SMAW Welding
Section 8
Unit 26
1
Arc Welding Safety
1. Recognize that arc welding produces a lot of
heat.
2. Use equipment according to manufacturers
recommendations.
3. Insure fire extinguishers are available
4. Provide a first aid kit
5. Use water filled containers to receive hot
metal from cutting operations.
6. Practice good housekeeping
7. Use appropriate PPE
2
Arc Welding Safety-cont.
7. Insure all wiring is correctly installed
and maintained.
8. Remove or shield all combustible materials
in work area.
9. Do not use gloves or clothing which contain
flammable substances
10.Protect others from arc flash.
11.Protect equipment from hot sparks.
12.Use a fume collector.
13.Never work in damp or wet area.
14.Shutoff power source before making repairs
or adjustments, including changing
electrode.
15.Don’t overload the welding cables or use
cables with damaged insulation.
3
Arc Welding PPE
Helmet
Shade 10 or darker
Face protection
Always wear safety glasses underneath
Auto helmet recommended
Clothing
Long sleeves
Button up shirt
Work shoes
Protective apron, sleeves, jackets or pants if
available. (Fig 26-6)
4
SMAW Process
• The arc temperature over 9,000 oF melts the base
metal, the wire core and the coating on the
electrode.
• The high temperature causes some of the
ingredients in the flux to form a gaseous shield.
• The electric energy is provided by a special power
source.
• As the weld cools slag forms on top of the weld
puddle.
5
SMAW Power Supplies
SMAW requires a constant current (CC) of either
DC or AC.
Some power supplies will supply both DC and AC.
Power supply capacity determines the maximum
diameter of electrode that can be used.
6
Equipment
Power Supply Polarity Switch Power
Cord
Electrode Holder
Power Switch
Electrode
Amperage
Adjustment
Amperage
Scale
Base Metal
(work Piece)
Ground Cable Ground Clamp
Electrode Cable
7
Open Circuit Voltage (OCV)
Open circuit voltage is the potential between
the welding electrode and the base metal when
the machine is on, but there is no arc.
The higher the OCV a machine has, the easier it
will be to strike an arc.
Only adjustable of dual control machines.
8
Arc Voltage
Arc voltage is the potential between the electrode
and the base metal when the arc is present.
Arc voltage is less than OCV.
Adjustable on dual control machines.
9
Polarity
The polarity of an object is its physical
alignment of atoms.
The term is often used to describe the positive
and negative ends of batteries and magnets.
The negative end has an excess of electrons
The positive end has a deficiency of electrons.
10
Five (5) Common Power
Supplies
Transformer
AC only
Rectifier
DC only
Transformer/rectifier
AC or DC
Generator
DC and/or AC
Inverter
AC and DC
11
Striking The Arc
Select the best
electrode
Set the welder (Fig 26-
8)
Turn on welder
Warn bystanders
Lower helmet
Start arc (two methods)
Brushing
Tapping
12
Brushing Method
Hold end of electrode about 1/4 -
1/2 inch above the surface.
Lower helmet
Gently brush surface of the metal
with the end of the electrode.
When arc starts, lift electrode 1/8
inch.
If electrode sticks, twist it back and forth. If it does not break loose,
release electrode from electrode holder.
Do not shut off the welder with the electrode stuck to the metal.
Recommended method for beginning weldors.
13
Tapping Method
Set up welder
Hold the electrode at
the travel angle and
1/4 - 1/2 inch above
the metal.
Quickly lower the
electrode until it
touches the metal and
then lift it 1/8
inch.
More difficult method to learn
14
Arc Welding Bead Nomenclature
Flux Electrode
Gas Electrode
Slag shield metal
Penetration
Base metal Bead Molten
puddle
15
Running Beads
Practice running stringer beads
No weaving or pattern.
Remember the electrode burns off as the weld is
made.
Speed used should result in a bead 2-3 times
wider than the diameter of the electrode.
Cool metal between beads.
Practice holding a long arc for a couple of
seconds after striking the arc.
Preheats the weld
Practice filling in the crater.
16
Five (5) Factors of Arc Welding
1. Heat
2. Electrode
3. Electrode angle
4. Arc length
5. Speed of travel
17
Five (5) Factors
1. Heat
The arc welder must produce sufficient heat (electric arc)
to melt the electrode and the base metal to the desired
depth.
The amount of heat produced is determined by the amperage.
Amperage is limited by the diameter of the electrode and the
capacity of the welder.
The amount of heat needed to complete the weld is
determined by several factors:
Thickness of the Excessive heat. Insufficient heat.
metal Electrode easier to Hard to start
Type of joint, start Reduced
Electrode type Excessive penetration
penetration
Electrode (burn through)
diameter Excessive bead width Narrow bead
Weld position Excessive splatter Coarse ripples
Electrode overheating
18
Five (5) Factors
2. Electrodes
The SMAW process uses Another useful group
a consumable of electrodes is
electrode.
hardsurfacing.
Electrode must be
compatible with base
NEMA color coding
metal. System of of colors
Electrodes are on the end or dots
available for on the bare wire
different metals. indicating the class
Carbon steels of electrode.
Low alloy steels
Not very common
Corrosion resisting
today.
steels AWS numerical coding
Cast irons Most popular method.
Aluminum and alloys
Copper and alloys
Nickel and alloys 19
American Welding Society (AWS)
Classification System
The AWS system
distinguishes the
tensile strength, weld
position and, coating
and current.
Manufactures may and do
use there own numbering
system and produce
electrodes that do not
fit in the AWS system.
20
Welding Currents
Not all electrodes are designed to work with
all currents.
Common SMAW currents.
Alternating Current (AC)
Direct Current straight polarity (DCSP) or (DCEN)
Direct Current Reverse polarity (DCRP) or (DCEP)
21
Arc Welding Electrode Flux
Flux: A material used during arc welding,
brazing or braze welding to clean the surfaces
of the joint chemically, to prevent atmospheric
oxidation and to reduce impurities and/or float
them to the surface. (British Standard 499)
Seven (7) Classifications of Flux constituents
– Protection from atmospheric contamination
– Fluxing agents
– Arc initiators and stabilizers
– Deoxidizes
– Physical properties of the flux
– Fillers and metallic additions
– Binders and flux strength improvers
22
Electrode Grouping
Electrodes are also grouped
according to there
performance - Fill-freeze
characteristics. • General purpose
Fast-freeze electrodes
• Mild steel • Characteristics of
• Quick solidification of weld fast-freeze and fast-
pool fill
• Deep penetrating Low hydrogen
• Recommended for out of • Welding
position welds characteristics of
• Deep penetrating arc fill-freeze
Fast-fill • Designed for medium
• carbon and alloy
Highest deposition rate
steels
• Stable arc
• Thick flux
• Flat position and horizontal
laps only
23
Selecting Electrode Size
The optimum electrode
diameter is A diameter of 3/32 or
determined by the 1/8 inch can be used on
thickness of the base
metal, the welding metals up to 1/4 inches
position and the thick without joint
capacity of the preparation.
welding power supply. ROT: the diameter of
A smaller diameter is
the electrode should
usually recommended for not exceed the
out of position welding. thickness of the metal.
When completing root
passes in V-joints, a
smaller diameter maybe
used and then a larger
diameter is used for the
filler passes.
24
Electrode Storage
Electrodes are damaged by rough treatment,
temperature extremes and moisture.
The should be kept in their original container
until used.
They should be stored in a heated cabinet that
maintains them at a constant temperature.
The storage of low hydrogen electrodes is very
critical.
Designed to reduce underbead cracking in alloy and
medium carbon steels by reducing the the amount of
hydrogen in the weld pool.
The flux is hydroscopic--attracts moisture (H 2O).
Moisture in the flux also causes excessive gasses to
develop in the weld pool and causes a defect in the
weld caused worm holes.
25
Five (5) Factors
3. Electrode Angle
The electrode angle
influences the placement of
the heat.
Two angles are important:
Travel
Work
The travel angle is the
angle of the electrode
parallel to the joint.
The correct travel angle must be used for each
joint.
Beads = 15o from vertical or 75o from the work.
Butt joint = 15o from vertical or 75o from the work.
Lap joint = 45o.
T joint = 45o.
Corner = 15o from vertical or 75o from the work.
26
Five (5) Factors
Electrode Angle-cont.
The work angle is the angle
of the electrode
perpendicular to the joint.
The appropriate angle must be used for
each joint.
Beads = 90o
Butt joint = 90o
Lap joint = 45o
T joint = 45o
Corner = 90o
The work angle may need to be
modified for some situations.
For example, a butt joint
with two different thickness
of metal.
27
Five (5) Factors
4. Arc Length
The arc length is the distance from the metal part of
the electrode to the weld puddle.
The best arc length is not a fixed distance, but
should be approximately equal to the diameter of the
electrode.
Arc length can be adjusted slightly to
change the welding process.
Excessive length
Excessive spatter
Reduced penetration
Poor quality weld
Insufficient length
Electrode sticks
Narrow weld
Poor quality weld
28
Five (5) Factors
5. Speed of Travel
The speed of travel (inches per minute) is an
important factor when arc welding.
The best speed of travel (welding speed) is
determined by several factors:
The size of the joint,
The type of electrode
The size of the electrode
The amperage setting on the machine
Deposition rate of the electrode (cubic inches
per minute)
The deposition rate of an electrode will change
with the welding amperage.
29
Five (5) Factors
5. Speed-cont.
The ideal speed can be
calculated using the volume of
the joint and the deposition
rate of the electrode.
Step one: determine the area
of the weld. (Assuming 1/16
inch penetration.)
1 0.25 in x 0.25 in 2
Area = bh = = 0.0625 in
2 2
Step Two: knowing the deposition rate of the
electrode,
€ determine the welding speed.
(Deposition rate = 2.5 in3/min.)
3
in 2.5 in 1 in
= x 2
= 40
min min 0.0625 in min
€
30
Five (5) Factors
5. Speed-cont.
The correct welding speed is indicated by the
shape of the ripples.
Too slow = excessive width,
excessive penetration
Too fast = narrower
width, elongated ripple
pattern, shallow
penetration.
Recommended = width 2-3 times
diameter of electrode, uniform
ripple pattern, full
penetration.
31
SMAW Joints
32
Square Groove
A butt joint can be completed with a groove
welded on metal up to 1/8 inch thick with a
single pass on one side, with no root opening.
Electrode manipulation should only be used to
prevent burning through.
33
Square Groove Thicker Metal
A groove weld on metal up to 1/4 inch thick can
be welded with a single pass on one side but,
if possible, it should be completed with a
single pass on both sides.
Metal this thick requires a root opening to
achieve adequate penetration.
Electrode manipulation will reduce penetration.
34
Single V Groove Weld
Butt joints on metal greater than 1/4 inch thick
require joint preparation.
Note that the groove does not extend all the
way. A short distance, called the root face, is
left undisturbed.
The amount of joint preparation is dependent on
the diameter of the electrode and the amperage
capacity of the power supply.
Several different combinations of passes can be
used to complete this joint.
Note: this is the principle use of pattern beads.
35
T-Joints
36
Information
In a T-joint the two welding surfaces are at an
angle close to 90 degrees from each other.
The welding side and number of passes uses
depends on the thickness of the metal, the
welding access and capacity of the power
supply.
Common joints include.
Plane T
T with joint gap
Single preparation
Double preparation
37
Plane T-Joint
The plane T joint is very useful for thin
metal.
Can be completed at angles other than 90
degrees.
Can be completed with metal of different
thickness.
The work angle must be changed to direct more
heat to the thicker piece.
38
T-joint--Thicker Metal
When the metal thickness exceeds 1/8 inch the
recommendation is to gap the joint.
Improves penetration
May not be necessary if larger diameter electrode is
used and sufficient amperage is available.
The need for a joint gap varies with the type of
electrode, but should not exceed 1/8 inch.
39
T-joint Single Single Bevel
As with other
joints, thicker
metal must have
joint
preparation to
achieve full
penetration with
smaller diameter
electrodes.
Several different preparations can be used. A
popular one is the bevel.
A bevel can be completed by grinding or cutting.
The bevel joint can be completed with electrode
manipulation or no electrode manipulation.
When when electrode manipulation is used to fill
the joint, the first pass should be a straight
bead with no manipulation.
40
T-joint Double Bevel
The double bevel T-joint is recommended for metal
1/2 inch thick and thicker.
The root passes should be with not manipulation,
but the filler passes can be completed with either
straight beads or patterns beads.
Alternating sides reduces distortion.
41
Weld Defects
42
Common SMAW Defects
Under Cutting Porosity
Hot Cracks
Slag Inclusions
Hot cracks
Caused by excessive Undercutting
contraction of the metal improper welding
as it cools. parameters;
particularly the travel
Excessive bead size
speed and arc voltage.
May also be found at the Porosity
root of the weld. Atmospheric
Slag inclusions contamination or excess
Long arc gas in the weld pool.
Incomplete removal of
slag on multipass welds. 43
SMAW Weld Defects-cont.
Incomplete fusion
Microcracks Toe cracks
Underbead cracks
Toe Cracks
Excessive heat and rapid cooling.
Underbead cracks
Excessive hydrogen in weld pool
Microcracks
Caused by stresses as weld cools.
Incomplete fusion
Incorrect welding parameters or welding techniques.
44
Questions
45
