MANUAL METAL ARC

WELDING

MMA - Principle ofoperation

MMA welding
Main features:
Shielding provided by decomposition of flux
covering
Electrode consumable
Manual process

Welder controls:

Arc length
Angle of electrode
Speed of travel
Amperage settings

Arc characteristics
Welding involves striking an arc
between the electrode and the
workpiece, with the heat of the arc
melting the electrode (i.e. the filler
material), and with the coating
melting to form a protective slag

Uses
This has many operational uses such
as repair work to constructional
steel. It is ideal for outdoor uses as
the gasses needed to form the shield
are not blown away.

Manual Metal Arc BasicEquipment

Basic welding circuit

MMA Welding Plant

Transformer:
Changes mains supply voltage to a voltage suitable
for welding. This is a device used to change the
voltage of A.C. It is necessary to change the voltage
when welding thicker or different types of steel. Has
no moving parts and is often termed static plant .

Rectifier:
Changes A.C. to D.C., can be mechanically or
statically achieved.

MMA Welding Plant

Generator:
Produces welding current. The generator consists of
an armature rotating in a magnetic field, the
armature mustbe rotated at a constant speed either
by a motor unit or, in the absence ofelectrical
power, by an internalcombustion engine.

Inverter:
An inverter changes D.C. to A.C. at a higher
frequency.

AC or DC machine
Electrode
Electrode holder
Cables, cable connectors
Cable lug
Chipping hammer
Earthlings clamps
Wire brush
Helmet
Safety goggles
Hand gloves
Aprons, sleeves.

Terms associated with

electrisity

Conductor
In welding an electrical conductor is a metal trough which
electricity will easily flow. Copper is the most used conductor.

Voltage
This is the unit of electrical pressure. The voltage at the terminals
of an AC welding mashine is never more than 80 volts for safty
reasons. This electrical pressure (of force) is responsabile for the
current flow in a welding circuit.

Amperage
This is the measurement of the electron flow, or current, trough an
electrical conductor. Amperage is mesured in amps. An amp is a
unit quantity of electricity passing trough a given pointper second.
This is similar to the rate water flows trough a pipeline.

Electric arc welding process

This is also called manual metal arc welding or MMAW. In MMAW a

high output amperage (low voltage) is pased trough a consumable
flux coated electrode and the work piece. This sets up an electrical
resistense between the tip of the electrode and the work which
causes the elctrode to melt off and form a weld bead.

nstant Current Power Source

ooping Characteristic)

stant Current Power Source

ooping Characteristic)

Constant Current Power Source

(Drooping Characteristic)
The staticcharacteristic:

Constant Current Power Source

(Drooping Characteristic)

Factors to be considered when selecting a MMA powe

Constant Current Power Source

(Drooping Characteristic)

Combined characteristic - the arc force op

MMA Welding Variables

Voltage
The arc voltage in the MMA process ismeasured as
close. It isvariable with a change in arc lengththe arc
as possible.

O.C.V.
The open circuit voltage is the voltage required
toinitiate, orre-ignite the electrical arc and will change
with the type ofelectrode being used e.g 70-90 volts

Current
The current used will be determined by the choice
ofelectrode, electrode diameter and material type and
thickness. Current has the most effect on penetration.

Polarity
Polarity is generally determined by operation and
electrode type e.g DC +ve, DC ve or AC

MMA Welding Checks

OCV open circuit volts
A check should be made to ensurethat the equipment
can produce the OCV required by the consumable and
that any voltage selector has been moved to the correct
position
Current & polarity
A check should be made to ensurethe current type and
range is as detailed on the WPS
Other variables
Checks should be made for correct electrode angle, arc
gap and travel speed SafetyCheck should be made on
the current carrying capacity, orduty cycle of the
equipment and all electrical insulation is sound and in
place. Correct extraction systems should be in use to
avoid exposure to toxic fume.

MMA Welding Checks

The welding equipment
A visual check should be made on theequipment
to ensure it is in good working order
The electrodes
Checks should be made to ensure that thecorrect
specification of electrode is being used, the
electrode is the correct diameter and in good
condition.
Basic fluxed electrodes ensure the correct heat
treatment is being carried out before use
Rutile electrodes do not require pre-baking but
should be stored in a dry condition.
Cellulosic electrodes should not be dried

MMA electrode holder

MMA weldingparameters
Welding current

approx. 35 A/mm of diameter

governed by thickness, type of joint and welding posit

Too low

Welding
current

poor starting
slag inclusions
weld bead contour too high
lack oflack offusion/penetration

Too high
spatterspatt
er
excess
penetration
undercut
burn-through

MMA weldingparameters
Arc length = arc voltage
Too low
arc can be extinguished
stubbing

Arc voltage

Too high

spatter
porosity
excess penetration
under cut
burn-through

Polarity: DCEP generally gives deeper penetration

MMA welding parameters

Type of current:
voltage drop in welding cables is lower with
AC
inductive looses can appear with AC if cables
arecoiled
cheaper power source for AC
no problems with arc blow with AC
DC provides a more stable and easyto strike
arc,especially with low current
better mechanical properties
DC provides a smoother metal transfer

MMA - Troubleshooting

MMA quality (left to right)- current, arc length and tra

normal; current too low; current too high; arc length t
arc length too long; travel speed too slow; travel spee

MMA welding typical defects

Most welding defects in MMA are caused by
alack of welderskill (notan
easilycontrolled process),the
incorrectsettings of the equipment, or the
incorrect use, and treatmentofelectrodes

Typical Welding Defects:

Slag inclusions
Arc strikes
Porosity
Undercut
Shape defects (overlap, excessive root
penetration, etc.)

Manual Metal Arc Welding (MMA)

Advantages:
Field or shop use
Range of consumables
All positions
Portable
Simple equipment
Disadvantages:
High welder skill required
High levels of fume
Hydrogen control (flux)
Stop/start problems
Comparatively uneconomic when compared with
some other processes i.e MAG, SAW and FCAW

Hazards

Hazards in the welding workshop include electric shock, fumes,

heat, glare and harmful rays.

Electric shocks-low voltage

Electric shocks are possible on the secondary (low voltage) side of
the welding circuit. They may be caused by:
working on wet floors as hock may be felt when putting an
electrode in the holder. Always stand on insulated mats or wooden
boards to reduce the risk and wear dry leather gloves
Working in a very humid climate or rainy weather-as hock may be
felt when changing electrodes. Keep electrodes and gloves dry.
Electrical shocks-high voltage
High voltage shocks shouldn't happen if precautions are taken such
as ensuring welding machines are maintained by licensed electrical
tradesmen and that you never interfere with the inside part soft he
welding machines.

Symptoms of electrical shock

Often electric shock stuns but doesn't kill. However when electricity
passes through the body it causes muscles to contract and can stop
the heart from beating or cause breathing to stop. Electricity can also
cause serious burns.

Fumes
Fumes can result from:
the production of oxides and nitrous gases from in complete
combustion or oxidation of nitrogen from the atmosphere
the surface coatings on steel such as galvanising, cadmium or
chrome plating and paints and solvents such as red oxide
parts/degreasing solvents
elements within the parent metal
electrode flux coatings.
Safty
Welding should be carried out in well ventilated areas. If an
extraction system is not available, an approved respirator should be
used to filter out the fumes.

Dangerous fumes
Gases, dusts and vapours are given off during welding. They
can cause:
gassing or asphyxiation because the oxygen has been used
up in the work area (common in confined spaces)
build up of poisonous metals in the body, such as lead,
cadmium, zinc, beryllium or mercury
respiratory ailments from wheeziness to serious lung
disorders.
Heat
Heat may be generated by various means. In manual metal
arc welding it is generated by the passage of an electric
current across an arc gap.
The electric arc (about 6000C) generates the heat to melt
and fuse the metal surfaces. Heat is transferred in two ways,
by conduction and by radiation.

Protective clothing
Protective clothing will help
to protect from heat,
hot metal and harmful rays.

Safty
Wear safety glasses at all times.

 Wear appropriate clothing to protect your

eyes and skin, from welding rays.

Prevention, is the best policy, avoid exposing

eyes to harmful rays.