1

SMAW Welding
Section 8
Unit 26
2
Arc Welding Safety
1. Recognize that arc welding produces a lot of heat.
2. Use equipment according to manufacturers
recommendations.
3. Insure fire extinguishers are available
4. Provide a first aid kit
5. Use water filled containers to receive hot metal from
cutting operations.
6. Practice good housekeeping
7. Use appropriate PPE
3
Arc Welding Safety-cont.
7. Insure all wiring is correctly installed and
maintained.
8. Remove or shield all combustible materials in work
area.
9. Do not use gloves or clothing which contain
flammable substances
10. Protect others from arc flash.
11. Protect equipment from hot sparks.
12. Use a fume collector.
13. Never work in damp or wet area.
14. Shutoff power source before making repairs or
adjustments, including changing electrode.
15. Dont overload the welding cables or use cables with
damaged insulation.

4
Arc Welding PPE
Helmet
Shade 10 or darker
Face protection
Always wear safety glasses underneath
Auto helmet recommended
Clothing
Long sleeves
Button up shirt
Work shoes
Protective apron, sleeves, jackets or pants if available. (Fig 26-6)

5
SMAW Process
The arc temperature over 9,000
o
F melts the base
metal, the wire core and the coating on the
electrode.
The high temperature causes some of the
ingredients in the flux to form a gaseous shield.
The electric energy is provided by a special power
source.
As the weld cools slag forms on top of the weld
puddle.
6
SMAW Power Supplies
SMAW requires a constant current (CC) of either DC or
AC.
Some power supplies will supply both DC and AC.
Power supply capacity determines the maximum diameter
of electrode that can be used.

7
Equipment
Power Supply
Polarity Switch
Electrode
Base Metal
(work Piece)
Ground Clamp
Ground Cable
Amperage
Scale
Power Switch
Amperage
Adjustment
Electrode Cable
Electrode Holder
Power
Cord
8
Open Circuit Voltage (OCV)
Open circuit voltage is the potential between the welding
electrode and the base metal when the machine is on, but
there is no arc.
The higher the OCV a machine has, the easier it will be to
strike an arc.
Only adjustable of dual control machines.
9
Arc Voltage
Arc voltage is the potential between the electrode and
the base metal when the arc is present.
Arc voltage is less than OCV.
Adjustable on dual control machines.
10
Polarity
The polarity of an object is its physical alignment of
atoms.
The term is often used to describe the positive and
negative ends of batteries and magnets.
The negative end has an excess of electrons
The positive end has a deficiency of electrons.
11
Five (5) Common Power
Supplies
Transformer
AC only
Rectifier
DC only
Transformer/rectifier
AC or DC
Generator
DC and/or AC
Inverter
AC and DC
12
Striking The Arc
Select the best electrode
Set the welder (Fig 26-8)
Turn on welder
Warn bystanders
Lower helmet
Start arc (two methods)
Brushing
Tapping
13
Brushing Method
Hold end of electrode about 1/4 -
1/2 inch above the surface.
Lower helmet
Gently brush surface of the metal
with the end of the electrode.
When arc starts, lift electrode 1/8
inch.
If electrode sticks, twist it back and forth. If it does not break loose,
release electrode from electrode holder.
Do not shut off the welder with the electrode stuck to the metal.
Recommended method for beginning weldors.
14
Tapping Method
Set up welder
Hold the electrode at the
travel angle and 1/4 -
1/2 inch above the metal.
Quickly lower the
electrode until it touches
the metal and then lift it
1/8 inch.

More difficult method to learn
15
Arc Welding Bead Nomenclature
Flux
Electrode
Electrode
metal
Penetration
Molten
puddle
Bead
Base metal
Slag
Gas
shield
16
Running Beads
Practice running stringer beads
No weaving or pattern.
Remember the electrode burns off as the weld is made.
Speed used should result in a bead 2-3 times wider than
the diameter of the electrode.
Cool metal between beads.
Practice holding a long arc for a couple of seconds after
striking the arc.
Preheats the weld
Practice filling in the crater.
17
Five (5) Factors of Arc Welding
1. Heat
2. Electrode
3. Electrode angle
4. Arc length
5. Speed of travel
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Five (5) Factors
1. Heat
The arc welder must produce sufficient heat (electric arc) to melt
the electrode and the base metal to the desired depth.
The amount of heat produced is determined by the amperage.
Amperage is limited by the diameter of the electrode and the capacity of the
welder.
The amount of heat needed to complete the weld is determined
by several factors:
Excessive heat.
Electrode easier to
start
Excessive penetration
(burn through)
Excessive bead width
Excessive splatter
Electrode overheating
Insufficient heat.
Hard to start
Reduced
penetration
Narrow bead
Coarse ripples
Thickness of the
metal
Type of joint,
Electrode type
Electrode
diameter
Weld position

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Five (5) Factors
2. Electrodes
The SMAW process uses
a consumable electrode.
Electrode must be
compatible with base
metal.
Electrodes are available
for different metals.
Carbon steels
Low alloy steels
Corrosion resisting steels
Cast irons
Aluminum and alloys
Copper and alloys
Nickel and alloys
Another useful group of
electrodes is
hardsurfacing.
NEMA color coding
System of of colors on the
end or dots on the bare
wire indicating the class of
electrode.
Not very common today.
AWS numerical coding
Most popular method.
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American Welding Society (AWS)
Classification System
The AWS system
distinguishes the tensile
strength, weld position and,
coating and current.
Manufactures may and do
use there own numbering
system and produce
electrodes that do not fit in
the AWS system.
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Welding Currents
Not all electrodes are designed to work with all currents.
Common SMAW currents.
Alternating Current (AC)
Direct Current straight polarity (DCSP) or (DCEN)
Direct Current Reverse polarity (DCR P) or (DCEP)
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Arc Welding Electrode Flux
Flux: A material used during arc welding, brazing or braze
welding to clean the surfaces of the joint chemically, to
prevent atmospheric oxidation and to reduce impurities
and/or float them to the surface. (British Standard 499)
Seven (7) Classifications of Flux constituents
1. Protection from atmospheric contamination
2. Fluxing agents
3. Arc initiators and stabilizers
4. Deoxidizes
5. Physical properties of the flux
6. Fillers and metallic additions
7. Binders and flux strength improvers
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Electrode Grouping
Electrodes are also grouped
according to there performance
characteristics.
Fast-freeze
Mild steel
Quick solidification of weld
pool
Deep penetrating
Recommended for out of
position welds
Deep penetrating arc
Fast-fill
Highest deposition rate
Stable arc
Thick flux
Flat position and horizontal
laps only
- Fill-freeze
General purpose
electrodes
Characteristics of
fast-freeze and fast-
fill
Low hydrogen
Welding
characteristics of
fill-freeze
Designed for medium
carbon and alloy
steels
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Selecting Electrode Size
The optimum electrode
diameter is determined
by the thickness of the
base metal, the welding
position and the capacity
of the welding power
supply.
A diameter of 3/32 or 1/8
inch can be used on metals
up to 1/4 inches thick
without joint preparation.
ROT: the diameter of the
electrode should not
exceed the thickness of the
metal.
A smaller diameter is
usually recommended for
out of position welding.
When completing root
passes in V-joints, a
smaller diameter maybe
used and then a larger
diameter is used for the
filler passes.
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Electrode Storage
Electrodes are damaged by rough treatment, temperature
extremes and moisture.
The should be kept in their original container until used.
They should be stored in a heated cabinet that maintains
them at a constant temperature.
The storage of low hydrogen electrodes is very critical.
Designed to reduce underbead cracking in alloy and medium
carbon steels by reducing the the amount of hydrogen in the weld
pool.
The flux is hydroscopic--attracts moisture (H
2
O).
Moisture in the flux also causes excessive gasses to develop in the
weld pool and causes a defect in the weld caused worm holes.

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Five (5) Factors
3. Electrode Angle
The electrode angle influences the
placement of the heat.
Two angles are important:
Travel
Work
The travel angle is the angle of the
electrode parallel to the joint.
The correct travel angle must be used for each joint.
Beads = 15
o
from vertical or 75
o
from the work.
Butt joint = 15
o
from vertical or 75
o
from the work.
Lap joint = 45
o
.
T joint = 45
o
.
Corner = 15
o
from vertical or 75
o
from the work.
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Five (5) Factors
Electrode Angle-cont.
The work angle is the angle of the
electrode perpendicular to the
joint.
Beads = 90
o

Butt joint = 90
o

Lap joint = 45
o

T joint = 45
o

Corner = 90
o

The appropriate angle must be used for
each joint.
The work angle may need to be
modified for some situations.
For example, a butt joint with two
different thickness of metal.
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Five (5) Factors
4. Arc Length
The arc length is the distance from the metal part of the
electrode to the weld puddle.
The best arc length is not a fixed distance, but should be
approximately equal to the diameter of the electrode.
Arc length can be adjusted slightly to
change the welding process.
Excessive length
Excessive spatter
Reduced penetration
Poor quality weld
Insufficient length
Electrode sticks
Narrow weld
Poor quality weld
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Five (5) Factors
5. Speed of Travel
The speed of travel (inches per minute) is an important
factor when arc welding.
The best speed of travel (welding speed) is determined by
several factors:
The size of the joint,
The type of electrode
The size of the electrode
The amperage setting on the machine
Deposition rate of the electrode (cubic inches per minute)
The deposition rate of an electrode will change with the
welding amperage.
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Five (5) Factors
5. Speed-cont.
The ideal speed can be calculated
using the volume of the joint and
the deposition rate of the electrode.


Area =
1
2
bh =
0.25 in x 0.25 in
2
= 0.0625 in
2

Step one: determine the area of
the weld. (Assuming 1/16 inch
penetration.)
Step Two: knowing the deposition rate of the electrode,
determine the welding speed. (Deposition rate = 2.5
in
3
/min.)


in
min
=
2.5 in
3
min
x
1
0.0625 in
2
= 40
in
min

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Five (5) Factors
5. Speed-cont.
The correct welding speed is indicated by the shape of the
ripples.
Too fast = narrower width,
elongated ripple pattern,
shallow penetration.
Recommended = width 2-3
times diameter of electrode,
uniform ripple pattern, full
penetration.
Too slow = excessive width,
excessive penetration
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SMAW Joints
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Square Groove
A butt joint can be completed with a groove welded on
metal up to 1/8 inch thick with a single pass on one side,
with no root opening.
Electrode manipulation should only be used to prevent
burning through.
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Square Groove Thicker Metal
A groove weld on metal up to 1/4 inch thick can be
welded with a single pass on one side but, if possible, it
should be completed with a single pass on both sides.
Metal this thick requires a root opening to achieve
adequate penetration.
Electrode manipulation will reduce penetration.
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Single V Groove Weld
Butt joints on metal greater than 1/4 inch thick require
joint preparation.
Note that the groove does not extend all the way. A short
distance, called the root face, is left undisturbed.
The amount of joint preparation is dependent on the
diameter of the electrode and the amperage capacity of
the power supply.
Several different combinations of passes can be used to
complete this joint.
Note: this is the principle use of pattern beads.
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T-Joints
37
Information
In a T-joint the two welding surfaces are at an angle close
to 90 degrees from each other.
The welding side and number of passes uses depends on
the thickness of the metal, the welding access and
capacity of the power supply.
Common joints include.
Plane T
T with joint gap
Single preparation
Double preparation

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Plane T-Joint
The plane T joint is very useful for thin metal.
Can be completed at angles other than 90 degrees.
Can be completed with metal of different thickness.
The work angle must be changed to direct more heat to the thicker
piece.
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T-joint--Thicker Metal
When the metal thickness exceeds 1/8 inch the
recommendation is to gap the joint.
Improves penetration
May not be necessary if larger diameter electrode is used and sufficient
amperage is available.
The need for a joint gap varies with the type of electrode, but
should not exceed 1/8 inch.
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T-joint Single Single Bevel
As with other
joints, thicker
metal must have
joint preparation to
achieve full
penetration with
smaller diameter
electrodes.
Several different preparations can be used. A popular one is
the bevel.
A bevel can be completed by grinding or cutting.
The bevel joint can be completed with electrode manipulation
or no electrode manipulation.
When when electrode manipulation is used to fill the joint,
the first pass should be a straight bead with no
manipulation.
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T-joint Double Bevel
The double bevel T-joint is recommended for metal 1/2
inch thick and thicker.
The root passes should be with not manipulation, but the
filler passes can be completed with either straight beads or
patterns beads.
Alternating sides reduces distortion.
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Weld Defects
43
Common SMAW Defects
Undercutting
improper welding
parameters; particularly the
travel speed and arc voltage.
Porosity
Atmospheric contamination
or excess gas in the weld
pool.
Hot cracks
Caused by excessive contraction
of the metal as it cools.
Excessive bead size
May also be found at the root of
the weld.
Slag inclusions
Long arc
Incomplete removal of slag on
multipass welds.

Under Cutting
Hot Cracks
Slag Inclusions
Porosity
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SMAW Weld Defects-cont.
Toe Cracks
Excessive heat and rapid cooling.
Underbead cracks
Excessive hydrogen in weld pool
Microcracks
Caused by stresses as weld cools.
Incomplete fusion
Incorrect welding parameters or welding techniques.
Toe cracks
Underbead cracks
Microcracks
Incomplete fusion
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Questions