1. SMAW

2. SMAW SHIELDED METAL ARC WELDING ARC WELDING STICK WELDING
AWS Classification
ARC WELDING
STICK WELDING

3. FACTS ABOUT SMAW Originated at start of WWI for shipbuilding
SMAW is the least expensive arc welding processes
Is the most widely used welding process in the world
Can be used to weld most common metals and alloys

5. SMAW COMPONENTS

6. 1- The Electrode Consumable… 2 Part Composition
Core Rod (Metal Filler)
Carries welding current &
Becomes part of the weld
Flux Coating
Produces a shielding gas &
helps form slag

7. 2- The Arc
Turn on the light…An arc occurs when the electrode comes in contact with the work-piece and completes the circuit
The electric arc is established in the space between the end of the electrode and the work causing resistance
The arc reaches temperatures of 10,000°F which melts the electrode and base material
Can you identify the weld joint and position being used?

8. 3- Weld Puddle
As the core rod, flux coating, and work pieces heat up and melt, they form a pool of molten material called a weld puddle
The weld puddle is what a welder watches and manipulates while welding
1/8” E6013 at 125 Amps AC

9. 4- Shielding Gas A shielding gas is formed when the flux melts.
This protects the weld puddle from the atmosphere preventing contamination during the molten state 2 3
Shielding Gas 4
The shielding gas protects the molten puddle from the atmosphere while stabilizing the arc

10. 5- Solidified Weld Metal
As the molten weld puddle solidifies, it forms a joint or connection between two pieces of base material
When done properly on steel, it results in a weld stronger than the surrounding base metal
Bead width = 2.5 to 3 times electrode diameter
3/8”

11. 6- Slag Combination of melted flux & base metal impurities
Quickly solidifies to form a shell
Slows the cooling rate of weld
Chip and clean with hammer & brush
If proper technique is used it should come off easy
Never weld over slag!!
ALWAYS SIDE CHIP SLAG, DON’T HIT IT LIKE A HAMMER

12. Slag You Drag! Slag Welding Processes No-Slag Welding Processes
ALWAYS PULL THE PUDDLE
Shielded Metal Arc Welding (SMAW)
Flux Core Arc Welding (FCAW)
No-Slag Welding Processes
ALWAYS PUSH THE PUDDLE
Gas Metal Arc Welding (GMAW)
Gas Tungsten Arc Welding (GTAW)
Oxy-Fuel Welding

13. SMAW Process 1 2 3 4 5 6 1 4 6 3 2 5 Travel direction Electrode Arc
Weld Puddle 3
Shielding Gas 4
Solidified Weld Metal 5
Slag 6
Electrode 1
Travel direction
Shielding Gas 4
Slag 6 3
Weld Puddle 2
Arc 5
Solidified Weld Metal

14. Activity Let’s review the SMAW process … 1 = __________ 2 = __________
1 = __________
2 = __________
3 = __________
4 = __________
5 = __________
6 = __________

15. AWS Electrode Classification
Explain AWS identification of electrodes

16. Electrode Selection What type of welder do I have, AC or DC?
What am I welding, steel, cast, stainless, etc?
What is the metal condition, dirty or clean?
Is it a root or cover pass?
How strong does it have to be?
What electrodes do I have to chose from?

17. Electrode Selection

18. Amperage Chart
Amperage is dependent on electrode diameter, electrode type, and metal thickness
Reference charts whenever possible.

19. Not 100% accurate for all electrodes!
Amperage Electrode
Shorthand method will get you in the ballpark for fast freeze electrodes.
Not 100% accurate for all electrodes!
AWS: 1/8” diameter E6013
1/8”= .125”
125 Amps

20. Electrode Care Electrodes must be kept dry
Dampness will introduce hydrogen into the weld causing cracking or brittleness
Damp electrodes may cause the flux to “blow away” & cause porosity
Bake questionable electrodes for several hours.
6010 & 6011 (fast freeze) are exempt
Our electrodes are stored in a dry oven

21. Electrodes Care cont. Burn electrodes down to numbers!
Place stubs in stub box
Put unused electrodes back in oven
Only grab several electrodes at a time
Electrodes are not cheap

22. Striking an Arc and Making a Weld
SECTION OVERVIEW:
These slides discuss striking an arc and making a weld
TEACHER NOTES:
Slides 22-29: When using these slides, teachers may prefer to discuss the importance of the following topics:
Striking an arc
Work angle
Travel angle
Arc length
Travel speed
Filling a crater
Restarting the bead

23. Striking an Arc
To begin the SMAW Process, you must first strike an arc.
Scratch start – scratch the electrode on the base metal like a match
Tap Start – tap the rod against the base metal

24. Work Angle
The work angle is the angle between the electrode and the work as depicted on the left
Work angles can vary depending on the position the weld is being made in
90°

25. Travel Angle Also commonly called Lead Angle
The travel (lead) angle is the angle between the electrode and the plane perpendicular to the weld axis
20-30°

26. Arc Length
After striking the arc, maintain a 1/8” distance between the electrode and the workpiece
Too short: electrode will fuse itself to metal
Too long: spatter, undercut, and porosity
Arc Length = 1/8”

27. Travel Speed
Speed at which the electrode moves along the base material while welding
Too fast: ropey or convex weld
Too slow: wide weld, excessive deposit
The travel speed impacts the shape of the bead.

28. Filling the Crater
At the end of the weld, the operator breaks the arc which creates a ‘crater’
Use a short pause or slight back step at the end of the weld to fill the crater
Large craters can cause weld cracking
Back stepping is a short move in the opposite direction of weld travel

29. Restarting a Bead Remove electrode from stinger
Scratch electrode until metal can be seen
Scratch in weld line: spatter
1. Strike Arc Here
2. Move Electrode to Crown of Crater
3. Resume Travel

30. Troubleshooting Activity
On a piece of scratch paper, describe welds A-G.
Good, bad, arc length, speed, lead angle, etc. A B C D E F G
A – Good Weld: Proper Current, Travel Speed and Arc Length
B – Current too low: Ropey, convex bead appearance
C – Current too High: Excess spatter and possible burn-through of base materials
D – Arc Length too short: Poor wet-in at toes, electrode can ‘short’ to base material
E – Arc Length too Long: Excess spatter, undercut and porosity
F – Travel Speed too slow: Wide weld with excess metal deposit
G – Travel Speed too high: Ropey and convex bead

31. A – Good Weld: Proper Current, Speed and Arc Length
B – Current low: Ropey, convex bead appearance
C – Current too High: Excess spatter & burn-through
D – Arc Length too short: Poor wet-in at toes
E – Arc Length too Long: Spatter, undercut and porosity
F – Travel Speed too slow: Wide weld with excess deposit
G – Travel Speed too high: Ropey and convex bead

32. Lincoln V350 SMAW Setup Plug ground cable into the (-) terminal
Plug the whip cable into the (+) terminal
Turn on the welder
Select SMAW (CC-Stick Soft) mode
CC-Stick Crisp is for pipe welding
Select correct amps
Set Hot start to 2-3
(This will make starting the arc easier)
Set Arc Control to +4-5
(high arc control = crisp weld but more spatter)
(low arc control = soft weld with little spatter)