SHIELDED METAL ARC

WELDING
Arc Welding is also referred to as stick welding because you will be
using an electrode to lay your weld bead and it looks like a stick.

The technical term used to describe this welding process is

Shielded Metal Arc Welding or SMAW.

The Shielded Metal Arc Welding process is often used to weld

low and high alloy steels and structural steel. Pipe welders use this
process frequently. Also, it can be used on nickel, copper, and
aluminum alloys. 
Since arc welding requires basic equipment and it can be utilized in
flat, vertical, horizontal, and overhead welding positions, it is very good
for mobile welding work, and outside fieldwork.
Schematic Shows A Typical SMAW Setup:
 MATERIALS
PIPE/PLATE
– Mild steel plate 10mm X
150mm X 6m
– Mild steel plate 3.2mm X
150mm X 6m
– Carbon steel pipe, schedule
40 dia. 150 X 3m
 ELECTRODE
– E- Electrode
– 60: Tensile Strength
– 1: Positioning or all positioning
– 3: Type of flux coating/welding current
AC DC MACHINE
E6011 E7011 Deep medium penetrating electrode
E6013 E7018 Medium penetrating electrode
ESSENTIALS
OF
WELDING
 THE FIVE ESSENTIAL
VARIABLES OF
SMAW WELDING
1. Correct Electrode Size
2. Correct Current
3. Correct Arc Length
4. Correct Electrode Angle
5. Correct Travel Speed
 CORRECT ELECTRODE SIZE
– The correct choice of electrode size involves
consideration of a variety of factors, such as the type,
position, preparation of the joint, the ability of the
electrode to carry high current values without injury to
the weld metal or loss of deposition efficiency, the
mass of work metal and its ability to maintain its
original properties after welding, the characteristic of
the assembly with reference to effect stresses set up by
heat application, the practicability to heat treatment
before and /or after welding, the specific requirements
as to welding quality and cost of achieving the desired
result.
Electrodes for shielded metal arc welding range in
diameter from 3/32 to 3/16 of an inch. You may also
come across some ¼ inch electrodes. They are commonly
found in 9, 14 and 18-inch lengths

Electrode diameter is based on the thickness of the base

metal, the welding position and the type of joint to be
welded.

Larger diameter electrodes are used on thicker metals

and for flat position welding because they offer higher
deposition rates.

Smaller diameter electrodes are used for horizontal,

vertical and overhead welding, because they produce a
smaller weld puddle that is easier to control than the
bigger puddle produced by larger diameter electrodes.
Joint design also affects electrode diameter. On groove
welds for example, the electrode has to be small enough
to access the root of the joint. he welder’s skill also has a
bearing on electrode diameter because a more capable
welder can control a larger, more fluid weld puddle.

As a general rule, when there is no welding procedure

specification, use the largest diameter electrode possible.
Larger diameter electrodes produce welds of the required
dimensions in the least amount of time and at lower cost,
because they have higher deposition rates and allow
faster travel speeds.
CORRECT CURRENT SIZE
The welding current or amperage is essential to
producing welds with good appearance and the
required strength characteristics. Amperage may be
referred to as the heat by some welders.
Current is measured in amperes, or amps. Each type of
electrode has recommended amperage ranges for
optimum performance. Amperage ranges are usually
specified in the welding procedure or in the
manufacturers’ data sheets.

If the amperage is set above the suggested operating

range, the electrode melts too fast. This increases
deposition and the weld puddle becomes too large to
control. It could also cause the electrode coating to
overheat and break down.
Amperage too high – The weld bead is wide and flat with
excessive penetration and spatter, and undercutting
frequently occurs along the toes.

If the amperage is set below the designated range, there

is insufficient heat to melt the base metal, and the weld
puddle is too small for proper control. The droplets
forming on the end of the electrode may bridge to the
weld puddle periodically extinguishing the arc. The weld
bead will be irregular with a crowned appearance and
insufficient penetration.

Amperage too low -The weld bead will be irregular with a

crowned appearance and insufficient penetration
ROOT PASS

E6011:
90 to 100 ampere
HOT OR FILL PASS

E6013:
120 to 160 ampere
COPPING

E6013:
110 to 120 ampere
CORRECT ARC LENGTH
Arc length is the distance from the tip of the electrode
core wire to the weld puddle. Arc length can be
deceiving, because the core wire is recessed inside a
cup that forms at the tip of the electrode. You have to
take this into consideration when gauging arc length.

The correct arc length varies according to the electrode

classification, diameter and composition of the flux
coating, as well as the amperage and welding position.

As a general rule, when amperage is set within the

specified range, arc length should not exceed the
diameter of the core wire. Increasing the arc length
increases the arc voltage, and reduces the amperage
slightly.
If the arc is too long, the metal core melts off in large globules
that wobble from side to side and drop onto the work as spatter,
rather than forming useful weld metal. The weld bead is wide
with excessive spatter and undercut. The base metal is not
properly melted, so the weld metal is deposited on top of the
plate with incomplete penetration, and slag inclusions will
probably occur. Long arcing is often used to preheat the base
metal directly after striking the arc.

Shortening the arc length reduces the arc voltage and increases
the amperage slightly. If the arc length is too short, the arc has
a tendency to short out and the electrode freezes to the work.
CORRECT ELECTRODE ANGLE
In shielded metal arc welding, the work and travel
angles are used to control the shape of the weld
puddle and the amount of penetration. The travel
angle is the angle between the joint and the electrode
along the axis of the weld.

A push angle exists when the electrode points in the

direction of travel. And a drag angle points away the
direction of travel.
When all other essentials are under control, a change
in the direction of travel changes the heat input to the
puddle. A drag travel angle increases heat input
because the arc is pointing into the puddle. A push
travel angle reduces heat input because the arc is
pointing away from the puddle.

The work angle is pointing between the electrode and

the work surface along the work plane, which runs
perpendicular to the axis of the weld. An incorrect
work angle can cause you to favor one side of the joint
more than another. The result is undercut and lack of
fusion.
CORRECT TRAVEL SPEED
Travel speed is the rate at which the electrode moves
along the work. The key to correct travel speed is
“reading” the weld puddle, because the weld puddle is
a liquid version of the weld bead.

A properly formed weld bead has an oval shape with

an oval crater and uniform ripple pattern. Travel
speed is influenced by the type of welding current
(DCEN, DCEP or AC), amperage, welding position,
electrode melt rate, material thickness, surface
condition of the base metal, type of joint, joint fit up
and electrode manipulation.
If you travel too fast, the puddle cools too quickly
trapping gasses and slag. The ripples are pointed
and narrow with irregular penetration and undercut
along the toes.

If you travel too slowly, the weld metal piles up

forming a high, wide weld-bead with too much
reinforcement that may result in overlap. So read
the puddle, and keep the arc on the leading edge.
 BASIC
WELDING
POSITIONS
PARTS OF A WELD
 FILLET AND GROOVE WELDS
• Groove and fillet welds can be made on many
types of joints
Basic Welding Positions

The four basic welding positions are: flat, horizontal, vertical,

and overhead.
The most common type of weld you will do is a Fillet weld and a
Groove weld, and you can accomplish these welds in all four
positions. But you also do surface welds in all four positions as
well, thought you will not do this type of weld very often.
There are numbers that are used to designate the type of
welding position and weld. For example:
• 1 = Flat Position
• 2 = Horizontal Position
• 3 = Vertical Position
• 4 = Overhead Position
In addition there are letters that designate the type of weld
you will do in that postion. For example:
• F = Fillet Weld
• G = Groove Weld
The Flat Position:
In the flat welding position you will do your weld on the top side of
your joint. But the actual face of your weld will be in a near
horizontal position.
The common term for this kind of weld is called, 'flat position' but it
is also referred to as the 'downhand' position.
The image on the left is a flat position fillet weld, and the image on
the right is a flat position groove weld example.
Out Of Position Welding:
The flat welding position is the easiest position and most
desirable position to weld in. In the flat position the metal is flat
and your welding torch or rod is going to move in a horizontal
direction.
The other positions are called Out Of Position because the are
more difficult and require more skill to do them well. The out of
position welding positions are: Horizontal, Vertical, and
Overhead.
The Horizontal Position:
The image on the left (above) is a horizontal position fillet weld,
and the image on the right is a horizontal position groove weld
example.
 In the Fillet Weld position you will weld on the top side of the
surface that is horizontal (or close to it) and against a surface
that is vertical (or close to it). See the illustration above.

 In the Groove Weld position the weld axis is in a horizontal

plane (approximately), and the face of the weld is on a vertical
plane (approximately).  See Image B above.

 The Horizontal Fixed Weld position is a pipe welding position

and the pipes axis is nearly horizontal. Note that the pipe
being welded is not being rotated as you weld. See below for
more information on Pipe welding positions..

 The Horizontal Rolled Weld is a pipe welding position as well

and it is being done in the flat position. Note that the pipe is
turning (rotating). You can see the pipe weld positions below.
Vertical Position:

The illustration image on the left (above)

is a vertical position fillet weld, and the
image on the right is a vertical position
groove weld example.
In the Vertical position welding the welds
axis is almost vertical.
When welding pipe in the vertical position
the pipes axis is vertical and you will be
welding in a horizontal position. The pipe
might rotate, or not. It just depends.
Overhead:
In the overhead welding position you will do the welding beneath
the joint.
Groove Welds: Summary Of
Welding Positions
Thank you