpiece. ! Weld current can damage electronic
parts in vehicles. Disconnect both battery cables
before welding on a vehicle. Place work clamp as
close to the weld as possible. Always wear
appropriate personal protective clothing.
1) Workpiece Make sure workpiece is clean before
welding.
2) Work Clamp Place as close to the weld as
possible.
3) Electrode Before striking an arc, insert an
electrode in the electrode holder. A small diameter
electrode requires less current than a large one.
Follow recommendations of the electrode
manufacturer when setting weld amperage
4) Insulated Electrode Holder
5) Electrode Holder Position
6) Arc Length Arc length is the distance from the electrode to the
workpiece. A short arc with correct amperage will give a sharp,
crackling sound. Correct arc length is related to electrode
diameter. Examine the weld bead to determine if the arc length is
correct. Arc length for 1/16 and 3/32 in. diameter electrodes should
be about 1/16 in. (1.6 mm); arc length for 1/8 and 5/32 in.
electrodes should be about 1/8 in. (3 mm).
7) Slag Use a chipping hammer and wire brush to remove slag.
Remove slag and check weld bead before making another weld
pass.
Electrode And Amperage Selection
Chart
Striking An
Arc −
Scratch
Start
Technique
Welding current starts as soon as electrode touches the
workpiece. The scratch-start technique is preferred for ac
welding.
1) Electrode
2) Workpiece
3) Arc Drag electrode across workpiece like striking a
match; immediately lift electrode slightly after touching
work. If arc goes out, electrode was lifted too high. If
electrode sticks to workpiece, use a quick twist to free it.
Striking An
Arc −
Tapping
Technique
Welding current starts as soon as
electrode touches the workpiece.
1) Electrode
2) Workpiece
3) Arc Bring electrode straight down to
workpiece; then lift slightly to start arc.
If arc goes out, electrode was lifted too
high. If electrode sticks to workpiece,
use a quick twist to free it
Positioning
Electrode Holder
After learning to start and hold an arc, practice running
beads of weld metal on flat plates using a full electrode.
Hold the electrode nearly perpendicular to the work,
although tilting it ahead (in the direction of travel) will be
helpful. To produce the best results, hold a short arc, travel
at a uniform speed, and feed the electrode downward at a
constant rate as it melts.
Electrode
Movement
During
Welding
A single stringer bead is satisfactory for most narrow
groove weld joints; however, for wide groove weld
joints or bridging across gaps, a weave bead or
multiple stringer beads work better. 1 Stringer Bead −
Steady Movement Along Seam 2 Weave Bead −
Side To Side Movement Along Seam 3 Weave
Patterns Use weave patterns to cover a wide area in
one pass of the electrode. Limit weave width to a
maximum of 2-1/2 times diameter of electrode
