1 Copyright  2004 Lincoln Global Inc. Introduction to SMAW What do the letters SMAW stand for?What do the letters SMAW stand for? Shielded Metal Arc Welding

2 Copyright  2004 Lincoln Global Inc. Shielded Metal Arc Welding SMAW (Stick)

3 Copyright  2004 Lincoln Global Inc. What is SMAW? SMAW = Shielded Metal Arc Welding “Stick” Welding or “Manual” Welding“Stick” Welding or “Manual” Welding Metal Rod Covered with Flux that Provides Shielding to Protect the WeldMetal Rod Covered with Flux that Provides Shielding to Protect the Weld Uses Constant Current Power SourcesUses Constant Current Power Sources Most Widely Used Arc Welding Process in the WorldMost Widely Used Arc Welding Process in the World

4 Copyright  2004 Lincoln Global Inc. Definition of a SMAW An arc welding process with an arc between a covered electrode and the weld pool.An arc welding process with an arc between a covered electrode and the weld pool. This process uses shielding from the decomposition of the electrode covering with filler metal from the electrodeThis process uses shielding from the decomposition of the electrode covering with filler metal from the electrode

5 Copyright  2004 Lincoln Global Inc. SMAW Process

6 Copyright  2004 Lincoln Global Inc. Components of a SMAW system

7 Copyright  2004 Lincoln Global Inc. Advantages Low Start Up Costs- (inexpensive compared to other processes) e.g. machine, cables, power sourceLow Start Up Costs- (inexpensive compared to other processes) e.g. machine, cables, power source Portability- (just add lengths of cable)Portability- (just add lengths of cable) Outdoor Weld ability- (inert gases not affected by windy or wet conditions)Outdoor Weld ability- (inert gases not affected by windy or wet conditions)

8 Copyright  2004 Lincoln Global Inc. Advantages continued All Position WeldingAll Position Welding (flat, horizontal, vertical and overhead) Variety of MetalsVariety of Metals

9 Copyright  2004 Lincoln Global Inc. Limitations Operator SkillOperator Skill Restarts- (continually changing the electrode)Restarts- (continually changing the electrode) Weld Splatter- (depending on type of electrode being used)Weld Splatter- (depending on type of electrode being used) Slag- (could result in inclusion or porosity, contamination of weld joint)Slag- (could result in inclusion or porosity, contamination of weld joint)

10 Copyright  2004 Lincoln Global Inc. End Part 1 REVIEW

11 Copyright  2004 Lincoln Global Inc. Review 1. SMAW stands for: Shielded Metal Arc Welding 2.Definition of SMAW: An arc welding process with an arc between a covered electrode and the weld pool. This process uses shielding from the decomposition of the electrode covering with filler metal from the electrode 3. Components of a SMAW system: See handout

12 Copyright  2004 Lincoln Global Inc. Review con’t 4. Advantages of SMAW: Low start up costsLow start up costs PortabilityPortability Outdoor Weld abilityOutdoor Weld ability All position weldingAll position welding (flat, horizontal, vertical, overhead) Variety of metalsVariety of metals

13 Copyright  2004 Lincoln Global Inc. Limitations Operator SkillOperator Skill RestartsRestarts Weld SplatterWeld Splatter SlagSlag

14 Copyright  2004 Lincoln Global Inc. Components of a SMAW system

15 Copyright  2004 Lincoln Global Inc. Shielded Metal Arc Welding Safety

16 Copyright  2004 Lincoln Global Inc. Safety Eye & Ear Protection Welding Helmet with Proper Lens Shade Number Welding Gloves & Optional Covering Proper Attire

17 Copyright  2004 Lincoln Global Inc. Hearing Protectors Safety Glasses Goggles Ear Plugs Eye & Ear Protection

18 Copyright  2004 Lincoln Global Inc. Welding Helmet

19 Copyright  2004 Lincoln Global Inc. AWS/ANSI Lens Shade Numbers

20 Copyright  2004 Lincoln Global Inc. Leather Welding Trousers Leather Cape Sleeves/Bib Leather Welding Jacket Leather Welding Gloves Leather Welding Apron Welding Coverings

21 Copyright  2004 Lincoln Global Inc. Proper Attire (no polyester)

22 Copyright  2004 Lincoln Global Inc. Safety (five areas) Electrical Hazards Fumes and Gases Arc Radiation Fire or Explosion Hazards in the Work Area

23 Copyright  2004 Lincoln Global Inc. Electrical Hazards High Voltage Can Kill Do Not Operate With Covers RemovedDo Not Operate With Covers Removed Disconnect Input Power Before ServicingDisconnect Input Power Before Servicing Do Not Touch Electrically Live PartsDo Not Touch Electrically Live Parts Electrical Shock Can Kill Do Not Touch Electrode With Skin or Wet ClothingDo Not Touch Electrode With Skin or Wet Clothing Insulate Yourself From Work and GroundInsulate Yourself From Work and Ground

24 Copyright  2004 Lincoln Global Inc. Fumes & Gases Welding May Produce Hazardous Fumes And GasesWelding May Produce Hazardous Fumes And Gases Shielding Gases Can Displace Air and May Cause Injury or DeathShielding Gases Can Displace Air and May Cause Injury or Death Use Ventilation To Keep Air Breathing Zone ClearUse Ventilation To Keep Air Breathing Zone Clear

25 Copyright  2004 Lincoln Global Inc. Arc Radiation Electric Arc Welding Rays Can Burn Eyes and Skin (ultra-violet, infra-red rays)Electric Arc Welding Rays Can Burn Eyes and Skin (ultra-violet, infra-red rays) Always Use a Helmet When Arc WeldingAlways Use a Helmet When Arc Welding Select Appropriate Filter Lens (#10-#12)Select Appropriate Filter Lens (#10-#12) Wear Appropriate Clothing (no polyester)Wear Appropriate Clothing (no polyester) Provide Non-Flammable Shielding to Protect OthersProvide Non-Flammable Shielding to Protect Others

26 Copyright  2004 Lincoln Global Inc. Fire or Explosion Remove Flammable Materials From The Welding Area Keep a Fire Extinguisher in the Welding Area Wear Fire Retardant Clothing Do Not Weld on Containers Which Have Held Combustible Materials

27 Copyright  2004 Lincoln Global Inc. General Work Area Hazards Keep Power Source Cables, Welding Materials and Tools Neatly OrganizedKeep Power Source Cables, Welding Materials and Tools Neatly Organized Connect Work Cable (ground clamp) as Close as Possible to the Weld AreaConnect Work Cable (ground clamp) as Close as Possible to the Weld Area Use Only Properly Grounded EquipmentUse Only Properly Grounded Equipment Always Disconnect Power to Arc Welding Equipment Before ServicingAlways Disconnect Power to Arc Welding Equipment Before Servicing

28 Copyright  2004 Lincoln Global Inc. Safety Review

29 Safety Review Ways to protect your eyes: Safety glasses with side shieldsSafety glasses with side shields GogglesGoggles Arc welding helmet with proper shaded lensArc welding helmet with proper shaded lens(#10-12) Ways to protect your ears: Ear plugs Ear muffs (protectors)

30 Copyright  2004 Lincoln Global Inc. Safety Review cont’d Proper Attire Definition: Consists of all exposed skin being covered and the use of proper PPE, (Personal Protective Equipment) to protect yourself from injury. Fumes and Gases: Fumes and Gases: Welding May Produce Hazardous Fumes And GasesWelding May Produce Hazardous Fumes And Gases Shielding Gases Can Displace Air and May Cause Injury or DeathShielding Gases Can Displace Air and May Cause Injury or Death Use Ventilation To Keep Air Breathing Zone ClearUse Ventilation To Keep Air Breathing Zone Clear

31 Copyright  2004 Lincoln Global Inc. Safety cont’d High voltage can kill: Disconnect input power source before servicingDisconnect input power source before servicing Never touch electrically live partsNever touch electrically live parts Do not operate with machine covers removedDo not operate with machine covers removed Electric shock can kill: Do not touch welding rod on bare skin or wet clothingDo not touch welding rod on bare skin or wet clothing Insulate yourself from the work and groundInsulate yourself from the work and ground

32 Copyright  2004 Lincoln Global Inc. Safety cont’d Arc Radiation: Electric Arc Welding Rays Can Burn Eyes and Skin (ultra-violet, infra-red rays)Electric Arc Welding Rays Can Burn Eyes and Skin (ultra-violet, infra-red rays) Always Use a Helmet When Arc WeldingAlways Use a Helmet When Arc Welding Select Appropriate Filter Lens (#10-#12)Select Appropriate Filter Lens (#10-#12) Wear Appropriate Clothing (no polyester)Wear Appropriate Clothing (no polyester) Provide Non-Flammable Shielding to Protect OthersProvide Non-Flammable Shielding to Protect Others

33 Copyright  2004 Lincoln Global Inc. Safety cont’ Prevention of Fire and Explosion: Remove Flammable Materials From The Welding AreaRemove Flammable Materials From The Welding Area Keep a Fire Extinguisher in the Welding AreaKeep a Fire Extinguisher in the Welding Area Wear Fire Retardant ClothingWear Fire Retardant Clothing Do Not Weld on Containers Which Have Held Combustible MaterialsDo Not Weld on Containers Which Have Held Combustible Materials

34 Copyright  2004 Lincoln Global Inc. Safety cont’d General Work Areas: Keep Power Source Cables, Welding Materials and Tools Neatly OrganizedKeep Power Source Cables, Welding Materials and Tools Neatly Organized Connect Work Cable (ground clamp) as Close as Possible to the Weld AreaConnect Work Cable (ground clamp) as Close as Possible to the Weld Area Use Only Properly Grounded EquipmentUse Only Properly Grounded Equipment Always Disconnect Power to Arc Welding Equipment Before ServicingAlways Disconnect Power to Arc Welding Equipment Before Servicing

35 Copyright  2004 Lincoln Global Inc. Shielded Metal Arc Welding Principles of the SMAW Process

36 Copyright  2004 Lincoln Global Inc. Principles of the SMAW Process Electric Arc Between Electrode & Work, Melts the Electrode & Fuses the JointElectric Arc Between Electrode & Work, Melts the Electrode & Fuses the Joint Weld Metal & Slag FormWeld Metal & Slag Form Slag is lighter than the Molten Metal & Rises to the topSlag is lighter than the Molten Metal & Rises to the top AC or DC PolarityAC or DC Polarity

37 Copyright  2004 Lincoln Global Inc. Alternating Current Alternating Current (AC): A current which reverses at regularly recurring intervals of time (every 1/100 or 1/120 of a second) and which has alternately positive and negative values. Modern power systems normally generate a sinusoidal alternating current of either 50 or 60 Hertz (Hz).

38 Copyright  2004 Lincoln Global Inc. AC Polarity Medium PenetrationMedium Penetration Medium Travel SpeedsMedium Travel Speeds

39 Copyright  2004 Lincoln Global Inc. DCEN Direct Current Electrode Negative Direct Current Electrode Negative (DCEN):The arrangement of direct current arc welding cables/leads in which the electrode is the negative pole and the workpiece is the positive pole of the welding arc.

40 Copyright  2004 Lincoln Global Inc. DCEN (Straight) Polarity DC -DC - Heat Concentrated at ElectrodeHeat Concentrated at Electrode Lower PenetrationLower Penetration Increased Deposition RatesIncreased Deposition Rates

41 Copyright  2004 Lincoln Global Inc. DCEP Direct Current Electrode Positive Direct Current Electrode Positive (DCEP): The arrangement of direct current arc welding cables/leads in which the electrode is the positive pole and the workpiece is the negative pole of the welding arc.

42 Copyright  2004 Lincoln Global Inc. DCEP (Reverse) Polarity DC +DC + Heat Concentrated at Work pieceHeat Concentrated at Work piece Forceful, Digging ArcForceful, Digging Arc Medium to Deep PenetrationMedium to Deep Penetration

43 Copyright  2004 Lincoln Global Inc. The Duty Cycle of a power source is the percentage of a ten (10) minute period that it can operate at the rated output current setting. Duty Cycle

44 Copyright  2004 Lincoln Global Inc. Duty Cycle Duty CycleAmperes Time Available Available 30% Min/10 Min 30% Min/10 Min 40% Min/10 Min 40% Min/10 Min 50% Min/10 Min 50% Min/10 Min 60% Min/10 Min 60% Min/10 Min 70% Min/10 Min 70% Min/10 Min 80% Min/10 Min 80% Min/10 Min 90% Min/10 Min 90% Min/10 Min 100% Min/10 Min 100% Min/10 Min

45 Copyright  2004 Lincoln Global Inc. Electrode Coating Functions To Provide Deoxidizers & ScavengersTo Provide Deoxidizers & Scavengers To Produce Shielding GasesTo Produce Shielding Gases To Produce a Slag CoveringTo Produce a Slag Covering To Provide Mechanical and Physical PropertiesTo Provide Mechanical and Physical Properties To Increase Deposit RatesTo Increase Deposit Rates

46 Copyright  2004 Lincoln Global Inc. E70XX Electrode Tensile in Ksi Welding Position: 1 = All Position, 2 = Flat & Horizontal 1 = All Position, 2 = Flat & Horizontal Type of Current and Coating AWS Classification

47 Copyright  2004 Lincoln Global Inc. Electrode Characteristics

48 Copyright  2004 Lincoln Global Inc. Electrode Characteristics continued

49 Copyright  2004 Lincoln Global Inc. Approximate Amperage Settings

50 Copyright  2004 Lincoln Global Inc. Electrode Oven Rod Box Electrode Storage

51 Copyright  2004 Lincoln Global Inc. Shielded Metal Arc Welding Lincoln Equipment Setup

52 Copyright  2004 Lincoln Global Inc. On/Off Switch Electrode Lead Work Clamp Work Lead Amperage Dial Electrode Holder Amperage Indicator Polarity Switch Lincoln Equipment Setup

53 Copyright  2004 Lincoln Global Inc. Instruction Panel Input Voltage Settings Input Power Cord Wiring Diagram Rectifier Fan Motor ChokeReactor Transformer Lincoln Equipment Setup

54 Copyright  2004 Lincoln Global Inc. Input Voltage Settings Input Power Cord Rectifier Choke Reactor Transformer Switch Lincoln Equipment Setup

55 Copyright  2004 Lincoln Global Inc. Lincoln Equipment Setup

56 Copyright  2004 Lincoln Global Inc. Core Wire Functions Conducts CurrentConducts Current Primarily SteelPrimarily Steel Major Component of Weld DepositMajor Component of Weld Deposit Additional Elements Contained in the Core Wire:Additional Elements Contained in the Core Wire: C MnMn SiSi P and S are Additional ElementsP and S are Additional Elements

57 Copyright  2004 Lincoln Global Inc. Electrode Coating Elements Common Elements & Their Function CalciumProvide Shielding & Form SlagCalciumProvide Shielding & Form Slag Carbon Increase Hardness & StrengthCarbon Increase Hardness & Strength Manganese Deoxidize & Increase StrengthManganese Deoxidize & Increase Strength Molybdenum Increase Hardness & StrengthMolybdenum Increase Hardness & Strength

58 Copyright  2004 Lincoln Global Inc. Electrode Coating Elements continued Common Elements & Their Function Nickel Hardness, Toughness, Corrosion ResistanceNickel Hardness, Toughness, Corrosion Resistance Potassium Stabilize the Arc & Form SlagPotassium Stabilize the Arc & Form Slag Silicon Deoxidize & Form SlagSilicon Deoxidize & Form Slag Sodium Stabilize Arc & Form SlagSodium Stabilize Arc & Form Slag Titanium DioxideScale FormerTitanium DioxideScale Former

59 Copyright  2004 Lincoln Global Inc. Shielded Metal Arc Welding Initiating an Arc

60 Copyright  2004 Lincoln Global Inc. Shielded Metal Arc Welding Known as Stick or Manual WeldingKnown as Stick or Manual Welding Uses CC Power SourceUses CC Power Source Versatile ProcessVersatile Process All PolaritiesAll Polarities Match Electrode with Power Source, Base Metal, and Joint DesignMatch Electrode with Power Source, Base Metal, and Joint Design

61 Copyright  2004 Lincoln Global Inc. The SMAW Process Basics

62 Copyright  2004 Lincoln Global Inc. Arc Length

63 Copyright  2004 Lincoln Global Inc. Electrode Angles

64 Copyright  2004 Lincoln Global Inc. Starting The Arc

65 Copyright  2004 Lincoln Global Inc. 1. Strike Arc Here 2. Move Electrode to Crown of Crater 3. Resume Travel Forward Restarting Interrupted Bead

66 Copyright  2004 Lincoln Global Inc. Travel Speed

67 Copyright  2004 Lincoln Global Inc. Sample Beads For Quality Welding

68 Copyright  2004 Lincoln Global Inc.

69 Bead Initiation

70 Copyright  2004 Lincoln Global Inc. Bead Formation

71 Copyright  2004 Lincoln Global Inc. Bead Termination

72 Copyright  2004 Lincoln Global Inc. Arc Blow

73 Copyright  2004 Lincoln Global Inc. Cross Section of a Fillet Weld

74 Copyright  2004 Lincoln Global Inc. Cross Section of a Groove Weld

75 Copyright  2004 Lincoln Global Inc. Shielded Metal Arc Welding Definitions