Shielded Metal Arc Welding

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 stick electrode has an outer coating, called flux, that 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.

Electrode Travel Direction Shielding Gas Slag Weld Puddle Arc

Solidified Weld Metal

Part of SMAW Machine

1.

Power Source

The power supply used in SMAW has constant current output, ensuring that the current (and thus the heat) remains relatively constant, even if the arc distance and voltage change. This is important because most applications of SMAW are manual, requiring that an operator hold the torch. Maintaining a suitably steady arc distance is difficult if a constant voltage power source is used instead, since it can cause dramatic heat variations and make welding more difficult. However, because the current is not maintained absolutely constant, skilled welders performing complicated welds can vary the arc length to cause minor fluctuations in the current.

2.

Electrode

An electrode is an electrical conductor used to conduct current through a workpiece to fuse two pieces together. 3. Electrode Holder

The electrode holder has a few functions. Firstly, it is used to provide the electricity from welding machine to metal work. It is also used to hold the electrode during the welding operations. 4. Clamp

Clamp is connected to the workpiece lead cable and clamped to the work metal or to the work table. It has a spring so that is can be easily clipped and unclipped. Without this equipment, welding operation definitely cannot be done. 5. Cables

The function of cables are to connecting the electric current.

Equipment
1. Gloves

It must be made from high quality leather. Use to protect your hand from fire-bolt and hot metal welding. 2. Shield (Goggles)

cIt is made from inflammable material. In the middle of the shield there is a bright rectangular glass coated with dark colored glass. It is used to protect the user from fire-bolt and harmful rays during welding work. There are two types of shield, one is the helmet type and the other one is the hand held type. 3. Chipping Hammer

It is used commonly to remove the slag from the surface of the work metal. 4. Wire Brush

It is used to clean the surface of the stringer bed after the slag is chipped away and to remove dirt from the surface of metal work before welding can be done. 5. Leather Jacket / Appron

Leather jacket is used to protect the user from the intense heat produced during welding operations. It is made of high quality leather to provide greater comfort for the user. 6. Tongs

It is used to hold hot work metal after welding process.

7.

Ventilation System

It is needed if we are working indoor.

SMAW Advantages

Equipment is self contained, portable and relatively inexpensive. Electrode provides its own flux. Most metals and alloys can be welded with SMAW. Useful process for welding in confined spaces. Performs better on unclean surfaces than other welding processes. Most metal thickness can be welded with SMAW. All welding positions are possible with SMAW. Can be used under almost all weather conditions. Arc is continuously visible to the welder.

Welder controls the arc.

SMAW Disadvantages

Not recommended for welding metals less than 1/16 thick. Excessive spatter. Slag cleanup is required. Produces weld beads with rough surfaces. Welds are subjected to porosity. Arc blow must be controlled. Some electrode waste (about 10% from discarded stub loss). Potential electric shock from open circuit voltage. Ventilation must be provided when welding in confined spaces. The SMAW process

produces large amounts of fumes and smoke.

Procedure :
a) b)

Clip the clamp to the work table. Clip an electrode with the electrode holder. Make sure that the flux is not in contact with

the holder. Undesired spark may occur if the flux is in contact with any metal. c) d) e)
f)

Switch on the machine and set the dial to 90 amps. Before we begin welding, we should put on our gloves and shield. Take a piece of scrap metal and put it on the working table. Hold the electrode about 90o above the scrap metal. Tilt the electrode 20o-25o degrees to

the right or left depending on which hand do you use from the work metal. g) Scratch the front end of the electrode onto the work metal to start the burning. After the electrode has started burning, hold it at 10mm above the work metal. Try to avoid the electrode from being in contact with the surface of work because the electrode might be stucked onto the work.

h) i)

Repeat the welding process for several times until you get a straight and firm stringer bead line when welding. When you finish welding a line, use the chipping hammer to chipped off the slag and brush it off using a wire brush.

Safety Precautions.
a)

Please wear all the personal protective equipment Always protect your eyes from arc rays. Protect your face and body from heat radiation and molten metal. Move all the flammable material off the working place or cover it up using fireproof

b) c) d) e) f) g) h) i) j) k) l) m) n)

material. Make sure that the welding machine is earthen. Make sure that all line holder, earth clip and connection placed on good place. Make sure that your working place is clean and tidy. Make sure that all electric connection is tight, clean and dry. Avoid pulling the cable on top or near sharp things. Do not ever scratch arc on top of gas cylinder. Turn off the welding machine when not in use. Avoid welding cable from be in contact with hot metal, water, oil and grease. Wear all safety clothing when welding. All equipment such as hammer, chisel, brush and others must be well maintained.

ENGLISH

Shielded Metal Arc Welding Machine

1. 2.

Nizar Muslim (NIM. 1031210011)

Ribut Pristiwanto W. (NIM. 1031210007)

JURUSAN TEKNIK MESIN POLITEKNIK NEGERI MALANG MALANG

2011