SMAW Basics For School PDF

Shielded Metal Arc Welding
(stick welding)
Copyright © ZSCMST Permission

required for reproduction or display. 11 - 1
SMAW Unit Topics
•During this overview, we will discuss

the following topics:
• Safety
• SMAW Basics
• Equipment Set-Up
• Welding Variables
• Process Advantages and Limitations
Copyright © ZSCMST Permission required for reproduction or display.

SMAW - 2
SMAW Unit Objectives
• Upon successful completion of the SMAW Unit of

Study, you will have learned to:
• Properly protect yourself and others while welding
• Set up and operate SMAW equipment
• Strike and maintain an arc
• Make welds in four positions using electrodes
• Understand a weld inspection process
• Take the next step to becoming a welder

SMAW - 3
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
• Is commonly known as ‘Stick’ welding or manual arc welding
• Is the most widely used arc welding process in the world
• Can be used to weld most common metals and alloys
• Electric energy from the arc produces temperatures ~ 10,000 F
(5500 C), hot enough to melt any metal
• Electrode - Metal rod which conducts a current from the electrode
holder to the base metal
• Base Metal/ Work - Metal to be welded

SMAW - 4
Terms & Definitions
• 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
• Arc welding
• Heat for welding generated by electric arc established
between flux-covered consumable metal rod (electrode)
and work
• Combustion and decomposition of electrode creases gaseous
shield (Gases given off)
• Protects electrode tip, weld puddle, arc, and highly heated
work from atmospheric contamination
• Additional shielding provided by covering of molten slag
(flux)
SMAW - 5
Five Types of Arc Welding
1. SMAW-Shielded Metal Arc Welding

2. GTAW/TIG-Gas Tungsten Arc
Welding
3. GMAW-Gas Metal Arc Welding
4. FCAW-Flux Core Arc Welding
5. SAW-Submerged Arc Welding

SMAW - 6
Why Welding is Important
• Provides a permanent joint
• Welded components become a single
entity
• One of the most economical ways to join
parts in terms of material usage and
fabrication costs
• Mechanical fastening usually requires
additional hardware (e.g., screws) and
geometric alterations of the
assembled parts (e.g., holes)
• Not restricted to a factory environment
• Welding can be accomplished "in the
field"

SMAW - 7
SMAW Safety
• Fumes and Gases can be dangerous
• Keep your head out of the fumes
• Use enough ventilation, exhaust at the
arc, or both, to keep fumes and gases
from your breathing zone and the
general area
• The SMAW process can withstand
wind and exhaust near the arc from
ventilation equipment
• Electric Shock can kill – to receive a
shock your body must touch the
electrode and work or ground at the
same time
• Do not touch the electrode or metal
parts of the electrode holder with skin
or wet clothing
• Keep dry insulation between your
body and the metal being welded or
ground
SMAW - 8
SMAW Safety
• Arc Rays can injure eyes and skin -
Choose correct filter shade (See chart
below)

SMAW - 9
SMAW Safety
• 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
• 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.

SMAW - 10
SMAW Safety
• Do not weld around combustible or flammable
materials.
• Do not pick up hot metal with the hands.
(NOTE) Use a pair of pliers/Tongs
• Do not weld in confined places without ventilation

• 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.
• Stand on dry footing when welding.
• Keep area around welder clean.
• Keep tools and metals in proper location.
SMAW - 11
SMAW Safety
Personal Protective Equipment

SMAW - 12
Common SMAW Tools/Equipment
• Power Supply
• Electrode Holder
• Ground clamp
• Shield or helmet
• Gloves
• Chipping hammer
• Safety goggles or glasses
• Wire brush/Steel Brush
• Electrode
• Tongs
• Cables

SMAW - 13
SMAW Welding Circuit
• Current flows through

the electrode cable, to
the electrode holder,
through the electrode,
and across the arc
• On the work side of the
arc, the current flows
through the base
material to the work
clamp and back to the
welding machine

SMAW - 14
SMAW Process
Let’s take a little closer look at the SMAW process…
Travel direction Electrode
Shielding Gas
1
4
Slag
6 3 Weld Puddle
2 Arc
5 Solidified Weld Metal

SMAW - 15
Types of Electrode
• Mild Steel
• High Carbon Steel
• Hard Surfacing
• Alloys – special purpose

SMAW - 16
The Electrode
• Is a consumable - it gets melted during
the welding process
• Is composed of two parts
• Core Rod (Metal Filler)
 Carries welding current
 Becomes part of the weld
• Flux Coating
 Produces a shielding gas
 Can provide additional filler
 Forms a slag

SMAW - 17
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

SMAW - 18
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.

SMAW - 19
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.)

SMAW - 20
Electrode Characteristics
•AMild
W S Steel C u rren t
C la s s C o v e r in g R e q u i r e m e n ts P o s i ti o n C h a r a c te r i s ti c s
• High Carbon Steel

E X X 10 C e llu lo s e DCEP A ll D e e p P e n e tr a tio n ,
S o d iu m W ith R ip p le s
• Hard Surfacing
E X X 11 C e llu lo s e AC , D C E P A ll D e e p P e n e tr a tio n ,
P o ta s s iu m F la t D e c k in g W ith R ip p le s
• Alloys – special purpose

E X X 22 R u tile D C E N, AC F la t, H o r iz . F ille t D e e p P e n e tr a tio n ,
S o d iu m W ith R ip p le s
E X X 24 R u tile AC , D C E P, D C E N F la t, H o r iz . F ille t H ig h D e p o s itio n

5 0 % Ir o n S h a llo w P e n e tr a tio n
P ow der
E X X 27 M in e r a l A C ,D C E P , D C E N F la t, H o r iz . F ille t H ig h D e p o s itio n
5 0 % Ir o n S h a llo w P e n e tr a tio n
P ow der

SMAW - 21
AWS C u rren t
C la s s C o v e r in g R e q u ir e m e n ts P o s itio n C h a r a c te r is tic s
E X X 12 R u tile D C E N, AC A ll M ild to M e d iu m P e n e tr a tio n

S o d iu m
E X X 13 R u tile AC , D C E P, D C E N A ll M ild P e n e tr a tio n

S o d iu m
E X X 14 R u tile AC , D C E N A ll M e d iu m P e n e tr a tio n
3 0 % Ir o n
P ow der
E X X 18 L o w -H y d ro g e n D C E P, AC A ll M e d iu m P e n e tr a tio n
3 0 % Ir o n
P ow der
E X X 28 L o w -H y d ro g e n AC , D C E P F la t, H o r iz . F ille t H ig h D e p o s itio n
5 0 % Ir o n
P ow der

SMAW - 22

SMAW - 23
Electrode Identification

SMAW - 24
The Arc
• An arc occurs when the
electrode comes in contact
with the work-piece and
completes the circuit … like
turning on a light!
• The electric arc is
established in the space
between the end of the
electrode and the work
• The arc reaches
temperatures of 10,000°F
which melts the electrode
and base material

SMAW - 25
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 and
manipulates while welding
1/8” E6013 at 125 Amps AC

SMAW - 26
Shielding Gas
• A shielding gas is
Shielding Gas formed when the flux
4
coating melts.
• This protects the weld
3 puddle from the
2 atmosphere preventing
contamination during
the molten state
The shielding gas protects
the molten puddle from the
atmosphere while stabilizing
the arc

SMAW - 27
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

SMAW - 28
Slag
• Slag is a combination of
the flux coating and
impurities from the base
metal that float to the
surface of the weld.
• Slag quickly solidifies to
form a solid coating
• The slag also slows the
cooling rate of the weld
• The slag can be chipped
This welder chips the slag off of away and cleaned with a
a weld during the repair of wire brush when hard
railroad tracks
SMAW - 29
SMAW Equipment Set Up
1. Turn power supply on 4. Adjust output
2. Connect work clamp a. Polarity
3. Select electrode b. Amperage
a. Type
6. Insert electrode into electrode
b. Diameter holder

SMAW - 30
Methods of Establishing an Arc
• Scratching
• Similar to striking a match
• Tapping
• Straight down and up

SMAW - 31
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

SMAW - 32
Running a Bead
• Important to keep
• Proper arc gap
• About 3/16”
• Should sound like sizzling
bacon
• Forward motion
• Need to maintain proper
bead width (about 2-3
times the width of the
electrode)
• Electrode angle
• Tipped forward 20° in the
direction of travel

SMAW - 33
Electrode Movement

SMAW - 34
Work Angle
• The work angle is the
angle between the
electrode and the work
as depicted on the left
• Work angles can vary
depending on the
position the weld is
being made in

SMAW - 35
Travel Angle
• Also commonly called
Lead Angle
• The travel (lead) angle
is the angle between
the electrode and the
plane perpendicular to
the weld axis

SMAW - 36
Travel Speed
• The travel speed is the
speed at which the
electrode moves along
the base material while
welding
• Too fast of a travel
speed results in a ropey
or convex weld
• Too slow of a travel
speed results in a wide The travel speed impacts the
weld with an excessive shape of the bead.
metal deposit

SMAW - 37
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 Back stepping is a short
weld cracking move in the opposite
direction of weld travel

SMAW - 38
Troubleshooting Welds
A B C D E F G
These welds were cut and etched with nitric acid to show
penetration
SMAW - 39
Good Amps Amps Arc Arc Travel Travel

too too Length Length Speed Speed
Low High too too too too
Short Long Slow Fast

SMAW - 40
Good Amps Amps Arc Arc Travel Travel

too too Length Length Speed Speed
Low High too too too too
Short Long Slow Fast

SMAW - 41
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
• Copyright © ZSCMST Permission required for reproduction or display.
SMAW - 42
Kinds of Weld
Fillet
Groove
Bead
SMAW - 43
Types of Weld Joints
Butt Joint
Lap Joint
Tee Joint
Corner Joint
Edge Joint
SMAW - 44
Square Butt Joint

SMAW - 45
Lap Joint
A- single lap joint,

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

SMAW - 46
Tee Joint
A- plain tee
B- single beveled
C- double beveled
D- single J
E- double J

SMAW - 47
Corner Joint

SMAW - 48
Edge Joint

SMAW - 49
Welding Positions
Flat
1F & 1G
Horizontal
2F & 2G
Vertical
3F & 3G
Overhead
4F & 4G
SMAW - 50
Welding Positions

SMAW - 51
SMAW
Following proper procedures when preparing to weld and
striking the arc will develop confidence in your abilities
• Prepare the work area so that everything is ready and
convenient before you start
• Make a final check to see that flammable materials are out
of the way and that unnecessary tools are not lying around
• Be sure the machine is turned off
• Set the machine to the desired amperage
• Insert the bare end of the electrode in the electrode holder
and hold the end of the electrode about 1 inch above the
metal at the point where the weld is to be started
• Turn the welder on

SMAW - 52
SMAW
• Lower the helmet over your eyes, bring the electrode in
contact with the work and withdraw it slightly
 Current jumps this small gap creating
the electric arc.
 The moment the arc is struck the
concentration of intense heat,
estimated between 6,000 and 9,000
degrees F, melts the base metal and the
end of the electrode forming a molten
metal pool called crate
a r
SMAW - 53
SMAW
• Use the two methods of starting the arc its either by striking
or tapping on the surface of the metal to prevent it from
sticking to the base metal/work
• If the electrode is not instantly pulled away it will fuse with
the base metal and stick
• If the electrode is pulled too far away, the arc will be
extinguished
• Raise the tip of the electrode to about 3 /16 inch above the
base metal. This forms a long arc which is held for a three
count in order to preheat the base metal
• Lower the electrode to the correct arc length
SMAW - 54
SMAW
• Weaving is running a bead with a sideways or oscillating
motion. It is used when covering a wide area with weld
metal or to maintain a large molten weld crater
• Padding is the process of building up several layers of weld
deposit by running over-lapping passes. Padding is used to
rebuild worn pieces by building up the piece to an oversized
condition and grinding or machining to the correct size

SMAW - 55
GAS WELDING & CUTTING
• Oxyfuel welding is a welding process
where the heat for fusion is supplied by
an torch using oxygen and a fuel gas.
• The oxyfuel cutting process uses a
combination of oxygen and a fuel to
provide a high temperature flame.
• Oxyacetylene Welding is a manual
process in which the welder must
personally control the torch movement
and filler rod application.

OAW - 56
GAS WELDING & CUTTING SAFETY
• Make sure regulators are tight.
• Never use oily rags around cylinders and regulators.
• Check hoses for leaks before lighting the torch.
• Make sure regulators are at proper settings.
15 psi max. acetylene 40 psi max. oxygen
• Make sure mixing knob is off before lighting torch.
• Light acetylene first then mix oxygen.
• Do not pick up material with gloves after it is cut.
• Cut off cylinders when through cutting.
• The light from cutting can be dangerous, a #5 shade
filter lens is recommended for most cutting
applications.
• There is not enough UV light created by the flame to
burn your skin.
• Sparks, molten metal and the flame can burn you,
wear protective clothing.
OAW - 57
Industrial Cap with Visor

Quality Safety Turned to the
Glasses Back
Gauntlet Long Sleeve
Leather Shirt
Welding
Gloves Pants without
High Top Cuffs
Leather Boots
(Steel Toes)
OAW - 58
• Welding or Cutting May
Produce Hazardous
Fumes & Gases
• Leaking Gases May Cause
Injury or Death
• Use Ventilation To Keep
Air Breathing Zone Clear
& Comfortable
• Use Special Care When Welding or Cutting In a Confined Area or on a
Container
• Do Not Weld or Cut Near Flammables
• Remove Flammable Materials
From The Work Area
• Keep a Fire Extinguisher in
the Work Area
• Wear Fire Retardant Clothing
& a Hat When Welding or Cutting
• Do Not Weld on Containers Which Have Held Combustible Materials
or Closed Containers of Any Kind

OAW - 59
• Cylinders may Explode if Damaged
• Keep Cylinders Upright &

Chained to Support or
Approved Carrier
• Keep Cylinder Free from Sparks
& Out of the Spark Zone
• Never Allow Flames from a Torch to Come in Contact
with a Cylinder or Hose

OAW - 60
GAS WELDING & CUTTING EQUIPMENT
High
Pressure
Hazard Flammable
Monolithic
Fusible Porous
Plugs Filler
Hollow
Material
Vigorously
Acetone
Supports
dissolves
Combustion
acetylene
Oxygen Acetylene
Cylinder Cylinder
OAW - 61
Oxygen Regulator Acetylene Regulator

•2250 psi – full tank •225 psi – full tank
•Clockwise Threads (right hand) •Counterclockwise Threads (left
hand)
•5-10 psi line pressure (25-35 psi
for cutting) •5-7 psi line pressure

OAW - 62
Red (Acetylene) Hose
Nuts Have Left-Handed
Threads
Green (Oxygen) Hose Nuts

Have Right-Handed Threads

OAW - 63
Welding Mixer & Tip
Tip Mixer
Nut Hand
Tight
OAW - 64
Welding Tips
Welding Tip (Single Piece)
Torch Tip Tube with Welding Tip (Two Piece)

OAW - 65
Heating Tips (Rosebuds)
Heating Tip Assemblies for

Acetylene

OAW - 66
Welding Torch Handle

Combination Welding Torch with Mixer and
Welding Tip
Handle
Tip
Valves

OAW - 67
Welding Torch Handle
Oxygen
Tip Mixer Handle Valve
Oxygen
Acetylene Acetylene
Mixed Valve
Copyright ©Gases
ZSCMST Permission required for reproduction or display.
OAW - 68
Cutting Torch Handles
Combination Cutting Torch with Cutting
Attachment
Straight Cutting Torch

OAW - 69
Cutting Torch Handle
Combination Torch with Cutting Attachment
Cutting Lever Oxygen Valve

Oxygen
Mixer
Cutting Tip Cutting Valve Union Nut Acetylene Acetylen

e Valve
OAW - 70
Flint Striker

OAW - 71
Tip Cleaner

OAW - 72
OPERATIONS & APPLICATIONS
Uses of Oxy-acetylene
• Welding
• Cutting
• Heating
• Brazing
• Soldering

OAW - 73
Three Steps for Setting Up Unit
1. Loosen Regulators
2. Turn on Tanks
• Oxygen – all the way (double seated valve – all the way for
consistent gas flow)
• Acetylene – ¼ turn
3. Adjust Line Pressure

• Oxygen – 5-10 psi (25-35 for cutting)
• Acetylene – 5-7 psi
OAW - 74
Three Steps for Shutting Down Unit
1. Turn Tanks Off
2. Bleed Lines
3. Loosen Regulators

OAW - 75
Advantages
• Low Cost Equipment
• No Electricity Required
• All Position Welding
• Extremely Portable

OAW - 76
Advantages
Variety of Thickness
No Slag
No Spatter

OAW - 77
Limitations Of OFW
• Primarily Ferrous Materials
• Must Operate under “Hot Zone”
Concept
– (Fire Hazard)
• Various Hazards Associated with
Fuel Gases, Oxygen and High
Pressure Gases
• Flashbacks & Backfires
• Often Slow
• Cannot Weld with All Fuel Gases

OAW - 78
Welding Flame Parts
Primary Flame Secondary Flame

• Inner cone • Shields weld from air
• Small, blue part

OAW - 79
Welding Flame Types
Carburizing Flame – excess acetylene; has feather
Neutral Flame – when feather reaches inner cone - 5800 degrees
Oxidizing Flame – excess oxygen; small cone, hisses

OAW - 80
Welding Basics
Forehand Welding

OAW - 81
Welding Basics
Bead without Filler Metal Bead with Filler Metal

OAW - 82
Welding Tip Height
Bead with Filler Metal
Flame to Work Distance = (1/8 Inch)

OAW - 83
Welding Torch Angles
Bead with Filler Metal
45o Travel
Angle
90o Work
Angle

OAW - 84
Welding Bead Initiation
Heat until both metals begin to melt
When puddles coalesce, begin traveling forward

OAW - 85
Welding Bead Termination
Pull away before burning through

OAW - 86
Weld Quality
Torch Torch Torch Torch

OK
High Low Slow Fast

OAW - 87
Oxy Fuel Welding Troubleshooting
Tip Popping:
• Excess oxygen
• Carbon buildup
• Too close to metal (metal too hot)
• Bad seals in torch tip
4 ways to control heat:

• Gas mixture
• Distance between tip & metal
• Speed of travel
• Tip size

OAW - 88
Oxy Fuel Welding Joints
Butt Lap
Joint Joint
Fillet Edge Corner

Joint (Tee Joint Joint
Joint)
OAW - 89
Oxy Fuel Welding Joints

OAW - 90
Brazing Basics
• Non-fusion Weld
• 800 degrees
• Use smaller tip/flame
• Use flux coated brazing
rod
• Grind metal surfaces
before welding

OAW - 91
Brazing Tip Height
Flame to Work Distance = (1 to 1 1/2 Inches)

OAW - 92
Brazing Torch Angles
45o Travel
Angle
90o Work
Angle

OAW - 93
Cutting Basics

OAW - 94
Cutting Flame Types
Carburizing Flame Neutral Flame
Neutral Flame with Oxygen Oxidizing Flame

Cutting Stream

OAW - 95
Cutting Tip Height
1/8 Inch
Between Inner
Cones &
Material to be
cut
OAW - 96
Cutting Travel Speed

OAW - 97
Cutting Torch Angles
90 Degree
Angle
In All
Directions

OAW - 98
Cut Initiation

OAW - 99
Cut Initiation

OAW - 100
Cut Progression

OAW - 101
Cut Termination

OAW - 102
Cut Quality
Good Cut Poor Cut

Quality Quality

OAW - 103
Dirty Tip
Dirty Tip

OAW - 104
Speed
Extremely Fast Extremely Slow
Slightly Too Fast Slightly Too Slow

OAW - 105
Tip Height
Too High
Too Low

OAW - 106
Other
Too Much Cutting

Oxygen
Too Hot Pre-

Heat
OAW - 107


OAW - 108

Summary
• High Quality Cuts on Various Plate
Thicknesses
• Cuts Made on a Variety of Steels
• Uses Non-Consumable Cutting Tip
• Operator Requires Some Skills
• Cuts Should Have No Dross or
Spatter

OAW - 109

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Shielded Metal Arc Welding

Copyright © ZSCMST Permission

•During this overview, we will discuss

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• Upon successful completion of the SMAW Unit of

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1. SMAW-Shielded Metal Arc Welding

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• Do not strike an arc or weld until you are sure those

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• Do not weld in conﬁned places without ventilation

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• Current ﬂows through

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Travel direction Electrode

5 Solidiﬁed Weld Metal

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• High Carbon Steel

• Alloys – special purpose

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(Note: On thicker metals more heat is

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• High Carbon Steel

• Alloys – special purpose

E X X 24 R u tile AC , D C E P, D C E N F la t, H o r iz . F ille t H ig h D e p o s itio n

Copyright © ZSCMST Permission required for reproduction or display.

E X X 12 R u tile D C E N, AC A ll M ild to M e d iu m P e n e tr a tio n

E X X 13 R u tile AC , D C E P, D C E N A ll M ild P e n e tr a tio n

Copyright © ZSCMST Permission required for reproduction or display.

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1/8” E6013 at 125 Amps AC

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• Similar to striking a match

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Good Amps Amps Arc Arc Travel Travel

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Good Amps Amps Arc Arc Travel Travel

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Reason for Poor Welds

• Machine adjustment too hot or too

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A- single lap joint,

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