Experiment No 2

SHIELDED METAL ARC-WELDING (SMAW)

INTRODUCTION
Shielded metal arc welding (Stick welding, Manual metal arc welding) uses a metallic
consumable electrode of a proper composition for generating arc between itself and the
parent work piece. The molten electrode metal fills the weld gap and joins the work pieces.
This is the most popular welding process capable to produce a great variety of welds.

The electrodes are coated with a shielding flux of a suitable composition. The flux melts
together with the electrode metallic core, forming a gas and a slag, shielding the arc and the
weld pool. The flux cleans the metal surface, supplies some alloying elements to the weld,
protects the molten metal from oxidation and stabilizes the arc.
The slag is removed after Solidification.

Objective

To use the skill to do the welding used the knowledge and understanding of the theories
and also techniques discussed within the topics into the practical application.

Working Principle
SMAW is carried out closely just as other arc welding processes. It also uses an AC or DC
power supply that transfers current to the electrode holder in order to produce an arc
leading to intense heat to melt the tip of the electrode and the joining portion of the
workpiece with the arc.
Equipment
 Power Supply
 Workpiece Clamp
 Electrode Holder
 Protective Shield
 Flame Retardant Clothing
Power Supply
Two types of supply:
 Alternating current (AC) welders.
 Direct current (DC) welder.
 Wider variety of electrode available.
 Better for welding thin metals.
DC straight polarity (DC-EP) has electrode negative and workpiece positive. Produce high
electrode melting rate.

Figure 1: Power Supply (SMAW)

Protective Shield
Provides full facial protection from:
 Sparks and flying metals.
 Intense light from arc.
 Ultra-violet light.
 Infrared red.

Electrodes
 Common electrodes used in Stick welding are 6010, 6011, 6013, 7018 and
7024.
 The most common diameters ranging from 1/8- to 5/32-in.
 Fig no 2 welding electrodes

Electrode Holder
 Grips the electrode.
 Handles and clamp are insulated.
 Grooves in the clamp enable changing the position of electrode.

Fig no 3 electrode holder

Wire Brush
 Wire brush is used for cleaning rust and removing paint.
 It is also used to clean surfaces and to create a better conductive area for
attaching electrical connections.
Work piece Clamp
Complete the electric circuit from power supply, through the electrode across the arc through the
workpiece and back to the power supply.
Should be firmly attached to workpiece or worktable .

Fig no4 work piece clamp

The Variables of SMAW:

Different variables effect during the welding and the welder has control before and
during welding.

1. Welding Current:
The welding current or amperage is essential to producing welds with good
appearance and the required strength characteristics. The welder controls the amperage
variable by setting the amperage on the welding machine prior to welding.
Welding Current increases with increase in electrode size. The current increases with
coating thickness.
 Effects of high current:
 Spatter occurs in large drops alongside the weld.
 Bead is too wide too thin and undercut at edges.
 Flux melts too rapidly runs off the top of the weld.
 Effects of low current during weld:
 Inadequate penetration (weak weld).
 Difficulty in striking arc.
  Arc goes out often and difficulty in maintaining the arc.

2. Arc Length:

 Arc length should be as short as possible. Too long arc dissipates the heat
into the air increases spatter & slows down the speed of welding.
 It also results in Nitrogen pick up by the weld metal. In DC welding a long
arc is more susceptible to arc blow than a short arc.

3. Angle of Electrode:
In the Shielded Metal Arc Welding process there are two electrode angles that the
welder must control. The first angle is the one formed between the electrode and the base
metal, called the work angle. The second angle is the angle the electrode is held at relative
to the direction of travel, called the travel angle.
The travel angle for the flat horizontal and overhead can be either pulled or pushed and
the travel angle for the vertical can be either upward or downward.

4. Speed of Travel:
The rate of travel across the joint is controlled by the welder during welding and greatly
affects the appearance and strength characteristics of the weld.
The amount of weld metal deposited (weld deposition rate) and the travel speed may vary
with the type and size of electrode being used. The correct weld speed will result in a well-
formed weld bead that shows good fusion penetration and a gradual transition of weld
metal into the corners of the joint.

5. Selection of Electrode:
There are a variety of electrodes available for welding a wide range of metals. The
electrode for a given application must be selected carefully to provide the strength
characteristics required for the weld joint. One of the most useful tools for electrode
selection is the Electrode. In general the electrode weld metal must be matched to the type
and composition of the base metal being welded.

Operations
I. Shielded metal arc welding (SMAW) is a fusion welding process that uses a
consumable, flux-coated electrode to create an arc between the electrode and the
work piece. Molten metal travels from the electrode via the electrical arc and is
deposited into the work piece.
 II. The flux coating is also melted and it surfaces on top of the molten weld pool in the
form of slag.
III. Shielded metal arc welding is one of the oldest arc welding processes and is one of
the simplest and affordable welding processes that can be used to make quality
weldments.
IV. This is due to the simplicity of the equipment needed for shielded metal arc welding.
V. All the process requires is a constant current power source, an electrode, an
electrode holder, a ground clamp and a work piece.

Discussion:
1. Porosity:
 Porosity in welds may be caused by:

 Gases released during melting of the weld area, but trapped during solidification.
 Chemical reactions during welding.
 Porosity can be reduced by:
 Proper selection of electrodes and filler metals.
 Improved welding techniques such as preheating the weld area or increasing
the rate of heat input.
2. Slag Inclusions:

 Slag inclusions are compounds such as oxides fluxes and electrode coating materials
that are trapped in the weld zone.

3. Incomplete Penetration and fusion:

 Incomplete fusion produces poor weld beads. A better weld can be obtained by
the use of the following practices:

 Raising the temperature of the based metal.

 Cleaning the weld area before welding.
 Changing the type of electrode used.
  Providing sufficient shielding gas.

CONCLUSION
As conclusion the objective can achievable to do the practical welding. The student must
have skill to do the welding used the knowledge and understanding of the theories, and
also welding techniques are applied in the practical welding. The practical task has been
complete and the report will be accomplished to prove the student can be do the practical
task of Shielded metal arc-welding (SMAW).

Advantages of Shielded metal arc welding

1. Lower equipment cost than GTAW, FCAW and GMAW. (No bottle, gas hose,
flowmeter, and tig rig/Wire feeder needed.
2. Quick Change from one material to another.
3. The process lends itself to welding in confined spaces and various positions with few
problems.
4. Deposition Rates faster than GTAW Manual
5. Easy to move from one location to another. No Wire Feeder and Bottle.
6. Some special electrodes are made for cutting/gouging
7. Requires no outside shielding gas and can be used outdoors in light to medium wind.

Disadvantages of Shielded metal arc welding

1. Low deposition rate compared to GMAW/FCAW.
2. Filler metal cost per weld can be greater due to a low deposition efficiency that can
vary greatly with stub length.
3. Production factor is typically lower (Unless welding on various materials) due to rod
changes and chipping slag.
4. Needs more hand eye coordination than GMAW/FCAW.
5. Slag must be removed as compared to GTAW/GMAW