HISTORY
It is an first invented in arc welding family
MANUAL ARC WELDING
Started with bare electrode welding
SHIELDED METAL ARC WELDING
Developed With flux coated electrode
Electric arc started by striking work with electrode
Consumable electrode Process
Heat of arc melts electrode and surface of base
metal
Tiny globules of molten metal form on tip of
electrode and transferred by arc into molten pool
on work surface
After weld started, arc moved along work
American Welding Society
Shielding (Gas)
Flux
coating
Electrode
Travel direction
Weld Puddle
Shielding
Gas
6
6
Slag
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Slag
Weld Puddle
2
2
Arc
Arc
Solidified WeldSolidified
Metal Weld Metal
Is a consumable - it gets
melted during the welding
process
Is composed of two parts
Core Rod (Metal Filler)
Carries welding current
Becomes part of the weld
Flux Coating
Produces a shielding gas
Can provide additional filler
Forms a slag
An arc occurs when the electrode comes in
contact with the work-piece and completes the
circuit like turning on a light!
The electric arc is established in the space
between the end of the electrode and the work
The arc reaches temperatures of 10,000F which
melts the electrode and base material
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
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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 sound with the
surrounding base metal
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
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Arc column and weld puddle
Shielding (Fumes)
A shielding gas is formed when the flux coating
melts.
This protects the weld puddle from the atmosphere
preventing contamination during the molten
stateThe shielding gas protects the molten puddle from
the atmosphere while stabilizing the arc
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Flux melt in arc column and it deposit as slag over the weld
metal to protect the weld metal till the metal cools
Slag shall be removed before depositing another layer
12
A.C. (Alternating current) Welder current
alternates direction 120 times per second.
D.C. (Direct current) Welder current flows in the
same direction.
Two basic types
Constant current
Referred to as variable voltage
Constant voltage
Referred to as constant potential
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
16
17
Improper power selection
Machine adjustment too hot or too cold
Electrode size too large or too small
Improper movement of electrode
Improper angle of holding electrode
Improper base metal preparation
Arc length too long or too short
ANSI/AWS - 5.1 : Specification for Covered Carbon Steel
ANSI/AWS - 5.5 : Specification for Low Alloy Steel
ANSI/AWS - 5.4 : Specification for Corrosion Resistant Steel
AWS Website:
http://www.aws.org
E70XX-H4R
Electrode
Tensile in Ksi
Welding Position:
1 = All Position, 2 = Flat & Horizontal
Type of Current and Coating
*Hydrogen:
H4 = Less than 4ml/100g weld metal, H8 = Less than
8ml/100g Weld Metal
or H16 = Less than 16ml/100g weld metal
*Meets Requirements of Absorbed Moisture Test
*Optional Designators
AWS
Class
Covering
Current
Requirements
Position
Characteristics
EXX 10
Cellulose
Sodium
DCEP
All
Deep Penetration,
With Ripples
EXX 11
Cellulose
Potassium
AC, DCEP
All
Flat Decking
Deep Penetration,
With Ripples
EXX22
Rutile
Sodium
DCEN, AC
Flat, Horiz. Fillet
Deep Penetration,
With Ripples
EXX 24
Rutile
50% Iron
Powder
Mineral
50% Iron
Powder
EXX 27
AC, DCEP, DCEN Flat, Horiz. Fillet
High Deposition
Shallow Penetration
AC,DCEP, DCEN Flat, Horiz. Fillet
High Deposition
Shallow Penetration
AWS
Class
Covering
Current
Requirements
Position
Characteristics
EXX 12
Rutile
Sodium
DCEN, AC
All
Mild to Medium Penetration
EXX 13
Rutile
Sodium
AC, DCEP, DCEN
All
Mild Penetration
EXX 14
Rutile
30% Iron
Powder
Low-Hydrogen
30% Iron
Powder
Low-Hydrogen
50% Iron
Powder
AC, DCEN
All
Medium Penetration
DCEP, AC
All
Medium Penetration
AC, DCEP
Flat, Horiz. Fillet
High Deposition
EXX 18
EXX 28
1/8
5/32
Sizes of electrodes range from 1/16 to 3/8.
Electrode size is determined by the diameter of
the wire core.
Coating Materials -Partial List
Arc Stabilizers
Titania TiO2
Gas-Forming Materials
Wood Pulp
Limestone CaCO3
Slag-Forming
Materials
Alumina Al2O3
TiO2
SiO2
Fe3O4
Slipping Agents to Aid Extrusion
Clay
Talc
Glycerin
Binding Agents
Sodium Silicate
Asbestos
Starch
Sugar
Alloying and Deoxidizing Elements
Si, Al, Ti, Mn, Ni, Cr
Understand and follow all safety precautions listed in Safety in Welding,
Cutting, and Allied Processes (ANSI Z49.1) and Arc Welding Safety (E205)
Understand and follow all warning labels and material safety data sheet
found On welding equipment, consumables, tools
Wear suitable clothing to protect all parts of the body. (PPE) personal
protective equipment, fire resistant, shock resistant, light filter
Never look at the arc with the naked eye. The applicable shade shall be
used it ranges from 7-14
Fumes and Gases can be dangerous
Keep your head out of the fumes
Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases
from your breathing zone and the general area
The SMAW process can withstand wind and exhaust near the arc from ventilation
equipment
Electric Shock can kill to receive a shock your body must touch the electrode
and work or ground at the same time
Do not touch the electrode or metal parts of the electrode holder with skin or wet
clothing
Keep dry insulation between your body and the metal being welded or ground
Arc Rays can injure eyes and skin - Choose correct filter shade (See chart below
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Equipment less complex,
more portable, Flexible
Low initial cost
Less sensitive to drafts, dirty parts, poor fit-up
Electrodes Readily available for most base metals
Less operator training
Easy to change between many base materials
Low Deposition Rates Low Productivity
Operator Dependent
Difficult to weld very thin materials
Frequent restarts
Lower operating factor
Higher operator skill required for SMAW than
some other processes
Electrode need baking and storing for long time
not advisable
END
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