Shielded Metal Arc Welding

Shielded Metal Arc
Welding
By HARDISH TRIVEDI
PRESENTED BY: HARDISH

TRIVEDI 1
What Is Welding ?
Process of joining metals / alloys
The process performed by Heat with or

without Pressure
Filler metal may or may not be used
The joint will be homogeneous

TRIVEDI 2
Classification Of Welding
1 Pressure Welding – With Heat

& Pressure
2 Fusion Welding – With Heat &

mostly with Filler

TRIVEDI 3
Pressure Welding Process
Metal parts heated to forging

temperature
Heating by Oven, Oxy fuel flame or
Electric Resistance
Pressure applied on heated parts – by
Hammer, Hydraulic Press or Mechanical
lever
The Parts remain permanent
homogeneous joint
TRIVEDI 4
Types Of Pressure
Welding
Forge Welding
Resistance Butt / Flash Butt / Stud
Welding
Resistance Spot Welding
Resistance Seam welding

TRIVEDI 5
Fusion Welding Process
Metal parts locally heated to melt along the
joint.
Heating by oxy fuel flame or electric Arc.
Invariably filler metal added to molten pool.
On cooling, molten puddle solidifies to

permanent homogeneous joint.
TRIVEDI 6
Types Of Fusion Welding
Shielded Metal Arc Welding- SMAW

Gas Tungsten Arc Welding - GTAW
Gas Metal Arc Welding – GMAW (MIG / MAG / FCAW)
Submerged Arc Welding – SAW
Gas welding – Oxy Fuel Gas
Electron Beam Welding - EBW
Thermit Welding

TRIVEDI 7
SMAW Process
+
Core Wire
An electric Arc struck
between electrode and base
metal joint Flux
Base metal melts under arc Coating
Electrode tip melts in drops
and transfers to molten pool
of BM
Electrode with Arc moves Pool
along the joint keeping Arc
constant arc length _
Base Metal
On cooling pool solidifies
TRIVEDI 8
Equipment, Accessories &
tools
Power Source
Welding Cables, Holder & Earthing

Clamp
Head Screen, Hand gloves,

Chipping Hammer & Wire Brush
TRIVEDI 9
Types Of Power Source
Inverter- DC
Thyristor – DC
Diesel Generator Set -DC
Rectifier – DC
Transformer - AC

TRIVEDI 10
Characteristic Of Power
Source
Manual welding Machine welding
Drooping – Cons. A Linear – Cons. V
V V
V1
Vertical Horizontal
V2
Curve Curve
V1
V2
A A
A1 A2 A1 A2

TRIVEDI 11
Electrode
Consumable
Metallic Wire Coated with Flux
Conducts Current and generates Arc
Wire melts & deposited as filler in joint

TRIVEDI 12
Flux Coating On Electrode
Sodium Chloride
Potassium Chloride
Titanium Dioxide
Sodium Silicate
Ferrosilicon
Iron Powder
Alloying Elements
Binding Material
TRIVEDI 13
Function Of Flux In
welding
Stabilizes Arc
Prevents contamination of weld metal
Cleans the weld from unwanted impurities
Increases fluidity of molten metal
Generates inert gas shielding while metal
transfers

TRIVEDI 14
Function Of Flux In
welding
Forms slag after melting & covers weld
Allows deposited metal to cool slowly
Introduces alloying elements in the weld
Increases deposition efficiency
Minimizes the spatter generation
Helps in even & uniform bead finish

TRIVEDI 15
CS & LAS Electrode Sizes
& Recommended Currents
No Core Wire (in mm) Gage Current Time Average
required for electrodes
Dia Length burning in consumed in
seconds 8 Hrs shift
1 2 300 14 40 – 60 A 50-55 ---

2 2.5 350 12 60 – 85 A 60-65 ---
3 3.15 450 10 100 – 130 A 80 -85 120 - 140
4 4 450 8 130 – 180 A 85-90 110 - 120
5 5 450 6 150 – 210 A 90-95 80 - 90
6 6.3 450 4 240 BY:

PRESENTED – 250 A
HARDISH95-100 60 -70
TRIVEDI 16
Appx. Cost Of CS & SS
Electrodes
Electrode AWS Core Wire ( in mm ) Cost Per Piece
Quality Classification Dia Length ( in Rupees)
CS E6013 3.15 450 3.00

E7018 3.15 450 6.30
SS E308L 3.15 350 22.30
E309 3.15 350 31.60

TRIVEDI 17
ASME Classification Of
Electrodes
SFA 5.1
E 7018
E = Electrode
70 = UTS in 1000 psi ( 60/70/80/90/100/ 110)
1 = Position (1= all, 2= 1G, 1F & 2F, 3= 1G &
1F)
8 = Type of coating (0,1,2,3,5,6,8)

TRIVEDI 18
Baking Of Basic Coated
Electrodes
Bake the loose electrodes in a baking Oven
Baking Temperature 250° C to 300° C
Baking Time 2Hrs to 3 Hrs
Reduce the temperature to 100° C
Hold the electrodes at this temperature till use
Unused / left over electrodes to be re-baked

TRIVEDI 19
Why Baking?
To remove the moisture (H2O) from

coating to avoid possible cracking of
weld

TRIVEDI 20
How Does Moist Electrode
Generate Crack Within Weld?
Moist electrodes introduce atomic hydrogen at high
temperature in weld
On cooling, atomic hydrogen try to form molecules
The reaction results in stresses and fine cracks
Cracks occur within hardened metal - HAZ
Known as “Hydrogen Embrittlement” , “Under Bead
Crack”, HIC, Delayed Crack, Cold Crack.

TRIVEDI 21
Important Terminologies used
in Critical Welding Operation
Preheating
Post Heating or Dehydrogenation
Intermediate Stress leaving
Inter pass Temperature
Post Weld Heat Treatment

TRIVEDI 22
What Is Preheating?
Heating the base metal along the weld joint to a
predetermined minimum temperature
immediately before starting the weld.
Heating by Oxy fuel flame or electric resistant
coil
Heating from opposite side of welding wherever
possible
Temperature to be verified by thermo chalks
prior to starting the weld

TRIVEDI 23
Why Preheating?
Preheating eliminates possible cracking of
weld and HAZ
Applicable to
 Hardenable low alloy steels of all thickness
 Carbon steels of thickness above 25 mm.
 Restrained welds of CS & LAS of all thickness
Preheating temperature vary from 75°C to

300°C depending on hardenability of
material, thickness & joint restraint
TRIVEDI 24
How does Preheating
Eliminate Crack?
Preheating promotes slow cooling of

weld and HAZ
Slow cooling softens or prevents
hardening of weld and HAZ
Soft material not prone to crack even in
restrained condition

TRIVEDI 25
What Is Post
Heating/Dehydrogenation?
Raising the pre heating temperature of the weld joint to a
predetermined temperature range (250° C to 350° C) for a
minimum period of time (3 Hrs) before the weld cools down
to room temperature.
Post heating performed when welding is completed or
terminated any time in between.
Heating by Oxy fuel flame or electric resistant coil
Heating from opposite side of welding wherever possible
Temperature verified by thermo chalks during the period

TRIVEDI 26
Why Post Heating?
Post heating eliminates possible
delayed cracking of weld and HAZ
Applicable to
Thicker hardenable low alloy steels
Restrained hardenable welds of all
thickness
Post heating temperature and duration
depends on hardenability of material,
thickness & joint restrain
TRIVEDI 27
How does Post Heating
Eliminate Crack?
SMAW introduces hydrogen in weld metal
Entrapped hydrogen in weld metal induces delayed

cracks unless removed before cooling to room
temperature
Retaining the weld at a higher temperature for a

longer duration allows the hydrogen to come out of
weld

TRIVEDI 28
What Is Intermediate Stress
Relieving?
Heat treating a subassembly in a furnace to a
predetermined cycle immediately on completion of
critical restrained weld joint / joints without allowing
the welds to go down the pre heat temperature.
Rate of heating, Soaking temperature, Soaking time
and rate of cooling depends on material quality and
thickness
Applicable to
Highly restrained air hardenable material

TRIVEDI 29
Why Intermediate Stress
Relieving?
Restrained welds in air hardenable steel highly prone
to crack on cooling to room temperature.
Cracks due to entrapped hydrogen, hardened HAZ

and built in stress
“Intermediate stress relieving” makes the joint free

from crack prone by
- Relieving built in stresses
- Relieving entrapped hydrogen.
- Softening HAZ.

TRIVEDI 30
What Is Inter- Pass
Temperature?
The temperature of a previously layed weld
bead immediately before depositing the next
bead over it
Temperature to be verified by thermo chalk
prior to starting next bead
Applicable to
 Stainless Steel
 Carbon Steel & LAS with minimum impact

TRIVEDI 31
Why Inter Pass Temperature?
Control on inter pass temperature avoids over

heating, there by
 Refines the weld metal with fine grains
 Improves the notch toughness properties
 Minimize the loss of alloying elements in welds
 Reduces the distortion

TRIVEDI 32
What Is Post Weld Heat
Treatment?
Heat treating an assembly on completion
of all applicable welding, in an enclosed
furnace with controlled heating/cooling
rate and soaking at a specific
temperature for a specific time.
Rate of heating, Soaking temperature,
Soaking time and rate of cooling depends
on material quality and thickness
Applicable to
 All type of CS & LAS

TRIVEDI 33
Why Post Weld Heat
Treatment?
Welded joints retain internal stresses within the

structure
HAZ of welds remains invariably hardened
“Post Weld Heat Treatment” relieves internal stresses
and softens HAZ. This reduces the cracking tendency
of the equipment in service

TRIVEDI 34
Welding Terminologies used
in Qualifications
Heat In Put
Heat Affected Zone – HAZ
Dilution
Overlap In Weld Overlay
Tempering Bead

TRIVEDI 35
What Is Heat In Put In
Welding?
The extent of heat energy generated in
Joules per unit length while making each
weld bead.
“Heat In Put” is the Function of Welding
Current, Arc Voltage, And the Welding Speed
It is measured in Joules -
Heat In Put In Joules / mm
= (A x V x 60) ÷ Travel Speed in mm / min

TRIVEDI 36
Why Control On Heat in Put?
Heat In put” controls the grain size of weld

metal.
 Lower the Heat in put finer the grain size.
 Finer the Grain size Better the impact properties
“Heat In Put” Also controls Dilution, HAZ &
Geometry of Bead size

TRIVEDI 37
What Is Heat Affected Zone
(HAZ)
A small volume of BM adjacent to weld
fusion line, which is totally changed in
its structure due to intense heat of
each weld bead is known HAZ
Diluted BM
HAZ Weld Zone
Fusion Line Diluted BM

Weld Zone
TRIVEDI 38
What Is Significant Of HAZ
It is a part and parcel of weld joint
It is inevitable
It has properties different from BM &
Weld Metal
Diluted BM
HAZ Weld Zone

Weld Zone
TRIVEDI 39
What Is Dilution In Weld
In all Fusion welding, a small portion of BM
very close to the welding heat gets melted and
added to weld zone / fusion zone. Dilution is the
ratio of molten base metal volume (Area) to the
volume ( Area) of total fusion zone
% Dilution = (Area of Diluted BM ÷Total Fused Area) × 100
HAZ Weld / Fusion Zone

TRIVEDI 40
What Is Significant Of
Dilution
Weld metal chemistry changes
depending on the extent of dilution
Chemical elements influence Physical
properties of the joint.
Weld chemistry influences corrosion
resistance of weld overlays
Diluted BM
HAZ Weld Zone

Weld Zone
TRIVEDI 41
What Is Overlap In Weld
Overlay?
The extent of covering or over lapping of previous weld bead
by the adjacent bead.
More
Less Dilution Thickness Less More Dilution
Thickness
40 to 50 % Over 10 to 15 % Over
Lap Lap

TRIVEDI 42
What Is Significant Of
Overlap In Weld Overlay?
Overlap of 40 to 50% results in Less Dilution &
more weld overlay Thickness per layer
Less dilution results weld metal chemistry more
towards filler metal chemistry
More
Less Dilution Thickness Less More Dilution
Thickness
40 to 50 % Over Lap 10 to 15 % Over Lap

TRIVEDI 43
What Is Temper Bead
Technique?
In a multi pass groove & Fillet Welds, each bead & its
HAZ are getting tempered (heat treated) by the
welding heat of the next bead.
Thus all beads & their HAZ, except those in last layer,
are tempered.
Temper beads are the specially & carefully welded
temporary beads on the top of final weld
reinforcement with out allowing to generate any HAZ
within the BM. Temper beads are to be ground flush
with the required reinforcement.

TRIVEDI 44
Temper Bead
Temper Bead T1 & T2 Not To

Generate HAZ In BM
Temper Beads To Be Ground Flush
T1 T2 T1 & T2 To be ground
Rqd.
Reinforcement
Flush
5 5
4 4
3 3
2
1
HAZ

TRIVEDI 45
Common Defects In SMAW
1. Crack 2. Lack Of Fusion
3. Slag 4. Porosity
5. Pinhole 6. Piping
7. Undercut 8. Overlap
9. Lack Of Penetration 10. Excess Penetration
11. Spatters 12. Suck Back
13. Under Flush 14. Burn Through
15. Uneven Bead 16.Stray Arcing

TRIVEDI 46
Crack
Cause Remedy
1) Wrong 1) Use Right
Consumable Electrode
2) Wrong Procedure 2) Qualify Procedure
3) Improper Preheat 3) Preheat Uniformly
4) Excessive Restrain 4) Post heating or
ISR
crack

TRIVEDI 47
Lack Of Fusion
Cause Remedy
1) Inadequate Current 1) Use Right Current
2) Wrong Electrode angle 2) Train /Qualify welder
3) Improper bead 3) Train/Qualify Welder
placement
Lack Of Fusion

TRIVEDI 48
Slag
Cause Remedy
1) Inadequate Cleaning 1) Clean each bead
2) Inadequate Current 2) Use Right Current
3) Wrong Electrode angle 3) Train / Qualify
4) Improper bead welder
placement 4) Train / Qualify
Welder
Slag

TRIVEDI 49
Porosity
Cause Remedy
1) Damp Electrode 1) Bake the electrodes
2) Damaged coating 2) Replace the
3) Wet surface of BM electrodes
4) Rusted core wire 3) Clean & warm the
BM
Porosity
4) Replace the
. .
electrodes

TRIVEDI 50
Pinhole
Cause Remedy
2) Damaged coating 2) Replace the
3) Wet surface of electrodes
BM/WM 3) Clean & warm the
4) Rusted core wire BM
Pinhole
•4) Replace the
electrodes

TRIVEDI 51
Piping
Cause Remedy
2) Damaged coating 2) Replace the electrodes
3) Previous beads 3) Clean & warm the weld
wet 4) Replace the electrodes
4) Rusted core wire
Piping
•

TRIVEDI 52
Undercut
Cause Remedy
1) Excess Current 1) Reduce the Current
2) Excess Voltage 2) Reduce Arc length
3) Improper Electrode 3) Train & Qualify the
Welder
angle 1) Replace the electrode
1) Eccentric Coating
Under cut

TRIVEDI 53
Overlap
Cause Remedy
1) Wrong Electrode 1) Train & Qualify
Angle welder
2) Inadequate current 2) Increase the current

Overlap

TRIVEDI 54
Lack Of Penetration*
Cause Remedy
1) Excess Root Face 1) Reduce Root Face
2) Inadequate Root 2) Increase Root
opening Opening
3) Over size electrode 3) Reduce electrode
4) Wrong Electrode angle size
5) Improper bead 4) Train / Qualify
placement Welder
6) Improper weaving 5) Train / Qualify
* Applicable to SSFPW Welder
technique
6) Train & Qualify
Welder
LOPPRESENTED BY: HARDISH
TRIVEDI 55
Excess Penetration*
Cause Remedy
1) Excess root opening 1) Reduce root gap

2) Excess Current 2) Reduce Current
3) Inadequate root face 3) Increase Root face
4) Wrong Electrode 4) Train / Qualify
angle Welder
* Applicable to SSFPW
Excess Penetration PRESENTED BY: HARDISH

TRIVEDI 56
Spatters
Cause Remedy
1) Excess Current 1) Reduce to Right Current
3) Wrong Polarity 3) Correct the polarity
4) Wet Electrodes 4) Use Baked electrodes
5) Rusted BM surface 5) Clean BM surface
6) Rusted Core wire 6) Replace the electrodes
7) Eccentrics coating 7) Replace the electrodes
Spatters
• ••

TRIVEDI 57
Suck Back*
Cause Remedy
1) Excess weaving in 1)Reduce weaving
root 2) Reduce Current
2) Excess Current 3) Increase Root face
3) Inadequate root face 4) Train / Qualify
4) Wrong Electrode Welder
*angle
Applicable to SSFPW in 4G, 3G & 2G

Suck Back TRIVEDI 58
Under Flush
Cause Remedy
1) Inadequate weld beads in 1) Weld some more beads
final layer in final layer
2) Inadequate understanding 2) Train / Qualify welder
on weld reinforcement
requirement 3) Train / Qualify Welder
3) Wrong selection of
Electrode
size for final layer
Under flush

TRIVEDI 59
Burn through*
Cause Remedy
1) Excess Current 1) Reduce the Current
2) Excess Root opening 2) Reduce root opening
3) Inadequate Root face 3) Increase root face
4) Improper weaving 4) Train / Qualify Welder
Burn trough *Applicable to root pass

TRIVEDI 60
Uneven Bead Finish
Cause Remedy
1) Improper bead 1) Train & Qualify the
placement Welder
3) Excess / inadequate 3) Train & Qualify the
current Welder
Uneven bead finish

TRIVEDI 61
Stray Arcing
Cause Remedy
1) Wrong Arc Striking 1) Train the Welder
Practice 2) Train the Welder
2) Inadequate Skill of
Welder
Arc Strikes

TRIVEDI 62
Good Engineering Practices
in
Shielded Metal Arc Welding

TRIVEDI 63
Good Engineering
Practices In SMAW
Do Welding with properly baked electrodes
Basic coated CS electrodes to be baked to
250°C to 300°C for two hours
Baked electrodes to be directly used on
job or to be retained in a hold over oven at
100°C until use
Unused balance electrodes shall be
returned to baking oven

TRIVEDI 64
Good Engineering
Practices In SMAW
Do not weld with damp Electrodes
Do not try to heat electrodes by touching the job (Short
circuiting)
Do not use electrodes with damaged coating
Do not use electrodes with cracked coating
Do not bend the electrodes after holding it in the holder

TRIVEDI 65
Good Engineering
Practices In SMAW
Do not weld on groove / surface with
mill scale or rusting
Prior to welding, clean the weld
groove with power wire wheel
Do not weld with unidentified
electrodes
Do not leave balance electrodes
unattended on shop
TRIVEDI 66
Good Engineering
Practices In SMAW
All connections with earthing and
welding cables shall be tight fitted
Earthing clamp shall always be
tightly connected to the job
Burn the full length of electrode till
37 mm stub length

TRIVEDI 67
Good Engineering
Practices In SMAW
Earthing cable shall directly connect
to the job with an earthing clamp.
Tacks for set up shall be minimum 5
times the electrode diameter
Weaving shall be limited to three
times the electrode diameter.
Only trained & qualified welders
shall be employed for welding
TRIVEDI 68
Good Engineering
Practices In SMAW
Do not direct fan or blower to welding arc

Remove paint if any from the area near
welding
While welding in open, area shall be
covered to protect from rain water &
breeze
Weld edge preparation shall be free from
serrations
TRIVEDI 69
Good Engineering
Practices In SMAW
Use poison plates between the job
material & structural supports.
Do not damage parent metal while
removing temporary supports.
Locations where from temporary
supports are removed shall be
touched up by welding / grinding and
PT checked.
TRIVEDI 70
Good Engineering
Practices In SMAW
Remove visible defects from welds before
placing the subsequent beads
Do not weld over a visible crack
Electrodes kept out side more than 2 Hrs
shall be returned to baking oven
Maximum 15 electrodes at a time shall be
taken from oven for welding

TRIVEDI 71
Good Engineering
Practices In SMAW
When preheat is required, heat from
opposite side of welding.
Use temperature indicating crayons
for checking temperature
Do not Weld more than specified
weld size- Fillet / Reinforcement.

TRIVEDI 72
Safety Precautions in
Shielded Metal Arc Welding

TRIVEDI 73
Safety Precautions In
SMAW
Welders shall use safety devises – Hand

gloves, Head screen with right glass &
Safety shoes
Welders shall use full sleeve boiler suit
Use welding glass-DIN 11/12 up to 250
Amps and 13 above 250 Amps
Do not look at the arc with naked eyes

TRIVEDI 74
SMAW
Do not throw Stubs on ground. They shall

be placed in stub collector.
Do not keep electrode in the holder when
work is not in progress
Do not touch the electrode held on holder
and the the job when the power source is
on
Keep welding cables duly wound near
power source when no welding is done
TRIVEDI 75
SMAW
Do not breath welding fumes

When working in confined area,
ensure adequate ventilation / exhaust
Gas cutting torch / preheating burner
shall not be taken inside confined area
unless the flame is lit
When not in use, switch off the the
power source from electric supply

TRIVEDI 76
SMAW
Acetone / inflammable liquids

(Chemical for dye penetrant test)
shall not be brought near welding
Gas cutting unit / fuel gas cylinders
shall be away from welding area
Wet safety Shoes or wet hand gloves
shall not be worn while welding

TRIVEDI 77
Thank You

TRIVEDI 78

Shielded Metal Arc Welding

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Shielded Metal Arc Welding

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Shielded Metal Arc

PRESENTED BY: HARDISH

The process performed by Heat with or

Filler metal may or may not be used

The joint will be homogeneous

1 Pressure Welding – With Heat

2 Fusion Welding – With Heat &

PRESENTED BY: HARDISH

Metal parts heated to forging

PRESENTED BY: HARDISH

Heating by oxy fuel flame or electric Arc.

Invariably filler metal added to molten pool.

On cooling, molten puddle solidifies to