INTRODUCTION TO ARC WELDING (SMAW)

Terms & Definitions

Welding - Joining of two or more pieces of metal together by the fusion process
NOTE: In arc welding, heat is produced by the electric arc created.

SMAW - Shielded Metal Arc Welding Electrode - Metal rod which conducts a current from the electrode holder to the base metal Base Metal - Metal to be welded

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Bead Weld - Made by one pass of the electrode Bevel Type of edge preparation containing an angle Butt Joint - Weld located between the two edges of metal. Crater - Depression at the end of a weld

Safety precautions in SMAW welding

Never look at the arc with the naked eye. Use a welding hood that is in good condition and has a #12 shade. Wear suitable clothing to protect all parts of the body. (PPE) personal
protective equipment

Long sleeved shirt Leather gloves Collar buttoned

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Cuffs turned down High topped shoes or boots

Do not strike an arc or weld until you are sure those in the vicinity have protective equipment or will look in the other direction.
(Note) Yell cover before striking an arc.

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Do not weld around combustible or flammable materials. Do not pick up hot metal with the hands.
(NOTE) Use a pair of pliers

Do not weld in confined places without ventilation

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Always turn off main switch or disconnect plug when checking over a welder. Do not leave electrode holder on the welding table or in contact with grounded metal. Do not use worn or frayed cables.

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Stand on dry footing when welding. Keep area around welder clean. Keep tools and metals in proper location.

Types of Arc Welders

A.C. (Alternating current) Welder current alternates direction 120 times per second. D.C. (Direct current) Welder current flows in the same direction. TIG (Tungsten Inert Gas) Welder may use either A.C. or D.C. with a non-consumable tungsten electrode and an inert shielding gas.

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MIG (Metal Inert Gas) May use A.C. or D.C. with a base wire filler material that is fed automatically into weld; also has an inert shielding gas.

Common SMAW Tools

Welder Electrode Holder Ground clamp Shield or helmet Gloves Chipping hammer Safety goggles or glasses Wire brush Electrodes

Types of Electrodes
Mild Steel High Carbon Steel Hard Surfacing Alloys special purpose

Electrode Characteristics
AWS Class
EXX 10

Covering
Cellulose Sodium Cellulose Potassium Rutile Sodium Rutile 50% Iron Powder Mineral 50% Iron Powder

Current Requirements
DCEP

Position
All

Characteristics
Deep Penetration, With Ripples Deep Penetration, With Ripples Deep Penetration, With Ripples High Deposition Shallow Penetration High Deposition Shallow Penetration

EXX 11

AC, DCEP

All Flat Decking Flat, Horiz. Fillet

EXX22

DCEN, AC

EXX 24

AC, DCEP, DCEN Flat, Horiz. Fillet

EXX 27

AC,DCEP, DCEN Flat, Horiz. Fillet

Electrode Characteristics continued

AWS Class
EXX 12

Covering
Rutile Sodium Rutile Sodium Rutile 30% Iron Powder Low-Hydrogen 30% Iron Powder Low-Hydrogen 50% Iron Powder

Current Requirements
DCEN, AC

Position
All

Characteristics
Mild to Medium Penetration

EXX 13

AC, DCEP, DCEN

All

Mild Penetration

EXX 14

AC, DCEN

All

Medium Penetration

EXX 18

DCEP, AC

All

Medium Penetration

EXX 28

AC, DCEP

Flat, Horiz. Fillet

High Deposition

Common Sizes of Electrodes

1/8 5/32

Sizes of electrodes range from 1/16 to 3/8. Electrode size is determined by the diameter of the wire core.

AWS Classification

E70XX-H4R
Electrode Tensile in Ksi Welding Position:
1 = All Position, 2 = Flat & Horizontal

Type of Current and Coating *Hydrogen:

H4 = Less than 4ml/100g weld metal, H8 = Less than 8ml/100g Weld Metal or H16 = Less than 16ml/100g weld metal

*Meets Requirements of Absorbed Moisture Test

*Optional Designators

Electrode Coating Functions

To Provide Deoxidizers & Scavengers To Produce Shielding Gases To Produce a Slag Covering To Provide Mechanical and Physical Properties To Increase Deposit Rates

Effects of Raising & Lowering Current

Raising current
Produces more heat

Lowering current
Produces less heat

(Note: On thicker metals more heat is necessary in order to get penetration of the weld.)

Methods of Establishing an Arc

Scratching
Similar to striking a match

Tapping
Straight down and up

Characteristics of Proper Arc Length

End of electrode is the same distance from the base metal as the diameter of electrode.
1/8 electrode = arc length 1/8

Correct arc length makes a steady hum of the welder. Correct arc length makes a frying sound at the arc
Like bacon frying in a pan

Parts of the welding process

Electrode Wire core Coating (flux) Arc Gaseous shield Weld Slag

Parts Continued
Heat lines Base metal Penetration Crater 15 30 degree angle Direction of travel

Principles of the SMAW Process

Kinds of Welds
Fillet Groove Bead

Fillet Weld

Groove Welds

Continued

Types of Weld Joints

Butt Joint Lap Joint

Tee Joint
Corner Joint Edge Joint

Square Butt Joint

Tee Joints
A- plain tee B- single beveled C- double beveled D- single J E- double J

Lap Joints
A- single lap joint, one weld. B- single lap joint, two welds. C- offset lap joint.

Corner Joints

Edge Joints

Welding Positions
Flat
1F & 1G

Horizontal
2F & 2G

Vertical
3F & 3G

Overhead
4F & 4G

Weld Positions

Reason for Poor Welds

Machine adjustment too hot or too cold Electrode size too large or too small Improper movement of electrode Improper angle of holding electrode Improper base metal preparation Arc length too long or too short