Basic Principles

Current
DBT 204  The amount of electron flow through an
electrical circuit.
Technology of Metal Welding I
Electrical circuit
 The path which current flows
SHIELD METAL ARC WELDING
Conductor
(SMAW)  Any material through which current flows
The art of writing easily

An ampere (amp or A)
 Amount of electrons flow per unit of time
 Measured using an ammeter 2
Azmi Kamardin
2015-2016 S01

Circuits Welding Current

Heat generated from
-ve terminal SMAW comes from
an arc that develops
Welding cable when electron jumps
across an air/gas gap
electrode between the end of
the electrode and the
base metal.
Work piece
Heat: 33005500oC
+ve terminal
3 4
 Welding Current Polarity
Direct Current (DC) Determine the direction of current flows in DC circuit
 Current flows in 1
direction only DCEN
Alternative Current (AC) Electrode is
 Current flows in connected to
alternate direction. ve terminal
Frequency Workpiece is
connected to
 # of cycle per second
+ve terminal
 Unit: Hertz (Hz)
 1 Hz = 1 cyc/sec 5 6

Polarity Welding Equipment

Required welding equipment includes:

 Welding cables
DCEP  Electrode holders
Electrode is
 Work clamps/leads
connected to
+ve terminal
Workpiece is
connected to
-ve terminal

7 8
Welding Leads Electrode Holders

Conduct current to and
Holds the electrode

from the workpiece during welding.

Electrode lead:
The jaws must be
From welding machine properly insulated
to the electrode holder to prevent flash

Workpiece lead:
Must able to easily
Attached to the work secure and release
piece or work bench electrodes.

Must be clamped tight
to prevent overheating 9 10

Workpiece Connections Shop Tools

To produce a strong weld, the surface of the base
metal must be free of rust, oil and paint.

A wire brush is used to clean metal surfaces.

A chipping hammer
is used to remove
welding slag.

If slag is not removed,

Attached to the work piece or work bench to it becomes trapped in
complete the circuit. the weld and may form

Connections should be made as close to the gas holes in the bead
welding locations as possible. 11 that result in porosity which weakens the weld.12
Ventilation System Selecting Electrodes

SMAW emit a great deal of smoke and fumes

SMAW should not be performed w/o sufficient  Formation of arc
movement of air through the room.  Melting of electrode
coating & metal and

Brilliant light, ultraviolet & infrared rays the base metal.
 Extremely dangerous to eyes and skin  Solidification between
 Full body cover, leather apron & glove the two work-piece.

Slag, flying metal pieces & sparks  Formation of a slag
that slows the cooling
 Extremely dangerous to eyes rate of the deposited
 Face shield, helmet & safety glasses metal.
13 14

Selecting Electrodes Selecting Electrodes

Classification of electrodes:
Most arc welding is done with electrodes in the

 High-carbon steel mild steel groups.
 Mild-steel
Types of mild steel electrodes:
 Alloy steel Shielded
 Cast iron Bare
 Non ferrous
Heavily coated with various substances such as
cellulose sodium, cellulose potassium, iron oxide
etc.

15 16
Shielded Electrodes Bare Electrodes

Functions of electrode coating:
Uncoated metal rods.

 Cleaning & deoxidizing agent
Rarely used because:
 Releasing CO2 to protect the molten metal  Difficult to weld
from atmospheric oxides and nitrides  Produce brittle weld with low strength
 Prevent O2 and N2 to come in contact with
molten metal can weaken the welding
 Form a slag prevent contamination &
promote slow cooling
 Provide easy arc starting, stabilize the arc,
reduce spatter & permit better penetration 17 18

Identifying Electrodes Identifying Electrodes

WP: 1
all position

19 2
flat & horizontal ONLY 20
Identifying Electrodes Group of electrodes
 Fast-freezing electrode
 Produce snappy, deep penetrating arc and fast-
freezing deposit
 Little slag & flat beads
 Most preferred for vertical & overhead welding
 Fill-freezing electrode
 Moderate penetrating arc and freezing rate
 Complete slag coverage + ripples
 Not recommended for vertical & overhead welding
 Fast-fill electrode
 Soft arc & slow deposit rate
 Heavy slag + smooth weld beads
 Recommended for flat position only
21 22

Electrodes Classification Sustaining A Welding Arc

Machine setting @ current

 Electrode size & type
 Position of weld
 Type of base metal

23 24
Sustaining A Welding Arc Sustaining A Welding Arc

Electrode angle Arc Length

 Sufficient penetration &  Provide sufficient heat
bead formation.  Too long:
 Depends on weld position unstable arc, spatter,
& joint type. shallow penetration, flat &
wide beads, insufficient
gas shield.
 Too short:
Less heat, sticking, poor
25
penetration, uneven beads 26

with irregular ripples.

Sustaining A Welding Arc Checking & Adjusting Equipment

Travel Speed
Check the machine, electrode, electrode holder,

 Depends on: electrode lead, work piece lead & workpiece
o type & size of electrode connection REGULARLY to ensure quality
welding & your own SAFETY.
o current
o weld position
o type of base metal

27 28
Checking & Adjusting Equipment Gripping the Electrode

Follow the procedure:
Grip near the end so that most of the coated
 Inspect lead connections. portion can be used.
 Bench top & base metal are dry and free
Keep the jaw clean to ensure good electrical
contact.
from dirt, rust & grease.

Avoid flash
 Adjust the current properly

Hang the holder if not
in use

Do not hold the holder
too tight
29 30

Gripping the Electrode Adjusting the Current

Recommendation = Approximation

Set the current midway between the two limits

Strike an arc and run short weld beads.

Vary the current to see how it affects the weld
beads.

Try again with current reduced about 5 A

Reverse the process by gradually raising the
current about 5 A

Find the perfect tune!
31 32
Adjusting the Current Striking the Arc

Tapping method:
 Straight down to contact with workpiece &
withdrawn instantly

33 34

Striking the Arc Depositing Short Weld Beads

Scratching method:
Cracking or frying noise
 Strike like a match
Humming sound

Popping sound

Weld pool indicates the quality
of the welding

Clear & bright weld
 slag & weld pool do not mix

Dull & irregular weld edge
 slag is trapped in the weld
pool.
 Prevent sticking by twisting & releasing 35 36
Essentials of Arc Welding Factors of a quality weld

The heat from the arc
Electrode selection

melts the base metal
Arc length

Form a crater into which
Current
the molten metal base

Travel speed
and filler metal flow.

Electrode angle

Molten metal solidifies

A layer of slag forms on
top of
the weld.

37 38

Electrode Selection Arc Length

Different electrodes for different welding
Arc length is correct:

requirements. Approx. equivalent to electrode diameter

Take into account the following concerns: Prevent impurities from entering the weld
Welding position Produce uniformly space ripples
Property and type of base metal
Diameter of electrode
Type of joint
Current
* Refer to slide no 25 & 27!
39 40
Arc Length

Arc length is too short:
Not enough heat to melt the base metal
High, uneven beads with irregular ripples
High chance of sticking
Arc Length

Arc length is too long:
 Large globules that wobble
 Produce wide, spattered and irregular bead
 Insufficient fusion base metal & deposited
filler metal.

41 42

Current Selection Current Selection

Current is too low:
Current is too high:

Not enough heat Electrode melts too fast
Weld pool is small. Weld pool is large,
Poor fusion irregular and hard
Pile up to control
Irregular shape
Sticking problem
Continual break

43 44
Travel Speed

Speed is correct:
Smooth weld bead
Evenly spaced ripples

Speed is too slow:
Excessive metal pile up
Bead is high & wide
Straight ripples
45
Electrode Angle

Electrode angle affects
the bead shape.

Travel angle ~ 15o-30o

Work angle ~ 90o

Lower the angle when
undercut occurs
47
Travel Speed

Speed is too fast:
Narrow bead
Pointed ripples
Weld pool does not
last long enough
Impurities are
locked in the weld
46
Electrode Angle: Multiple-Pass
48
Crater formation

Depression (pool or pocket)
in the molten base metal
made by the arc.

The size & depth of a crater
determine the amount of
penetration.

Short arc length 
insufficient heat to form the
correct size crater
49
Controlling Craters

Re-melting Craters:
Remove flux / slag
completely
Strike the arc approx
in front of the crater
Move the arc back
through the crater
At the back edge of the
crater, start at the
welding pool & continue
51
welding
Crater formation

Long arc length  non-
centralized heat is not
intense enough to form
correct size crater
50
Controlling Craters

Undercutting:
Creates a groove in the
base metal without
completely filled by weld
metal.
Due to excessive current
& insufficient deposition.
Can be corrected by
slightly lowering the
electrode angle.
52
Controlling Craters Cleaning Welds

Overlapping:
Layer of slag must be removed after welding.

Extension of weld metal
Strike the weld with chipping hammer
beyond the weld toes. AWAY FROM YOUR EYES, FACE & BODY!
Due to low current
molten metal deposited
without fusing into the
base metal.

53 54

Cleaning Welds Welding in Flat Position: Lap Joints

Remove remaining slag using wire brush.
Surfaces must be cleaned & evenly aligned.

A fillet weld is used to join the work pieces.

55 56
Welding in Flat Position: Lap Joints Welding in Flat Position: T-Joints

Form a lap joint and
Form a T at 90o angle
tack together. and tack together.

Work angle 45o &
Work angle 45o &
travel angle ~ 30o. travel angle ~ 30o.

Concave filler  weak
Advance in a straight

Convex filler  waste line without any
metal weaving motion

Watch out for
undercutting at the
bottom piece.
57 58

Welding in Flat Position: Butt Joints Welding in Flat Position: Butt Joints

Closed, open or beveled.
Backing bar is used to prevent burning through

A closed butt joint is
suitable for thickness not
exceeding 3/16

Multiple-pass is required
for thicker metal.

Edge spacing 3/32 1/8

Backing bar to prevent
burning through

Edge should be beveled if 59 60

thickness > 1/8

Welding in Flat Position: Corner Joints Weave Patterns

Form a corner joint at a 90o angle and tack weld

Work angle 45o and travel angle 30o

61 62