Heat for welding generated by electric arc

established between flux-covered consumable metal rod (electrode) and work

Called stick electrode welding Combustion and decomposition of electrode creases gaseous shield
Protects electrode tip, weld puddle, arc, and

highly heated work from atmospheric contamination Additional shielding provided by covering of molten slag (flux)

Shielded Metal Arc Welding (SMAW) (continued)

Also known as stick welding Uses an arc between a covered electrode and a work piece Shielding is obtained from decomposition of the electrode cover Pressure is not used Filler metal is obtained from the electrode

Shielded Metal Arc Welding (SMAW) (continued)

Is popular because it can be used in the field without complicated equipment and gases Mainly used for repair work and occasional welding

An electric arc is generated between a coated electrode and the parent metal The coated electrode carries the electric current to form the arc, produces a gas to control the atmosphere and provides filler metal for the weld bead Electric current may be AC or DC. If the current is DC, the polarity will affect the weld size and application

Shielded metal arc welding one of most used of various electric arc welding processes
9% 13% 42% 2% SMAW GMAW/FCAW GTAW SAW Others

34%

Equipment less complex, more portable and less costly

Can be done indoors or outdoors, in any location and any position

Electrodes available to match properties and strength of most base metals
Not used for welding softer metals Not as efficient in deposition

Sets up electric circuit

Includes welding machine, work, electric

cables, electrode holder and electrodes, and a work clamp

Heat of electric arc brings work to be welded and consumable electrode to molten state
Heat intense: as high at 9,000F at center

Electric arc started by striking work with electrode Heat of arc melts electrode and surface of base metal Tiny globules of molten metal form on tip of electrode and transferred by arc into molten pool on work surface After weld started, arc moved along work

Each type of power source has fundamental electrical differences that best suit particular processes Welding machine

Must meet changing arc load and

environmental conditions instantly Must deliver exact amount of electric current precisely at right time to welding arc

Available in wide variety of types and sizes

Also known as power supplies and welding machines Two classifications

Output slope Whether constant current or constant voltage Power source type Transformer Transformer-rectifier Inverter Generator

Two basic types

Constant current
Referred to as variable voltage

Constant voltage
Referred to as constant potential

Relationship between output voltage and output current (amperage) of machine as current increased or decreased
Also called volt-ampere characteristic or curve

Largely determines how much welding current will change for given change in load voltage
Permits welding machine to control welding

heat and maintain stable arc

Indicates type and amount of electric current designed to produce Each arc welding process has characteristic output slope

SMAW and GTAW require steep output slope

from constant current welding machine GMAW and FCAW require relatively flat output slope from constant voltage power source Submerged arc welding adaptable to either slop

Engine-driven generators
Powered by gas or diesel combustion engine Can be found with a.c. or d.c. electric motor No longer being manufactured and rarely found

Transformer-rectifiers
Use basic electrical transformer to step down

a.c. line power voltage to a.c. welding voltage Welding voltage then passed through rectifier to convert a.c. output to d.c. welding current May be either d.c. or a.c.-d.c. machines

A.C. transformers
Used to step down a.c. line power voltage to

a.c. welding voltage

Inverters
Increases frequency of incoming primary

power
Constant current, constant voltage, or both Produce a.c. or d.c. welding current

Important to select right power source for each job Table 11-1 "Common types and uses of arc welding machines" should be studied Study of job indicates whether a.c. or d.c.

Shielded metal arc welding and gas tungsten

arc welding must use constant current machine Gas metal arc prefers constant voltage machine

Used for shielded metal arc welding and gas tungsten arc welding
Current remains fairly constant regardless of

changes in arc length

Called drooping voltage, variable voltage,

or droopers
Load voltage decreases as welding current increases

Constant current welding machines

Steep output slope Available in both d.c. and a.c. welding

current

Steeper the slope, the smaller current change Enables welder to control welding current in specific range by changing length of arc