1. Teknologi Dan Rekayasa
SHIELDED METAL ARC WELDING
(SMAW)

2. SHIELDED METAL ARC WELDING EQUIPMENT
OBJECTIVE :
After studying this lesson, the students can be to :
identify of welding equipments
explain the name of welding equipments
select for welding equipments
explain welding equipments setting
Teknologi dan Rekayasa

3. SHIELDED METAL ARC WELDING EQUIPMENT
UNDERSTANDING :
Shield metal arc welding is a process where coalescence is achieved by generating an electric arc between a coated metallic electrode and the work piece.
Teknologi dan Rekayasa

4. SHIELDED METAL ARC WELDING EQUIPMENT
Fig. 1. Shield metal arc welding process
Teknologi dan Rekayasa

5. SHIELDED METAL ARC WELDING EQUIPMENT
Application :
The Shielded Metal Arc Welding process is used extensively in welding both ferrous and non ferrous metals.
Shielded Metal Arc Welding is universal in repairing and servicing equipment.
Teknologi dan Rekayasa

6. SHIELDED METAL ARC WELDING EQUIPMENT
The general of welding equipment are three kinds :
Main equipment
Assist equipment
Health and safety equipment
Teknologi dan Rekayasa

7. THE MAIN WELDING EQUIPMENT
The basic units of any shielded metal arc welding system consist of :
Power Supply
Electrode holder
Ground clamp
Power cable
Protective shield
Teknologi dan Rekayasa 7

8. THE MAIN WELDING EQUIPMENT
Power Supply
The three basic welding machines are referred to as generators, transformers and rectifier
a. DC generator :
The direct current power supply consist of a generator driven by an electric motor or a gasoline engine. One of the characteristics of a direct current welding generator is that the welding can be done with straight or reverse polarity
Teknologi dan Rekayasa

9. THE MAIN WELDING EQUIPMENT
To identify this DC machine
Fig. 2. DC-welding machine
Teknologi dan Rekayasa

10. THE MAIN WELDING EQUIPMENT
In straight polarity the electrode is negative and the work piece positive and electrons flow from the electrode to the work piece.
STRAIGHT POLARITY (DCSP)
GENERATOR
WORK
Fig. 3. DCSP-welding machine connections
Teknologi dan Rekayasa

11. REVERSED POLARITY (DCRP)
THE MAIN WELDING EQUIPMENT
In reverse polarity the electrode is positive and the work piece negative and the electrons flow from the work piece to the electrode.
GENERATOR
WORK
REVERSED POLARITY (DCRP)
Fig. 4. DCRP-welding machine connections
Teknologi dan Rekayasa

12. THE MAIN WELDING EQUIPMENT
b. Transformer : The transformer type of welding machine produces alternating current where power is taken directly from a power supply line and transformed into a voltage required for welding. In its simplest form an AC transformer consists of a primary and secondary coil with an adjustment to regulate the current out put.
Teknologi dan Rekayasa

13. THE MAIN WELDING EQUIPMENT
To identify this AC machine
Fig. 5. AC-welding machine
Teknologi dan Rekayasa

14. THE MAIN WELDING EQUIPMENT
c. Rectifier : Rectifier is essentially transformers containing an electrical device which changes alternating current into direct current. Rectifier are made to provide DC current only or both DC and AC welding current.
Teknologi dan Rekayasa

15. THE MAIN WELDING EQUIPMENT
To identify this AC/DC machine
Fig. 5. AC/DC welding machine.
Teknologi dan Rekayasa

16. THE MAIN WELDING EQUIPMENT
2. Electrode Holder The electrode holder is used to hold the electrode and guide it over the seam to be welded.
Fig. 6. Electrode Holder
Teknologi dan Rekayasa

17. THE MAIN WELDING EQUIPMENT
3. Ground Clamp
A very important unit of any electrical welding equipment is the ground clamp. Without proper grounding the full potential of the circuit will fail to provide the required heat for welding
Fig.7. Ground Clamp
Teknologi dan Rekayasa

18. THE MAIN WELDING EQUIPMENT
4. Power cable
Power cable selection that will be used should appropriate with the burden, it is ampere and input tension voltage regulator includes : wire size, long wire and type wire (fiber or not)
Fig. 8. Power cable

19. THE MAIN WELDING EQUIPMENT
5. Protective shield
A suitable helmet or handshield is required for all arc welding.
An electric arc produces a brilliant light and also gives invisible ultraviolet and infrared rays which are extremely dangerous to the eyes and skin.
Both the helmet and hand shield are equipped with special colored lenses that reduce the brilliancy of the light and screen out the infrared and ultraviolet rays.
Teknologi dan Rekayasa

20. THE MAIN WELDING EQUIPMENT
Lenses come in different shades and the types used depends on the kind of welding done.
In general, the recommended practice is:
Shade 5 : for light spot welding
Shade 6 and 7: for welding up to 30 amperes
Shade 8 : for welding 30 to 75 amperes
Shade 10 : for welding 75 to 200 amperes
Shade 12 : for welding 200 to 400 amperes
Shade 14 : for over 400 amperes
Teknologi dan Rekayasa

21. THE MAIN WELDING EQUIPMENT
Lens
Clear lens
Filter lens
Fig. 9. Protective Shielded
Teknologi dan Rekayasa

22. ASSIST WELDING EQUIPMENT1
WELDING TABLE 2
CHINDER HAMMER 3
CURVE HAMMER 4
HAND GRINDSTONE

23. ASSIST WELDING EQUIPMENT
1. Welding table
Welding table is place to put work think in position

24. ASSIST WELDING EQUIPMENT
2. Chinder hammer
Chinder hammer is a tool for cleaning chinder from welding product

25. ASSIST WELDING EQUIPMENT
3. Curve hammer
Curve hammer is used to straighten, levelling the surface of curve or bend work think.

26. ASSIST WELDING EQUIPMENT
4. Hand Grindstone
Its function is to prepare materials that will be welding, it is preparing welding shawl, it is also used to support in welding process specially in cleaning welding product

27. HEALTH AND SAFETY EQUIPMENT
1. WELD CLOTHES
2. APPRON (CHEST PROTECTOR)
3. GLOVES
4. LEATHER SHOES

28. HEALTH AND SAFETY EQUIPMENT
1. Weld Clothes
By wearing this clothes, welder will fill comfort and free in movement

29. HEALTH AND SAFETY EQUIPMENT
2. Apron (Chest protector)
Appron is used to protect welder chest from UV ray, infra red, weld fire work sprinkling and the hot of welding.

30. HEALTH AND SAFETY EQUIPMENT
3. Gloves
Gloves it used to protect welder hand from electricity, the of welding and sharp material.

31. HEALTH AND SAFETY EQUIPMENT
4. Leather Shoes
This shoes made of leather that there is metal in top of it, this shoes will protect welder from electricity, downfall material, hot material and sharp material.

32. THE END
THANK YOU
Teknologi dan Rekayasa