Tech Connect

Welding

Shielded Metal
Arc Welding
(SMAW)

SMAW Safety Precautions

Electrical Safety
Make sure all electrical equipment has an
earth ground.
Keep electrical connections tight, clean, and
dry.
Keep work area, equipment, and clothing
dry.

SMAW Safety Precautions

(continued)

Electrical Safety (continued)

Never dip an electrode holder in water.
Never touch hot parts of the electrode
holders.
Remove the electrode from the electrode
holder when the work is complete.

SMAW Safety Precautions

(continued)

Electrical Safety (continued)

Always check the work area for any
electrical hazards before starting a project.
Keep welding cables free from conduits,
motors, and other equipment that can cause
a short circuit.
Keep the ground as far away from the arc
as possible.

SMAW Safety Precautions

(continued)

Handling welding cables

Never pull a welding cable to force it over an
obstruction.
Never drag a welding cable through oil.
Only use clean, dry rags to clean a welding
cable.
Properly store welding cables when not in
use.

SMAW Safety Precautions

(continued)

Handling welding cables (continued)

Never drape a welding cable over any type of
gas cylinder.

SMAW Safety Precautions

(continued)

Handling hollow castings and containers

Vent hollow castings before beginning any
heating, cutting, or welding activities.
Do not heat, cut, or weld any tanks, drums, or
containers.

SMAW Safety Precautions

(continued)

Working with arc rays

Wear appropriate personal protective
equipment.
Shield work areas to prevent an arc flash from
injuring nearby workers.

SMAW Safety Precautions

(continued)

Environmental concerns
Make sure the work area is properly
ventilated.
Wear a respirator when necessary to protect
from breathing dangerous fumes.
Wear earplugs during periods of continuous
loud noise.
Make sure the lighting is bright and free of
glare.

Personal Protective Equipment

for SMAW
Hoods

Personal Protective Equipment

for SMAW (continued)
Hoods (continued)

Personal Protective Equipment

for SMAW (continued)
Lenses
Electrode size and amperage determine the
level of lens protection.
Use the lens manufacturers selection chart to
select the appropriate shade.

Personal Protective Equipment

for SMAW (continued)
Protective clothing

Principles of SMAW
SMAW is the most common form of welding.
An arc welding machine supplies electric
current to an electrode wire.
The electric current travels through the air gap
between the end of the electrode wire and the
base metal.
As the electric current flows through this air
gap, an electric arc is formed.

Principles of SMAW

(continued)

The electric arc produces heat that heats the

base metal to its melting temperature.
The heat from the base metal produces a
shielding gas that protects the base metal, arc,
electrode, and weld from the atmosphere
during the welding process.
As the flux covering on the electrode wire
melts, a shielding gas is created.

Principles of SMAW

(continued)

When the flux cools, it solidifies and forms a

protective slag over the weld bead.
As the electrode wire melts, it becomes the
filler metal to the weld.

Advantages and Disadvantages

of SMAW
Advantages
Equipment is inexpensive.
Equipment is portable.
Applications are simple and adaptable to job
requirements.
Can be used with several types of filler
metals.

Advantages and Disadvantages

of SMAW
Disadvantages
Requires slag removal.
Harmful gases can be produced when the flux
melts.
Changing the electrodes can slow down the
process.

Welding Electrical Current

Direct current electrode negative (DCEN)
Electric current that flows from the electrode
to the base metal.
When the electrical current flows in this
direction, the electrode has a negative polarity
and the base metal has a positive polarity.

Welding Electrical Current

(continued)

Direct current electrode positive (DCEP)

Electric current that flows from the base metal
to the electrode.
When the electric current flows in this
direction, the electrode has a positive polarity
and the base metal has a negative polarity.

Different Types of Welding

Machines
AC transformer
Changes high-voltage, low-amperage AC to
low-voltage, high-amperage AC.
Used with a 220/240 volt input current.

Different Types of Welding

Machines (continued)
AC or DC transformer-rectifier
Changes high-voltage, low-amperage AC to
low-voltage, high-amperage AC or DC.
Ideal for adjusting to different materials and
welding positions.

Different Types of Welding

Machines (continued)
CD generator (motor or engine)
Current varies with the speed that the
armature turns.
Polarity changes can be made by flipping a
switch or reversing weld connections.
Some machines are powered with AC motors
and some machines are powered with gas or
diesel engines.

Different Types of Welding

Machines (continued)
Inverter power sources
Utilizes solid-state components to change the
incoming 60 Hz power to a higher frequency.
Changing the frequency results in greatly
reducing the size and weight of the
transformer.
This machine can be used with all processes.

Characteristics of Electrodes
Electrode covering
Adds filler metal to the weld.
Creates a protective gas shield around the arc
and molten metal.
Creates a flux to clean impurities from the
molten metal.
Creates a hard slag covering to protect the
molten weld bead as it cools.

Characteristics of Electrodes
(continued)

Electrode covering (continued)

Improves mechanical and chemical properties
of the weld by adding alloying elements to the
weld metal.
Determines the current type and polarity
specifications of the electrode.

Characteristics of Electrodes
(continued)

Electrode size
Available in a variety of lengths and
diameters.
Diameter of the electrode refers to the
diameter of the uncovered wire.

Factors that Affect Electrode

Selection
Type of base metal
Metal thickness
Groove design
Joint alignment
Available welding current
Skill level of the welder

Factors that Affect Electrode

Selection (continued)
Welding position
Rate of the weld deposit
Depth of penetration
Weld bead finish

Causes and Effects of a Good

or Bad Weld

Causes and Remedies for

Common SMAW Problems

Causes and Remedies for

Common SMAW Problems
(continued)

Procedure for Striking and

Maintaining an Arc
Scratch method
Move the electrode across the base metal at
an angle like you would use to strike a match.
When the arc starts, raise the electrode
slightly to make a long arc, and then return to
normal arc length.

Procedure for Striking and

Maintaining an Arc (continued)
Tap method
Move the electrode downward in a vertical
direction until it just taps the base metal.
Slightly raise the electrode to form a long arc.
Return to normal arc length.

Different Bead Patterns

Different Bead Patterns

(continued)

Different Bead Patterns

(continued)

Different Bead Patterns

(continued)

 2008
Oklahoma Department of
Career and Technology
Education