Shielded Metal Arc Welding

(SMAW)

NAME: 1) FARIS BIN MOHD FADZIL

2) MUHAMMAD AMYRUL HAKIEM BIN ONN
3) MUHAMMAD NOR IDHAM BIN RAFIEE
4) FAKHRUL IZZAM BIN KAMARAZAMAN
5) FAREEZ BIN MOHD HASSAN AHARI
6) ARIF AZHAR IRSYADUDDIN BIN IBRAHIM
7.1.5 BASIC SCHEMATIC ARC WELDING MACHINE CIRCUITS
7.1.6 DIFFERENTIATE THE TYPE OF POLARITY
A. define the terminology of straight polarity and reverse polarity

Polarity in resistance spot welding has to do with the direction of the current flow in the welding
process. With direct current (DC) the welding circuit can either be straight, or reverse polarity.
When the machine is set for straight polarity, the current flows from the electrode to the weld
surface and creates considerable heat in the metal. When the machine is in reverse polarity, the
current is backwards and is flowing from the metal to the electrode causing a greater
concentration of heat at the electrode. In an opposed weld, there are three material interfaces:
two electrode-to-part interfaces and one part-to-part interface. Since conductive electrodes are
generally placed against resistive materials, and vice-versa, it is not uncommon to have
dissimilar junctions in welding (see blog Spot Welding? Remember the old adage 'opposites
attract.') To take advantage of polarity, the negative electrode should be placed on the most
resistive part and the positive electrode against the most conductive part. This will increase the
heat at the interface of the two materials and reduce the heat at the electrodeto-part interfaces.
Reversing the polarity will cause the material interface to be colder and may cause electrode
sticking.
B. CHARACTERISTICS OF POLARITY

1. Clean base metal and position flat

2. Set amperage at 130 to 145 for 5/32" electrode
3. Adjust to either polarity
4. Strike an arc. Hold normal arc length and standard electrode angle and run a bead
5. Listen to the sound of the arc. Correct polarity, with normal arc length and amperage, will produce a
regular "crackling" sound. Incorrect polarity, with normal length and amperage setting will produce irregular
"crackling" and "popping" with an unstable arc
6. See above for characteristics of arc and bead when using metallic electrode on correct and incorrect
polarity
7. Adjust to the other polarity and run another bead
8. Clean beads and examine. With the wrong polarity, the electrode negative, you will get many of the bad
bead characteristics shown in Lesson 1.6
9. Repeat several times, until you can quickly recognize correct polarity
C. inquire the procedures to choose the type of polarity
The first important point is that not all electrodes can be used with all polarities. Electrode manufacturer
information and specifications such as BS EN ISO 2560:2005 and AWS A5.1-2004, define the polarity with
which different electrodes may be used. The choice of polarity also depends on the type of the material
and joint design. A welding procedure should specify the polarity for each run.

Unlike TIG/GTAW welding, more heat is generated at the cathode than the anode. This effects the choice
of polarity. With DC electrode positive (reverse) polarity, more heat is generated at the workpiece. This
results in deeper penetration of the weld bead, and can reduce the incidence of lack-of-fusion defects. An
example of an application may be the root run in a 25mm (1in) thick low-carbon steel fillet joint.

DC electrode negative (straight) polarity generates more heat at the electrode. This results in a higher
burn off rate, and therefore a higher deposition rate at a given current. However, it also produces a less
penetrating bead compared to DC electrode positive. Therefore, it is often used for welding thin sheet
materials, or joints with poor fit-up, where more control of the weld pool is needed due to the increased
risk of burn through.

Thus, in choosing the polarity of the electrode, the details and nature of job need to be considered.
7.1.7 classify the techniques of arc welding

A. welding process
B. EFFECT OF ARC LENGTH, ELECTRODE ANGLE AND SPEED OF
TRAVEL

Arc Length Faults

Arc Length Too Short
This weld was laid with the end of the rod covered by the molten slag. The surface
of the weld is uneven where it has been dragged along by the rod, and the weld
will be low on power and contain slag inclusions.
Arc Length OK
A normal arc weld. The weld has a consistent profile and minimal spatter.
Arc Length Too Long
Too great a distance between the rod and the work will increase the voltage
resulting in a flat and wide weld with a great deal of spatter. It also makes the arc
unstable, and the slag will be difficult to remove from the edges of the weld.
Sectioning this weld reveals undercutting to the left side.
Electrode Angle

As the angle between the electrode and the plate determines the point of
impingement and direction of the arc force, it has a critical effect on the weld
bead profile and depth of penetration.
Welding can be carried out with the electrode wire leading, trailing and normal
to the plate surface and the effects on weld shape, penetration and undercut
are shown in Fig.1a for flat plate. For most applications it is usual to weld with
the electrode wire pointing forwards, i.e. leading by 10, in order to obtain the
best combination of bead shape, penetration and resistance to undercut.
Travel Speed Faults
Speed OK
The bead is fairly consistent. The ridges in the weld are semi-circular.
Speed Too Fast
Excessive speed results in a thin, weak bead. The ridges in the weld are
elongated and triangular. Had the current been increased to compensate for the
speed the ridges would still remain elongated.
Speed Too Slow
Welding too slowly results in a wide tall build up of weld. The shape of the weld
is not consistent as the weld pool has built up and then collapsed into the
crater. The poor control of the weld pool can result in cold joints and slag
inclusions.
C. METHOD IN STARTING ARC WELDING

There are two general methods of striking the arc:

Scratching
Tapping
The scratching method is easier for beginners and when using an AC machine. The electrode is moved
across the plate inclined at an angle, as you would strike a match. As the electrode scratches the plate an
arc is struck. When the arc has formed, withdraw the electrode momentarily to form an excessively long
arc, then return to normal arc length (see figure 1).

Figure 1. "Scratching" method of arc

starting.
In the tapping method, the electrode is moved downward to the base metal in a vertical direction. As soon
as it touches the metal it is withdrawn momentarily to form an excessively long arc, then returned to
normal arc length (see figure 2)

Figure 2. "Tapping" method of arc starting

The principal difficulty encountered in striking the arc is "freezing," or when the electrode sticks or fuses to
the work. This is caused by the current melting the electrode tip and sticking it to the cold base metal
before it is withdrawn from contact. The extra high current drawn by the "short circuit" will soon overheat
an electrode and melt it or the flux, unless the circuit is broken. Giving the electrode holder a quick snap
backward from the direction of travel will generally free the electrode. If it does not, It will be necessary to
open the circuit by releasing the electrode from the holder.
7.1.8 type of welding joints