Grade

11

TVL-IA
SHIELDED METAL ARC WELDING
NCI

QUARTER II – Module 1-Week 1

WELD CARBON STEELPLATE USING SMAW

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 Set-up Welding Machine

OBJECTIVES:
1. Identify welding machine parts based on manufacturer’s
Manual.
2. Perform proper setting of welding machine according to
manufacturer’s manual.

INTRODUCTION:

PRINCIPLES OF 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 welding.
Thin 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.
Welding Current
 The arc that is produced during SMAW is current that jumps across the gap from the tip of the
electrode to the surface of the workpiece.
 If the electrode tip is touched and held against the workpiece instead of allowing for a gap
between the two, the electrode will pass the electricity directly to the workpiece without creating
an arc.
Types of Welding current
 SMAW welding machines are designed to produce an output of constant current (cc).
 The current may be AC or DC.
 The type of current used depends on the type of welding being done and/or the equipment being
used.
AC Welding Current
 Alternating current (AC) in welding machines is derived from either a transformer-type machine or
an alternator-type machine.
 The transformer changes high-voltage, low current AC power to low voltage, high-current power
for welding.
 The alternator uses an electric or fuel driven motor to turn a rotor inside a number of
electromagnets to produce the welding current.
DC Welding Current
 Direct welding current (DC) has no frequency.
 Direct current in welding is derived either from a transformer-rectifier type system or from a
generator.

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  In a transformer-rectifier type system, AC voltage first is reduced (transformed) to lower voltage
level through the application of a transformer and then converted (rectified) into DC voltage
 Most engine driven SMAW welding machines produce DC current through a generator.
Polarity
 Polarity only applies to DC current.
 Polarity in welding is determined by the way the welding leads are connected to the welding
machine.
 The universally accepted theory is that DC current always travels from the negative to the positive
pole.
 The plus marked terminal on the welding machine is the positive terminal.
 The minus marked terminal on the welding machine is the negative terminal
 DCEN generates more heat in the work piece than at the electrode and is used for GTAW
 DCEP puts more heat at the electrode than at the work piece.
Characteristics of Welding Current
 The voltage in a welding machine, whether the machine is connected to commercial power or
driven by an engine, is reduced or stepped down by a transformer called a step-down transformer.
 The step-down transformer reduces the voltage level and raises the current level.
Voltage
 Operating voltage, or arc voltage, is the voltage measured after the arc is struck.
 The higher open-circuit voltage is required to establish the arc because the air gap between the
electrode and the work has higher resistance to current flow.
 Once the arc is established, less voltage is needed.
Amperage
 Amperage is a measurement of the electric current flowing in a circuit.
 The unit of measurement for current is the ampere (amp or A).
 The number of amps produced by the welding machine determines the amount of heat available
to melt the electrode.
 The current is increased or decreased according to the size of the electrode being used and the
position in which the welding is being performed.
SMAW Machine Classifications
 SMAW machines are classified by the type of welding current they produce: AC, DC, or AC/DC
 Welding machines that produce only DC welding voltage and current can be further classified by
the characteristics of the welding current they produce.
SMAW Machine Types
 Several different type of basic SMAW welding machines are available.
 They include:
• Transformers
• Transformer-rectifiers
• Inverter
• Engine driven generators
 Transformer, transformer-rectifiers, and electric motor generators all require electrical power from
commercial power lines to operate called the primary current.
 The primary power required for this type machine is 240-volt single-phase or 480-volt three-phase.
Transformer Welding Machines
 Transformer welding machines without rectifiers produce AC welding current.
 They use a voltage step-down transformer, which converts high-voltage, low-amperage current
from commercial power lines to low-voltage, high-amperage welding current.
 Special light-duty transformer welding machine s used for sheet metal work are designed to be
plugged into 120-volt outlet.
 However, most light-duty transformer welding machines operate more efficiently on 240V primary
power.
 A transformer welder called a buzz box has an ON/OFF switch, an amperage control and weld lead
terminals.

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Transformer-Rectifier Welding machine
 A rectifier is a device that converts AC current to DC current.
 Depending on their size, transformer-rectifier machines require 240-volt three-phase or 480-volt
three-phase.
 Multiple transformer rectifiers are available grouped into a single cabinet called a pack.

Inverter Power Source


 Inverter power sources increase the frequency of the incoming primary power.
 This provides a smaller, lighter power source.
 An inverter supports both GTAW and SMAW processes

Engine Driven Generator and Alternator Machines

 Engine-driven generators often have an auxiliary power unit to produce 120-volt current for
power tools and lighting.
 When 120-volt current is required the engine must run at welding speed.
 Engine-driven weld machines have engine control and welding current controls.
 Some of the basic controls are:
 Starter
 Voltage gauge
 Temperature gauge
 Fuel gauge
 Hour meter
 Many engine-driven machines are mounted on trailers, which makes them portable so they can
be used in the field.

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SMAW Machine Ratings
 The size of a welding machine is determined by the amperage output of the machine at a given
duty cycle.
 The duty cycle of a welding machine is based on a ten-minute period.
 It is the percentage of ten minutes that the machine can continuously produce its rated amperage
without overheating.
 For example:
A machine with a rated output of 300A at 60% duty cycle can deliver 300A of welding current for six
minutes out of ten without overheating.
 The duty cycle of a welding machine will be 10%, 20%, 30%, 40%, 60%, or 100%.
 If the amperage is set below the rated amperage, the duty cycle will increase.

SUMMATIVE TEST
TEST I
Multiple Choice: Read and analyze the statement carefully. Choose the best answer and write the letter
only in your answer sheet.
1. Is a process which melts and joins metals by heating them with an arc between a coated metal electrode
and the work piece.
a.GTAW b. SAW c. GMAW d. SMAW
2. The electrode outer coating is called.
a. Flux b. Filer metal c. Core d. Arc
3. When the electrode is moved along the workpiece at the correct speed the metal deposits in a uniform
layer called a.
a. Bead b. Weaving c. Core d. Arc
4. The arc that is produced during SMAW is current that jumps across the gap from the tip of the electrode
to the surface of the work piece.
a. Welding Current b. AC Welding Current
c. DC Welding Current d. Polarity
5. Is derived from either a transformer-type machine or an alternator-type machine.
a. Welding Current b. AC Welding Current
c. DC Welding Current d. Polarity
6. Is derived from either a transformer-type machine or an alternator-type machine.
a. Welding Current b. AC Welding Current
c. DC Welding Current d. Polarity
7. Is determined by the way the welding leads are connected to the welding machine.
a. Welding Current b. AC Welding Current
c. DC Welding Current d. Polarity
8. They use a voltage step-down transformer, which converts high-voltage, low-amperage current from
commercial power lines to low-voltage, high-amperage welding current.
a. Transformer Welding Machines
b. Transformer-Rectifier Welding machine
c. Inverter Power Source
d. Engine Driven Generator and Alternator Machines
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9. A rectifier is a device that converts AC current to DC current.
a. Transformer Welding Machines
b. Transformer-Rectifier Welding machine
c. Inverter Power Source
d. Engine Driven Generator and Alternator Machines
10. This provides a smaller, lighter power source.
a. Transformer Welding Machines
b. Transformer-Rectifier Welding machine
c. Inverter Power Source
d. Engine Driven Generator and Alternator Machines

TEST II
Directions: Arrange the letters to form word or related to Set-up welding machine. Write your answer to
the space provided.

1. EGATLOV= __________________________
2. TRRENCU= ____________________________
3. ATIYPALOP = ____________________________
4. TICKS INGDLEW= _____________________________
5. ECTRID ENTRRUC= ______________________________
6. ANATTALINGE NURRECT = ______________________________
7. RETRIVEN= ______________________________
8. REANRTOMESF = ______________________________
9. TIERCREIF = _____________________________
10. CAR LEWDGNI=______________________________
TEST III

PERFORMANCE TASK

1. How do you set up a welding machine?

2. Why current setting is important to welding?

REFERENCES:

1.CBLM, TESDA
2.Welding Technology, Second Edition by Gower A. Kennedy
3. Welding Inspection Technology, Education Department, American welding Society
4.Welding Principles and Application by Larry Jeffus and Harold V. Johnson