SMAW -Shielded Metal Arc Welding (stick)

GMAW -Gas Metal Arc welding (mig)

GTAW-Gas Tungsten Arc welding (tig)

SMAW- Shielded Metal Arc Welding uses the heat of an electric arc between a covered
metal electrode and the work (pipe, plate, etc). Shielding comes from the decomposition
of the electrode flux coating. Filler is supplied by the electrode core wire and covering
(iron powder and alloys).

This process is usually done manually. The basic equipment is a power source, an
electrode holder, a work clamp and the electrode. Electrodes operate variously on
alternating current, direct current electrode positive (reverse polarity) or direct current
electrode negative (straight polarity).

SMAW welding metallurgy

– Weld is strengthened by adding alloying elements and by incorporating

iron powder in the electrode covering (flux). Some ingredients in the
covering may attract and hold moisture (a source of hydrogen) which
causes cracking in certain welds. A group of electrodes specifically
formulated to result in weld deposits having very low levels of hydrogen
are referred to as “Low Hydrogen” electrodes. These have identification
numbers ending in 5,6 or 8. Once removed from containers they require
electrically heated storage in a vented oven capable of holding the
electrodes between 250 – 350 deg F. (Low hydrogen electrodes should be
stored in their original containers until ready for use)

SMAW limiting factors

All of the welding manipulations are controlled by the welder, such as electrode
inclination, arc length and travel speed. The welder must set the proper current and select
polarity if direct current.

Discontinuities

Almost any discontinuity can be produced, but the most common is porosity, and slag
inclusions.

GMAW- Gas Metal Arc Welding, sometimes call Mig uses the heat of an electric arc
between a continuous bare wire filler metal electrode and the work. Shielding is obtained
entirely from an externally supplied inert gas (argon or helium) or reactive gases (C02 o
02) or a combination thereof. This process can be semi-automatic or automatic. GMAW
process deposits the weld metal in the joint by one of the following modes: spray transfer,
globular transfer and short circuiting transfer.

GMAW MODES:

Spray Transfer – Spray transfer occurs with high current and voltage combinations.
Spray transfer mode best defines the arc and the pool for the welder. Due to high heat
capacity this mode is best suited for flat and horizontal welding.

Globular Transfer – Occurs at low currents compared to spray transfer. Low current at
the tip produces large irregular drops without much direction which results in increased
amounts of spatter compared to spray mode.

GMAW MODES

Short Circuiting Transfer (GMAW-S) – The short circuiting mode is a rather “cold
process” and its misapplication may result in incomplete fusion. It is mainly used for
very light gauge sheet metal welding. Most refineries and petrochemical plants do not
allow the short circuiting mode of transfer in their welding specifications to weld on
pressure retaining equipment.

GMAW Welding Chemistry

Shielded gases protect gas metal arc welds from the atmosphere. Fluxes are not used in
this process. All deoxidizers and alloying elements are incorporated into the electrode
wire.

Limiting Factors

The semi-automatic features of gas metal arc welding simplify the training of the welder
and should make work more consistent, however the short circuiting mode may lead to
incomplete fusion.

Discontinuities

GMAW may result in any of the common

discontinuities with the exception of slag inclusions.

Porosity which is caused by gas trapped in the weld, is often the discontinuity found in
this process.

Incomplete fusion is possible especially in welds made in the short circuiting transfer
mode.
GTAW – Gas Tungsten Arc Welding (TIG) uses an electric arc between a non
consumable electrode (tungsten) and the work. Shielding is obtained from an inert gas or
inert gas mixture. Filler metal is added as needed. Welds may be made with or without
filler metal as required.

The most significant feature in GTAW is that the electrode (tungsten) used is not intended
to be consumed. Only the filler metal is consumed

Welding Chemistry

The tungsten electrode contributes neither deoxidation nor fluxing, so it is

fortunate that the melting is essentially slow and that most of the gases can escape from
the weld pool before it freezes. The filler rod contains the needed deoxidizers. The slow
heating and lower temperatures combined with slower cooling rates in GTAW will result
in improved weld metal and heat affected zone mechanical properties.

Limiting Factors

The outstanding factor of GTAW is the exceptional cleanliness that can be

obtained in the weld, producing crack free welds in alloys that are difficult to weld in
other process. However the limiting factor is the high skill level necessary to produce
high quality welds is acquired by long experience in manipulating the electrode and
feeding the filler wire when used.

Discontinuities
All of the common types of discontinuities are possible with the exception of slag
inclusions. Porosity is a common discontinuity due to the processes low tolerance for
contamination. Tungsten inclusions may also result from accidental touching (dipping )
of tungsten into the molten weld pool.