SMAW-Basics DEMO

Shielded Metal Arc Welding
(SMAW)
Arc welding
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 (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)
Copyright Journeyman Welding & Piping Services. Permission required for reproduction or display.
11 - 1
SMAW
American Welding Society
11 - 2
SMAW Advantages
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
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SMAW Operating Principles

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
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SMAW Operating Principle
American Welding Society
11 - 5
Welding Power Sources

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

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Four Types of Power Source

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
Inverters
Increases frequency of incoming primary power
Constant current, constant voltage, or both
Produce a.c. or d.c. welding current
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Four Types of Power Source

A.C. transformers
Used to step down a.c. line power voltage to a.c.
welding voltage
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
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Bridge Rectifier
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Output Slope
Two basic types
Constant current
Constant voltage
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Current Controls
Amperage
Quantity of current (flow)
Determines amount of heat produced at weld
Voltage
Measure of force of current (push)
Determines ability to strike an arc and maintain its
consistency
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Constant Current
Welding Machines
Used for shielded metal arc welding and gas tungsten
arc welding
Available in both d.c. and a.c. welding current
Current remains fairly constant regardless of changes in arc
length
Total Wattage stays the same
Voltage drops as amps increase (dropping arc voltage
(DAV) machine)
Enables welder to control welding current in specific

range by changing length of arc
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Open Circuit and Arc Voltage

Open circuit voltage runs between 50-100 volts (no
welding being done, volts high, no amps)
Drops to arc voltage when arc struck
Arc voltages (Voltage generated between electrode and work during

welding, voltage lower, amps higher)
Range: 36 volts (long arc) to 18 volts (short arc)

Determined by arc length held by welder and type of
electrode used
Arc lengthened, arc voltage increases and current

decreases
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Polarity
Electrode negative and electrode positive used in d.c.
welding
DCEN (d.c. electrode negative)
Electrode connected to negative terminal of power source
and work connected to positive terminal (current flows from
neg to pos) flow from electrode to work = more electrode
consumption.
DCEP (d.c. electrode positive)

Electrode connected to positive terminal of power source
and work connected to negative terminal
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D.C. Transformer-Rectifier
Welding Machines
Have many designs and purposes
Flexibility one reason for wide acceptance
Deliver either DCEN or DCEP
May be used for:
Stick electrode welding

Gas tungsten arc welding
Submerged arc welding
Multi-operator systems
Stud welding
Miller Electric Mfg. Co.

The Lincoln Electric Co.
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Transformer-Rectifier Machines
Have two basic parts
Transformer for producing and regulating
alternating current that enters machine
rectifier that converts a.c. to d.c.
Third important part is ventilating fan

Keeps rectifier from overheating
Design improves arc stability and makes it easy

to hold short arc which is soft and steady
No major rotating parts so consume little power
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A.C. Transformer Welding

Machines
Most popular a.c. welding machine
Function of transformer
Step down high voltage of input current to high
amperage, low voltage current required for welding
Especially suited
for heavy work
Miller Electric Mfg. Co
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Advantages of a.c. Power

Sources
Reduces tendency to arc blow
Can use larger electrodes
Resulting in faster speeds on heavy materials
Lower cost
Decreased power consumption
High overall electrical efficiency
Noiseless operation
Reduced maintenance
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D.C. and A.C.-D.C. Inverter

Welding Machines
Portable, lightweight, and versatile
May be either constant current, constant
voltage or both
Can perform several different processes
Miller electric Mfg. Co.
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Duty Cycle
Percentage of any given 10-minute period that
machine can operate at rated current without
overheating or breaking down
Rating of 100% means machine can be used at
rated amperage on continuous basis
Required by continuous, automatic machine welding
Rating of 60% means machine can be used at its

capacity 6 out of every 10 minutes without damage
Satisfactory for heavy SMAW and GTAW
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Twin Carbon Electrode Holder

Two leads are
required because
the arc is created
between the two
electrodes.
Larger than the
metal electrode
holder
Metal shield to protect welder's

hand from intense heat.
Holder is water cooled

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Atomic-Hydrogen Arc
Welding
Process in which electric arc surrounded by
atmosphere of hydrogen
Gas shields molten metal from oxidation and
contamination from the air
Transfers heat from electrode to work
Arc formed between two electrodes
Temperature produced by arc: 7,500F

Current supplied by a.c. welding transformer
Hydrogen supplied in cylinders
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Atomic-Hydrogen Electrode
Holder
General Electric Co.
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Atomic-Hydrogen Arc
Welding
Metal of same analysis as being welded can be
deposited
Welds may be heat treated
Unusually smooth, ductile, nonporous and free
from impurities
Surface free from scale
May weld hard-to-weld metals

Advantages: increased production, low
operating cost, and low maintenance cost
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SMAW-Basics DEMO

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Shielded Metal Arc Welding

Called stick electrode welding

American Welding Society

SMAW Operating Principles

Heat of electric arc brings work to be welded

SMAW Operating Principle

American Welding Society

Welding Power Sources

Available in wide variety of types and sizes

Four Types of Power Source

Four Types of Power Source

Enables welder to control welding current in specific

Open Circuit and Arc Voltage

Arc voltages (Voltage generated between electrode and work during

Range: 36 volts (long arc) to 18 volts (short arc)

Arc lengthened, arc voltage increases and current

DCEP (d.c. electrode positive)

May be used for:

Stick electrode welding

Miller Electric Mfg. Co.

Third important part is ventilating fan

Design improves arc stability and makes it easy

A.C. Transformer Welding

Miller Electric Mfg. Co

The Lincoln Electric Co.

Advantages of a.c. Power

D.C. and A.C.-D.C. Inverter

Miller electric Mfg. Co.

The Lincoln Electric Co.

Rating of 60% means machine can be used at its

Twin Carbon Electrode Holder

Metal shield to protect welder's

The Lincoln Electric Co.

Holder is water cooled

Temperature produced by arc: 7,500F

General Electric Co.

May weld hard-to-weld metals

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