13

Shielded Metal Arc

Welding Practice:
Jobs 13-J1J25 (Plate)

Introduction Chapter Objectives

Practice in shielded metal arc welding (SMAW), also After completing this chapter, you will be able to:
called stick electrode welding, is the basis for learning
13-1 Describe uses for the SMAW process.
the other types of welding, Fig. 13-1. SMAW accounts for
13-2 Explain the approach and operating characteristics of
less than 50 percent of the total amount of welding being
welding with the SMAW process.
done, while gas metal arc welding (MIG/MAG) and flux
cored arc welding (FCAW) make up over 50 percent of 13-3 Demonstrate the ability to troubleshoot the SMAW
equipment and process.
the welding being done. Submerged arc welding (SAW)
follows with less than 10 percent in popularity. 13-4 Demonstrate the ability to weld with the SMAW
Stick welding has great versatility. It is a dependable process on various joints, with various welds, in
process that welds any steel in any position. It is readily various positions.
available at modest cost. It will probably be used as long
as any type of welding is being done and especially in
maintenance and repair work.
The practice jobs in this and the next two chapters are
the basis for the mastery of welding. The jobs are num-
bered consecutively and include all of the basic joints and
welds in all positions and provide experience with all of
the commonly used electrodes. As you practice you will
also learn how to set the welding machine for all kinds of
welding situations. A welder must be able to set the weld-
ing machine to meet the varying conditions of the job in
order to produce satisfactory welds.
The jobs in this chapter provide practice on a number
of fundamental joints and welds. Welded joints include the
edge, lap, and T-joint. You will learn how to run stringer

330
Fig. 13-1 A young welder who has completed training is welding
a steel fabrication on the job with the shielded metal arc welding
process. VPC Travel Photo/Alamy Stock Photo
and weaved beads and make fillet welds in the flat, horizon-
tal, and vertical positions. You will experience the different
characteristics and heat requirements of various types of
electrodes with electrode negative, electrode positive, and
alternating current. You will also begin to read shop draw-
ings and become familiar with welding symbols. The satis-
factory completion of these jobs will provide a sound basis
for the more advanced jobs that require more skill to master.
Approach to the Job
Prior to starting any welding job, the welder should make
sure that the lenses in the welding hood are clean, of the
proper shade, and the hood is properly adjusted.
Be relaxed. This is necessary if you are to avoid fatigue.
When fatigue sets in, it is almost impossible to do good work.
Grip the electrode holder lightly. If the electrode holder is
held too tightly, your arm will tire, making it difficult to pro-
duce a sound weld. The electrode cable should be draped
around the shoulder or across the lap to take
the weight of it off the holder. When sitting or
standing, assume the most comfortable position
Arc Length
possible, Fig. 13-2. No part of the body should
be under the slightest strain. You should try to
position yourself so that the entire length of the
welding rod may be welded without obstruction
and without putting your arms in a bind. It is
equally important that you are at all times pro-
tected by use of the proper protective equipment.
Review of Operating Characteristics
Workpiece
What follows are descriptions of those basic Connection
arc welding techniques that the welding student
must be able to apply in order to improve with
practice. Discuss these points with your in- Fig. 13-3 Direction of current when welding is being done with electrode
structor to make sure that you understand them. positive polarity.
Shielded Metal Arc Welding Practice: Jobs 13-J1J25 (Plate) Chapter 13 331
Fig. 13-2 Student welder is making a fillet weld on a lap joint.
Seated at a workbench in order to be as relaxed and comfortable as
possible. Note the that they are wearing required protective gear.
Location: Northeast Wisconsin Technical College McGraw-Hill
Education/Mark A. Dierker, photographer
Polarity In a d.c. circuit the current always flows in one
direction. The electron theory has the current flow from
negative to positive. One line of the circuit is the positive
side, and the other line is the negative side. When welding is
being performed with electrode positive (DCEP), the elec-
trode lead becomes the positive (+) side of the circuit and
the work lead becomes the negative () side of the circuit,
Fig. 13-3. When welding is being performed with electrode
negative (DCEN), the electrode lead becomes the negative
() side of the circuit and the work lead becomes the posi-
tive (+) side of the circuit, Fig. 13-4, page 332. Electrode
positive will produce the deepest penetrating weld, while at
a given amperage (heat) electrode negative will produce the
shallowest penetration but greatest deposition rate.
The type of electrode determines the kind of polarity
necessary for operation. In a.c. welding there is no choice
Machine is in DCEP Polarity
Electrode Holder
Electrode Lead
Electrode
Current Flow
Direction
+
Positive
+
Negative
Workpiece Lead Ground
 Machine is in DCEN Polarity
Arc Length Electrode Holder
Electrode Lead
Electrode
Current Flow
Direction
+
+ Positive
Workpiece
Connection
Workpiece Lead
Fig. 13-4 Direction of current when welding is being done with electrode
negative polarity.
of polarity since the circuit is alternately positive and neg-
ative, first on one side and then on the other.
Arc Length and Arc Voltage A fairly short arc is neces-
sary for SMAW. A short arc permits the heat to be concen-
trated on the work, and it is more stable since it reduces the
effect of arc blow. The arc, consisting of vapors from the
coating, surrounds the electrode metal, the arc, and weld
pool and prevents air from destroying the weld metal.
With a long arc a great deal of the heat is lost into the
surrounding area, preventing good penetration and fu-
sion. The arc is very unstable, the effect of arc blow is
increased, and the arc has a tendency to blow out. The
greater arc length permits air to reach the molten globule
of metal as it passes from the electrode to the weld pool
itself. Thus the weld metal absorbs oxygen and nitrogen,
both of which are harmful. Weld metal deposited with a
long arc has low strength, poor ductility, and high poros-
ity. The weld shows poor fusion and excessive spatter.
The length of arc gap that the welder should maintain
depends on the type and size of electrode, the position of
welding, and the amount of current.
A shorter arc is maintained for vertical, horizontal, and
overhead welding than for flat welding. The normal arc
voltage in the flat position for 18- to 14inch electrodes is 22
to 40 volts. Voltages for the other positions are 2 to 5 volts
less. Since the arc voltage increases with the arc length,
a shorter arc gap is necessary when welding in the verti-
cal, horizontal, and overhead positions. A 20-volt arc with
lightly coated electrodes is approximately 18 inch long, and
a 40-volt covered electrode arc is approximately 14 inch
long. The type of coating on the electrode also has some
effect on the arc length.
Good welders can tell if they are welding with the proper
arc length by the appearance of the metal transfer and the
332 Chapter 13 Shielded Metal Arc Welding Practice: Jobs 13-J1J25 (Plate)
weld pool and by listening to the sound of the
arc. With a long arc they can see the globule of
molten metal flutter from side to side, throwing
off small particles of metal in all directions. The
proper arc gap transfers the metal in a steady
stream that is not easily apparent. A short arc
makes a sharp crackling sound like grease fry-
ing in a pan. A long arc is identified by a hiss-
Negative ing sound and explosions at steady intervals.
Arc Blow The welding student will find arc
blow a disturbing feature of arc welding. Arc
Ground blow is the swerving of an electric arc from its
normal path because of magnetic forces. It may
be likened to a number of magnets all pulling
at a ball of steel. The ball will waver between
the different magnets and will finally be at-
tracted toward the magnet with the strongest pull.
Arc blow is especially noticeable when welding with
large diameter electrodes. Excessive arc blow may cause
lack of fusion, porosity, and excessive spatter.
Arc blow may be controlled somewhat by moving the
work clamp to another location and by changing the
position of the electrode.
Current Values It is impossible to give a table that will in-
dicate the exact amount of current needed to burn a certain
size of electrode for every welding condition. The best that
can be done is to offer a basic heat table, the values of which
can be increased or decreased for the different conditions.
The following have a bearing on the amount of current:
Type and size of electrode: A 316-inch electrode re-
quires higher heat than a 18-inch electrode. An elec-
trode negative polarity electrode requires more heat
than a positive polarity electrode.
Material to be welded: Materials that are good
conductors require more heat than materials that
are poor conductors.
SH OP TA L K
Save the Earth
Companies can lessen their impact on the
planet by:
1. Using an environmental management system.
2. Assessing the life cycle of each product.
3. Limiting the use of natural resources and focusing on
renewable ones.
4. Proper use and disposal of hazardous substances.
5. Minimizing energy consumption.
 Size and shape of the work: A piece of material 20inches
square and 1 inch thick requires more heat for welding Table 13-1 How Heat Ranges Coincide
than one that is 10 inches square and 18inch thick. with the Decimal Equivalent of the
Type of joint: The first pass in a T-joint can be welded Fractional Electrode Size
with a higher current than the first pass of an open,
Diameter of Decimal Current
single-V, groove butt joint. Electrode (in.) Equivalent Range (A)
Position of the weld: Welding in the flat and horizon- 1
16 0.062 60
tal positions can be done with a higher current than 3
32 0.093 75
welding in the vertical and overhead positions. 1
8 0.125 100
Obstructions around the weld site: A weld that must 5
32 0.156 150
be made behind obstructions requires a change in heat. 3
16 0.187 200
Kind and condition of equipment: No two machines 1
4 0.250 250
can be set in exactly the same manner. Even two ma- 5
16 0.312 300
chines of the same size and make differ somewhat. 3
8 0.375 400
Speed required: Speed has a direct bearing on the
current setting.
Skill of the welder: Some welders are able to use undercut and slag inclusions and makes it easier to deposit
higher heats than others on the same type of work. the filler metal in the weld. Because it influences surface
tension and the force of gravity on the molten metal, the
Table 13-1 is a simplified guide to approximate current correct angle promotes uniformity of fusion and weld
settings. Note that the decimal equivalent of the fractional contour in vertical and overhead welding.
sizes also gives some indication of the heat setting. Thus
5
32 inch is 0.156, and the corresponding current range is Learning Welding Skills
150. Table 13-2 lists both voltage and current settings
according to electrode classification and size. Study Table 13-3 (p. 334), the Welders Troubleshooter,
thoroughly before you begin welding practice. Look up
Electrode Angle The angle of the electrode to the work your weld defects in the table during practice and correct
affects the quality of the weld. The proper angle prevents them as instructed before beginning the next job.

Table 13-2 Current Variations with Covered Electrode Classifications and Sizes

Electrode Classification
Electrode Dia. E6010 E6011 E6013 E7016 E7018 E7028 E7024
1
16 2040 A 1
No size No size No size No size
1720 V2
32
3
3080 A 3080A 60100 A 70120 A No size 100145 A
2224 V 1721 V 1722 V 1721 V 2024 V
1
8 80120 A 70120 A 80120 A 100150 A 140190 A 140190 A
2426 V 1822 V 1822 V 1822 V 2125 V 2125 V
5
32 120160 A 120170 A 140190 A 120200 A 180250 A 180250 A
2426 V 1822 V 2024 V 2024 V 2226 V 2226 V
3
16 140220 A 140240 A 170250 A 200275 A 230305 A 230305 A
2630 V 2024 V 2125 V 2125 V 2327 V 2327 V
32
7
170250 A 210300 A 240320 A 260340 A 275365 A 275365 A
2630 V 2125 V 2327 V 2226 V 2328 V 2728 V
1
4 200300 A 200350 A 300400 A 300400 A 335430 A 335430 A
2832 V 2226 V 2428 V 2327 V 2429 V 2429 V
16
5
250450 A 250450 A 375475 A 375470 A 400525 A 400525 A
2832 V 2327 V 2428 V 2328 V 2430 V 2430 V
A indicates current in amperes.
1

V indicates voltage, arc volts.

2

Shielded Metal Arc Welding Practice: Jobs 13-J1J25 (Plate) Chapter 13 333
Welding with Shielded Metal
Arc Electrodes
Molten metal combines with the oxygen and nitrogen in
the surrounding air to form oxides and nitrides. Thus,
covered electrodes are required to get appropriate weld
strength, Table 13-4 (p. 337).
All industries use shielded arc (covered) electrodes for
metal arc welding because they reduce the formation of
oxides and nitrides by protecting the molten weld pool.
Protection is accomplished in the following manner.
Table 13-3 The Welders Troubleshooter
Problem Cause
Arc blow Magnetic field causing a d.c. arc to
blow away from the point at which
it is directed. Arc blow is particularly
noticeable at ends of joints and in
corners.
Brittle Air hardening base metal.
joints Improper welding procedure.
Unsatisfactory electrode.
Brittle Unsatisfactory electrode.
welds Excessive welding current causing
coarse grained and burnt metal.
High carbon or alloy base metal
that has not been taken into
consideration.
Corrosion Type of electrode used.
Improper weld deposit for corrosive
media.
Metallurgical effect of welding.
Improper cleaning of weld.
334 Chapter 13 Shielded Metal Arc Welding Practice: Jobs 13-J1J25 (Plate)
The covering is consumed at a lower rate than the
metallic core wire. Thus it projects over the core
wire so that it affords mechanical protection to the
wire and the arc and controls the direction of the arc,
Fig.13-5A, page 337.
A protective shield of gases is formed as the coating
burns, and the atmosphere is thus excluded, Fig.13-5B.
Slag is formed over the deposited weld metal,
Fig.13-5C. It protects the deposit from the
atmosphere while it is cooling.
Solution
Proper location of the work connection on the work. Placing the
work connection in the direction the arc blows from the point of
welding is often helpful.
Separating the work connection in two or more parts is helpful.
Weld toward the direction the arc blows.
Hold a short arc.
Arc blow is not present with a.c. welding.
When welding medium carbon steel or certain alloy steels, the
fusion zone may be hard as a result of rapid cooling. Preheat at
300500F before welding.
Multiple-layer welds will tend to anneal hard zones.
Heating at 1,1001,200F after welding will generally reduce hard
areas formed during welding.
Austenitic electrodes will often work on special steels, but the
fusion zone will generally contain an alloy that is hard.
Covered electrodes must be used if ductile welds are required. Low
hydrogen electrodes give the best ductility.
Do not use welding current that is too high. It may cause coarse
grain structure and oxidized deposits.
A single-pass weld may be more brittle than a multiple-layer weld
because it has not been refined by successive layers of weld metal.
Welds may absorb alloy elements from the base metal and become
hard. Do not weld a steel unless the analysis and characteristics
are known.
Covered electrodes produce welds that are more resistant to
corrosion than the base metal.
Do not expect more from the weld than you do from the base
metal. On stainless steels use electrodes that are equal to or better
than the base metal.
When welding austenitic stainless steel, be sure the analysis of the
steel and welding procedure is correct so that the groove welding
does not cause carbide precipitations. Condition can be corrected.
Anneal at 1,9002,100F and quench.
Certain metals, such as aluminum, require careful cleaning of all
slag to prevent corrosion.
Table 13-3 (Continued )
Problem Cause
Cracked Joint too rigid.
welds Welds too small for size of parts
joined.
Improper welding procedure.
Poor welds.
Improper preparation of joints.
Distortion Shrinkage of deposited metal pulls
parts together and changes relative
positions.
Nonuniform heating of parts during
welding causes them to distort
before welding is finished. Final
welding of parts in distorted
position prevents the maintenance
of proper dimensions.
Improper welding sequence.
Incomplete Improper preparation of joint.
penetration Too large an electrode.
Too low welding current.
Too fast a welding speed.
Poor fusion Improper diameter of electrode.
Improper welding current.
Improper welding technique.
Improper preparation of joint.
Poor weld Poor welding technique, improper
appearance current setting, or electrode
manipulation.
Characteristic of electrode used.
Welding in improper position for
which electrode is designed.
Improper joint preparation.
Shielded Metal Arc Welding Practice: Jobs 13-J1J25 (Plate) Chapter 13 335
Solution
Design the structure and develop a welding procedure to eliminate
rigid joints.
Do not use too small a weld between heavy plates. Increase the
size of welds.
Do not make welds in string beads. Make weld full size in short
section 8 to 10 inches long. Use low hydrogen electrodes.
Plan welding sequence to leave ends free to move as long as
possible.
Ensure welds are sound and the fusion is good.
Preheating parts to be welded is helpful.
Prepare joints with a uniform free space of the proper width. In
some cases a free space is essential. In other cases a shrink or
press fit may be required.
Clamp or tack parts properly to resist shrinkage.
Separate or preform parts to compensate for shrinkage of welds.
Distribute welding to prevent excessive local heating. Preheating is
desirable in some heavy structures.
Removal of rolling or forming strains before welding is sometimes
helpful.
Study structure and develop a definite sequence of welding.
Be sure to allow the proper free space at the bottom of a weld.
Do not expect too much penetration from an electrode.
Use small diameter electrodes in a narrow welding groove.
Use enough welding current to obtain proper penetration. Do not
weld too rapidly.
Use a backup bar if possible.
Chip or cut out the back of the joint and deposit a bead of weld
metal at this point.
When welding in narrow Vs, use an electrode small enough
to reach the bottom.
Use sufficient welding current to deposit the metal and penetrate
into the plates. Heavier plates require more current for a given
electrode than light plates.
Be sure the weave is wide enough to thoroughly melt the sides of
a joint.
The deposited metal should sweat on the plates and not curl away
from it.
Use the proper welding technique for the electrode.
Use an electrode designed for the type of weld and the position
in which the weld is to be made.
Do not make fillet welds with downhand-electrodes unless the
parts are positioned.
Do not use too high welding currents.
Use a uniform weave or rate of travel at all times.
Prepare all joints properly.
 Table 13-3 (Concluded )
Problem Cause
Porous Characteristic of some electrodes.
welds Improper welding procedure.
Not sufficient pooling time to allow
entrapped gas to escape.
Poor quality base metal.
Spatter Characteristic of some electrodes.
Excessive welding current for the
type or diameter of electrode used.
Some coated electrodes produce
large spatter.
Undercut Too high welding current.
Improper manipulation of electrode.
Attempting to weld in a position for
which the electrode is not designed.
Warping Shrinkage of deposited weld metal.
(thin plates) Excessive local heating at the joint.
Improper preparation of joint.
Improper clamping of parts.
Improper welding procedure.
Welding Joints too rigid.
stresses Improper welding procedure.
Stress occurs in all welds, especially
in heavy parts.
Adapted from Westinghouse Electric Co.
336 Chapter 13 Shielded Metal Arc Welding Practice: Jobs 13-J1J25 (Plate)
Solution
Some electrodes produce sounder welds than others. Be sure the
proper electrodes are used. If they are low hydrogen electrodes,
they must be dry.
Pooling keeps the weld metal molten longer and often ensures
sounder welds.
A weld made of a series of stringer beads is apt to contain minute
pinholes. Weaving will often eliminate this trouble.
Do not use welding currents that are too high.
In some cases the base metal may be at fault. Check it for
segregations and impurities.
Select proper type of electrode.
Do not use too much welding current. On power sources equipped
with arc control set for softer arc.
Paint parts next to weld with antispatter compound. This prevents
spatter from welding to parts, and they can be removed easily.
Use a moderate welding current and do not try to travel too rapidly.
Do not use too large an electrode. If the pool of molten metal
becomes too large, undercut may result.
Avoid too much weaving.
A uniform weave will aid greatly in preventing undercut in groove
welds.
If an electrode is held too near the vertical plane when making a
horizontal fillet weld, undercut will occur on the vertical plate.
Select electrode with high welding speed and moderate
penetrating properties.
Weld rapidly to prevent overheating the plates adjacent to the weld.
Do not have wide spaces between the parts to be welded.
Clamp parts next to the joint properly. Use backup strip to cool
parts rapidly.
Use backstep or skip welding sequence.
Hammer joint edges thinner than rest of plate before welding. This
elongates edges, and the weld shrinkage causes them to pull back
to the original shape.
Slight movement of parts during welding will reduce welding
stresses.
Make weld in as few passes as practical.
Peen weld metal as appropriate.
Heat finished product at 1,1001,200F for one hour per inch of
thickness.
Develop welding procedure that permits all parts to be free to
move as long as possible.