SMAW

SMAW
SHIELDED METAL ARC WELDING
AWS Classification

ARC WELDING

STICK WELDING
 FACTS ABOUT SMAW
Originated at start of WWI for shipbuilding

SMAW is the least expensive arc welding processes

Is the most widely used welding process in the world

Can be used to weld most common metals and alloys

SMAW COMPONENTS
 1- The Electrode
Consumable
2 Part Composition

Core Rod (Metal Filler)

Carries welding current &
Becomes part of the weld

Flux Coating
Produces a shielding gas &
helps form slag
6
 2- The Arc
Turn on the lightAn arc
occurs when the electrode
comes in contact with the
work-piece and completes
the circuit
The electric arc is
established in the space
between the end of the
electrode and the work
causing resistance
The arc reaches
Can you identify the weld joint temperatures of 10,000F
and position being used? which melts the electrode
and base material 7
 3- Weld Puddle
As the core rod, flux
coating, and work
pieces heat up and
melt, they form a pool
of molten material
called a weld puddle

The weld puddle is

what a welder watches
1/8 E6013 at
and manipulates while 125 Amps AC
welding
8
 4- Shielding Gas
A shielding gas is formed when the flux melts.

This protects the weld puddle from the atmosphere

preventing contamination during the molten state

The shielding gas protects the Shielding Gas

4
molten puddle from the
atmosphere while stabilizing
the arc 3
2

9
 5- Solidified Weld Metal
As the molten weld puddle solidifies, it forms a
joint or connection between two pieces of base
material
When done properly on steel, it results in a weld
stronger than the surrounding base metal
Bead width = 2.5 to 3 times electrode diameter

3/8 10
 6- Slag
Combination of melted flux & base metal impurities
Quickly solidifies to form a shell
Slows the cooling rate of weld
Chip and clean with hammer & brush
If proper technique is used it should come off easy
Never weld over slag!!

ALWAYS SIDE CHIP SLAG, DONT

HIT IT LIKE A HAMMER 11
 Slag You Drag!
Slag Welding Processes
ALWAYS PULL THE PUDDLE
Shielded Metal Arc Welding (SMAW)
Flux Core Arc Welding (FCAW)

No-Slag Welding Processes

ALWAYS PUSH THE PUDDLE
Gas Metal Arc Welding (GMAW)
Gas Tungsten Arc Welding (GTAW)
Oxy-Fuel Welding
 SMAW Process

Electrode
1
Travel direction

Shielding Gas
4

Slag
6 Slag
6
Weld Puddle 3
3 Weld Puddle 2 Arc
2 Arc

5 Solidified Weld Metal

5 Solidified Weld Metal

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 Activity
Lets review the SMAW process 1 = __________

1
2 = __________

4 3 = __________

4 = __________
6
3 5 = __________
2
6 = __________
5

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AWS Electrode Classification
 Electrode Selection
What type of welder do I have, AC or DC?
What am I welding, steel, cast, stainless, etc?
What is the metal condition, dirty or clean?
Is it a root or cover pass?
How strong does it have to be?
What electrodes do I have to chose from?
Electrode Selection
 Amperage Chart
Amperage is dependent on electrode
diameter, electrode type, and metal thickness
Reference charts whenever possible.
 Amperage Electrode
Shorthand method will get you in the
ballpark for fast freeze electrodes.

Not 100% accurate for all electrodes!

AWS: 1/8 diameter E6013

1/8= .125
125 Amps
 Electrode Care
Electrodes must be kept dry
Dampness will introduce hydrogen into the
weld causing cracking or brittleness
Damp electrodes may cause the flux to blow
away & cause porosity
Bake questionable electrodes for several
hours.
6010 & 6011 (fast freeze) are exempt
Our electrodes are stored in a dry oven
 Electrodes Care cont.
Burn electrodes down to numbers!
Place stubs in stub box
Put unused electrodes back in oven
Only grab several electrodes at a time
Electrodes are not cheap
 Striking an Arc and Making a Weld

22
 Striking an Arc
To begin the SMAW Process, you must first
strike an arc.
Scratch start scratch the electrode on the base
metal like a match
Tap Start tap the rod against the base metal

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 Work Angle
The work angle is the
angle between the
electrode and the work
as depicted on the left
90

Work angles can vary

depending on the
position the weld is being
made in
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 Travel Angle

Also commonly called

Lead Angle
20-30

The travel (lead) angle

is the angle between
the electrode and the
plane perpendicular to
the weld axis

25
 Arc Length
After striking the arc, maintain a 1/8
distance between the electrode and the
workpiece
Too short: electrode will fuse itself to metal
Too long: spatter, undercut, and porosity

Arc Length = 1/8

26
 Travel Speed
Speed at which the electrode moves along the
base material while welding
Too fast: ropey or convex weld
Too slow: wide weld, excessive deposit

The travel speed impacts

the shape of the bead.

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 Filling the Crater
At the end of the weld, the operator breaks the
arc which creates a crater
Use a short pause or slight back step at the end
of the weld to fill the crater
Large craters can cause weld cracking

Back stepping is a short

move in the opposite
direction of weld travel

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 Restarting a Bead
Remove electrode from stinger
Scratch electrode until metal can be seen
Scratch in weld line: spatter
1. Strike Arc Here

2. Move Electrode to
Crown of Crater

3. Resume Travel

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 Troubleshooting Activity
On a piece of scratch paper, describe welds A-G.
Good, bad, arc length, speed, lead angle, etc.
A B C D E F G

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 A Good Weld: Proper Current, Speed and Arc Length
B Current low: Ropey, convex bead appearance
C Current too High: Excess spatter & burn-through
D Arc Length too short: Poor wet-in at toes
E Arc Length too Long: Spatter, undercut and porosity
F Travel Speed too slow: Wide weld with excess deposit
G Travel Speed too high: Ropey and convex bead
 Lincoln V350 SMAW Setup
1. Plug ground cable into the (-) terminal
2. Plug the whip cable into the (+) terminal
3. Turn on the welder
4. Select SMAW (CC-Stick Soft) mode
CC-Stick Crisp is for pipe welding
5. Select correct amps
6. Set Hot start to 2-3
(This will make starting the arc easier)
7. Set Arc Control to +4-5
(high arc control = crisp weld but more spatter)
(low arc control = soft weld with little spatter)