1. SMAW (Stick Welding) SECTION OVERVIEW:
Section Overviews are provided on the introductory slides at the front of each topical area to explain the intended use for the slides included in the section.
Slide numbers are included on the Section Overview slides for easy reference when preparing for delivery of the slide content.
TEACHER NOTES:
Teacher Notes are included on the Section Overview slides as a reference tool when making class preparations.
Suggested Activities are included as ideas for teachers to use to help students gain practical experience with the welding content. However, these are designed to be supplemented by each teacher based on local program needs.
Slides have been developed to incorporate content information regarding performance standards from the American Welding Society (AWS) and the National Academic Standards for English, Science, and Math.
INDIVIDUAL WELDING LESSON NOTES ARE AVAILABLE IN LESSON PLAN FACILITATOR’S GUIDE
SMAW
(Stick Welding)

2. SMAW Principles SECTION OVERVIEW:
These slides are meant to lead into the discussion of the SMAW process
TEACHER NOTES:
Slides 7-16:
For more information on the American Welding Society, see ‘Arc Welding Basics’ and
Discussion could be given on stick electrodes commonly being between 9-18” long, and come in diameters ranging from 1/16” to 1/4”. An activity could be to show 3 electrodes all the same diameter: E6010 or E6011, E7018, and E Ask students to compare flux coatings (color, thickness, feel)
The size of the electrode is determined by the diameter of its metal core. PLEASE NOTE: The overall diameter of the electrode changes due to flux coating even though metal diameter remains the same.
An arc digs into the base metal much like water from a nozzle on a garden hose digs into the earth. (The flow of the water is like welding current and water pressure is similar to voltage)

3. SMAW Equipment Set Up
9.  
8.  
10. 
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5.  4. 1.
3.   2.

4. SMAW Process Let’s take a little closer look at the SMAW process… 1 2
Travel direction
Electrode
Arc 2
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

5. 1- The Electrode Is a consumable Two parts
it gets melted during the welding process
Two parts
Core Rod (Metal Filler)
Carries welding current
Becomes part of the weld
Flux Coating
Produces a shielding gas
Forms a slag
Protects from contaminates

6. Rods you will use

7. 2- The Arc
Occurs when the electrode comes in contact with the work-piece, completing the circuit
The electric arc is established in the space between the end of the electrode and the work
The arc reaches temperatures of 10,000°F which melts the electrode and base material

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. A shielding gas is formed when the flux coating melts.2 3
Shielding Gas 4
A shielding gas is formed when the flux coating melts.
This protects the weld puddle from the atmosphere preventing contamination during the molten state

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

11. 6- Slag
Slag is a combination of the flux coating and impurities from the base metal that float to the surface of the weld.
Slag quickly solidifies to form a solid coating
The slag also slows the cooling rate of the weld
The slag can be chipped away and cleaned with a wire brush when hard

12. Arc Safety Video
You will need to take at least half a page of notes on what is happening during the video
You will turn these in at the end

13. Application Activity SECTION OVERVIEW:
These slides provide an overview of the SMAW process.
TEACHER NOTES: (Explanation of Activity)
Slides 17-18: After discussing the parts included on this slide, students will take a quiz as an application activity.
For the activity, have participants work individually and mark 1-6 on a piece of paper.
Explain that this activity is meant to check whether each student understands SMAW before beginning to apply the process in the lab.
Project slide on the screen and have each student fill in the blanks on a piece of paper to be turned in. Collect papers and discuss.
Answers to the Application Activity are:
1. Electrode
2. Arc
3. Weld Puddle
4. Shielding Gas
5. Solidified Weld Metal
6. Slag

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

15. Equipment Set Up SECTION OVERVIEW:
These slides explain how to set up the equipment for SMAW and the process variables used.
TEACHER NOTES:
Slides 19-21: These slides explain SMAW equipment set up and operator controlled variables
The exposed metal end of the electrode should fit securely within the jaws of the electrode holder
Discuss how the correct amperage setting for any given electrode is important to ensure proper shape of bead, proper penetration, and minimal spatter.
Explain when the amperage is set too high the bead may be flat, have excessive spatter, have some porosity and the electrode will overheat. If the amperage setting is too low, difficulty is experienced in striking the arc and maintaining the correct arc length. The weld bead becomes convex with excessive overlap and poor penetration.
Discuss polarity – All stick electrodes run on DC. Not all will weld on AC. All electrodes have a preferred polarity and most are designated by the AWS.

16. SMAW Process Variables
Settings on the machine
Polarity : AC, DC+, DC-
Amperage Output
Operator Controlled Variables
Work Angle
Travel Angle
Arc Length
Travel Speed
A straight AC machine will not have a polarity switch like this AC/DC machine

17. 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

18. Striking an Arc
To begin the SMAW Process, you must first strike an arc. This can be done using one of the following techniques:
Scratch start – scratch the electrode on the base metal like a match
Tap Start – tap the rod against the base metal

19. 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°

20. Also commonly called Lead Angle
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°

21. Arc Length
After striking the arc, maintain a 1/8” distance between the electrode and the workpiece
If the arc length becomes too short, the electrode will get stuck to the workpiece or ‘short out’
If the arc length becomes too long; spatter, undercut, and porosity can occur
Arc Length = 1/8”

22. Travel Speed
The travel speed is the speed at which the electrode moves along the base material while welding
Too fast of a travel speed results in a ropey or convex weld
Too slow of a travel speed results in a wide weld with an excessive metal deposit
End of Weld
The travel speed impacts the shape of the bead.

23. 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

24. Restarting a Bead Here is the proper technique for restarting a weld:
1. Strike Arc Here
2. Move Electrode to Crown of Crater
3. Resume Forward Travel

25. Troubleshooting Welds
SECTION OVERVIEW:
The next slide discusses several troubleshooting topics.
TEACHER NOTES:
Slide 30-31: Weld troubleshooting. The beads on the pad depict changes in welding variables and their results. Discuss the following:
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

26. Troubleshooting WeldsA B C D E F G
These welds were cut and etched with nitric acid to show penetration

27. SMAW Advantages and Limitations
SECTION OVERVIEW:
This section is meant to lead into a discussion regarding the advantages and limitations of using the SMAW process.
TEACHER NOTES:
Slides 32-34: The advantages and limitations of SMAW
Advantages:
Low start up costs – SMAW equipment is less expensive than GMAW equipment
Portable – electrode leads are easy to move from job to job
Easy to use outdoors - The process does not require a shielding gas so it is resistant to winds
All position capabilities
SMAW can be used on variety of materials – just change the electrode and you’re ready for the next project
Limitations:
Electrodes are 60-65% efficient to 2” of the electrode (stub) is thrown away. The slag and spatter also contribute to SMAW consumable losses.
Difficult to weld very thin material –
Frequent restarts – Most electrodes are 9-18” in length. As the electrodes are consumed they continually need to be replaced
Operating factor of 5-25% - Operators using the SMAW process spend only 5-25% of their time welding. Time is spent chipping slag, cleaning spatter, changing electrodes, repositioning the part, etc.
It takes practice to become a good welder using the SMAW process. The GMAW process is generally easier to learn.

28. All position capabilities Easy to change between many base materials
Advantages of SMAW
Low initial cost
Portable
Easy to use outdoors
All position capabilities
Easy to change between many base materials
What safety precautions should be taken by these welders?

29. Lower consumable efficiency Difficult to weld very thin materials
Limitations of SMAW
Lower consumable efficiency
Difficult to weld very thin materials
Frequent restarts
Lower operating factor
Higher operator skill required for SMAW than some other processes
Building a barge in a large shipyard

30. AWS Classification of SMAW Electrodes
SECTION OVERVIEW:
This section is meant to lead into a discussion regarding the AWS Classification of SMAW Electrodes
TEACHER NOTES:
Slides 35-36:
For more information on the AWS classification of SMAW electrodes see Lincoln Electric’s free ‘Stick Electrode Product Catalog’ -

31. AWS Classification of SMAW Electrodes
E70XX
Electrode
Tensile in Ksi
Welding Position:
1 = All Position, 2 = Flat & Horizontal
Type of Current and Coating 9

32. Lesson Plans SECTION OVERVIEW:
These slides are used for practicing lesson content in the lab setting.
TEACHER NOTES:
Slides 37-53: When using these slides, teachers might want to reference information included in the Facilitator’s Guide.
Recommended equipment – Only one of the single process or multi-process machines is required to complete the lesson.

33. SMAW Lesson #1 Objective: Strike and establish an arc Equipment:
Single Process – Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate 1/8” or thicker
1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC

34. SMAW Lesson #2
Objective: To run a straight bead on flat plate and to fill the crater
Equipment:
Single Process Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate 3/16” or thicker
1/8” Fleetweld 37 (E6013)
Good
Poor

35. SMAW Lesson #3 Objective: To run a bead with the whip technique
Equipment:
Single Process - Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate 3/16” or thicker
1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC

36. SMAW Lesson #4 Objective: To build a pad Equipment: Material:
Single Process - Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate 3/16” or thicker
1/8” Fleetweld 37 (E6013)

37. SMAW Lesson #5 2F Top View Side View
Objective: To make a fillet weld on a lap joint in the horizontal position (AWS Position 2F)
Equipment:
Single Process - Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate - 10 gauge
1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 2F
Top View
Side View

38. SMAW Lesson #6
Objective: To make a fillet weld on a tee joint in the horizontal position (AWS Position 2F)
Equipment:
Single Process - Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate - 10 gauge
1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 2F

39. SMAW Lesson #7
Objective: To make a fillet weld on a tee joint in the horizontal position (AWS Position 2F)
Equipment:
Single Process - Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate - 10 gauge
1/8” Excalibur 7018 (E7018) for DC
or Lincoln 7018AC (E7018) for AC 2F

40. SMAW Lesson #8
Objective: To make a three pass fillet weld on a tee joint in the horizontal position (AWS Position 2F)
Equipment:
Single Process - Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate – ¼”
1/8” Excalibur 7018 (E7018) for DC or
Lincoln 7018AC (E7018) for AC 2F

41. SMAW Lesson #9
Objective: To make a fillet weld on a lap joint in the vertical position welding down (AWS Position 3FD)
Equipment:
Single Process - Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate - 10 gauge
1/8” Fleetweld 37 (E6013)
3FD

42. SMAW Lesson #10
Objective: To make a fillet weld on a tee joint in the vertical position welding down (AWS Position 3FD)
Equipment:
Single Process - Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate - 10 gauge
1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC
3FD

43. SMAW Lesson #11
Objective: To make a fillet weld on a lap joint in the overhead position (AWS Position 4F)
Equipment:
Single Process - Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate - 10 gauge
1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 4F

44. SMAW Lesson #12
Objective: To make a fillet weld on a tee joint in the overhead position (AWS Position 4F)
Equipment:
Single Process - Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate - 10 gauge
1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 4F

45. SMAW Lesson #13
Objective: To make a single pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F)
Equipment:
Single Process - Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate – 1/4”
1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 3F

46. SMAW Lesson #14
Objective: To make a three pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F)
Equipment:
Single Process - Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate – 1/4”
1/8” Fleetweld 5P+ (E6010) for DC or Fleetweld 180 (E6011) for AC 3F

47. SMAW Lesson #15
Objective: To make a single pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F)
Equipment:
Single Process - Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate – 1/4”
1/8” Excalibur 7018 (E7018) for DC or Lincoln 7018AC (E7018) for AC 3F

48. SMAW Lesson #16
Objective: To make a three pass fillet weld on a tee joint in the vertical position welding up (AWS Position 3F)
Equipment:
Single Process - Constant Current Power Source
Idealarc 250 and accessories
Precision TIG 225 and accessories
Multi-Process
Power MIG 350 MP
Material:
Mild Steel Plate – 1/4”
1/8” Excalibur 7018 (E7018) for DC or
Lincoln 7018AC (E7018) for AC 3F