1. Meridian Ag Department Course Information Packet
Arc Welding (SMAW)
Meridian Ag Department
Course Information Packet
Name:_____________________________________
Date:______________________________________

2. Shielded Metal Arc Welding
SMAW
(Stick) 1

3. What is SMAW? SMAW = Shielded Metal Arc Welding
“Stick” Welding or “Manual” Welding
Metal Rod Covered with Flux that Provides Shielding to Protect the Weld
Uses Constant
Current Power Sources
Most Widely Used Arc Welding Process in the World 2

4. Shielded Metal Arc Welding
An arc welding process with an arc between a covered electrode and the weld pool. The process is used with shielding from the decomposition of the electrode covering, without the application of pressure and with filler metal from the electrode.

5. Advantages
Low Start Up Costs
Portability
Outdoor Weld ability 3

6. Advantages continued All Position Welding Variety of Materials
Mechanical Properties

7. Limitations Low Efficiency (65%) Operating Factor Operator Skill
Restarts 4

8. Limitations continued
Amperage Limit
Slag
Spatter

9. Safety Eye & Ear Protection Welding Helmet with Lens Shade Number
Welding Gloves & Optional Covering
Proper Attire

10. Eye & Ear Protection Ear Plugs Goggles Safety Glasses
Hearing Protectors

11. Proper Attire
Long Sleeve
At least 50% cotton
No Cuffs

12. Welding Coverings Leather Welding Apron Leather Welding Jacket
Leather Welding Gloves
Leather Cape Sleeves/Bib
Leather Welding Trousers

14. Welding Helmet

16. AWS/ANSI Lens Shade Numbers

17. Safety Electrical Hazards Fumes and Gases Arc Radiation
Fire or Explosion
Hazards in the Work Area

18. Be safety conscious at all times.
ARC flash:
ultra violet
infrared
visible
Weld burns- wear gloves and coveralls

19. Electrical Hazards High Voltage Can Kill Electrical Shock Can Kill
Do Not Operate With Covers Removed
Disconnect Input Power Before Servicing
Do Not Touch Electrically Live Parts
Electrical Shock Can Kill
Do Not Touch Electrode With Skin or Wet Clothing
Insulate Yourself From Work and Ground

20. Fumes & Gases Welding May Produce Hazardous Fumes And Gases
Shielding Gases Can Displace Air and May Cause Injury or Death
Use Ventilation To Keep Air Breathing Zone Clear
Do Not Weld Near Chlorinated Hydrocarbons

21. Arc Radiation Electric Arc Welding Rays Can Burn Eyes and Skin
Always Use a Helmet When Arc Welding
Select Appropriate Filter Lens
Wear Appropriate Clothing
Provide Non-Flammable Shielding to Protect Others

22. 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

24. General Work Area Hazards
Keep Power Source Cables, Welding Materials and Tools Neatly Organized
Connect Work Cable as Close as Possible to the Weld Area
Do Not Allow Alternative Circuits Through Scaffold Cables, Hoist Chains, or Ground Leads
Use Only Properly Grounded Equipment
Always Disconnect Power to Arc Welding Equipment Before Servicing

25. Types of Welders: I. Alternating current (AC) A. Advantages:
pulls 37.5 amps of line draw
current constant in either direction (oscillates)
A. Advantages:
Less initial cost
B. Disadvantages:
limited to localized area
harder to strike an arc than DC
fewer electrodes to choose from as DC

26. Types of Welders: II. Direct Current: A. Advantages (DC)
current moves in on direction
straight polarity- Electrodes negative
reversed polarity- Electrodes positive
A. Advantages (DC)
mobile
easier to strike an arc
greater electrode selection
easier to weld in all positions
B. Disadvantages:
high initial cost
maintenance requirement
larger in size than AC
Bobcat™ 250
Trailblazer® 302

27. Types of Welders: III. AC. /D.C. Advantages of Both
Welders for your use in our shop
Dynasty® 200 Series
Thunderbolt® XL 225/150 AC/DC
Millermatic® 252

28. Maxstar 150s

30. SMAW Process Basics Electric Arc melts the electrode & fuses the joint
Metal deposited
Slag floats
All Polarities

31. The SMAW Process Basics

32. Electrode Holders
200, 300, and 400 Amp Electrode Holders 13

33. Work Clamps
300 and 500 Amp Work Clamps
GC 300
GC 500 13

35. AC Polarity
Medium Penetration
Medium Travel Speeds

36. DCEP (Reverse) Polarity
Heat Concentrated at Work piece
Forceful, Digging Arc
Medium to Deep Penetration

37. DCEN (Straight) Polarity
Heat Concentrated at Electrode
Lower Penetration
Increased Deposition Rates

38. Duty Cycle
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.

39. Duty Cycle
Duty Cycle Amperes Time Available 30% Min/10 Min 40% Min/10 Min 50% Min/10 Min 60% Min/10 Min 70% Min/10 Min 80% Min/10 Min 90% Min/10 Min 100% Min/10 Min

40. Electrode information: E6013 (example)
E- Electrode
60- 60,000 pound tensile strength per square inch
1- welding position
3- polarity

42. Welding position digits:
1- all positions
2- flat and horizontal positions
3- not approved number
4- vertical only

44. Polarity digits: 0- If 0, refer to previous digit
1- AC or DC reverse or straight
2- AC or DC straight
3- AC or DC straight or reverse
4- AC or DC straight or reverse
5- DC reverse
6- AC or DC reverse
7- AC or DC
8- AC or DC reverse or straight
Digits 5 through 8 are low hydrogen electrodes
Most common electrodes:
E6011- Fast freeze; good penetration. Marginal appearance
E6013- Fill freeze; marginal penetration, smooth appearance
E7018- Low hydrogen- stronger in tensile strength than mild steel

45. Electrode Characteristics

46. Electrode Characteristics continued

47. Electrode coatings (flux):
Synthetic
Iron powder
Alloys
Flux purpose:
Produces gaseous shield (keeps out oxygen and nitrogen)
Cleanses weld (slag floats to the surface)
Slows cooling rate for increased weld strength (slap)
Directs and stabilizes arc (barreling effect)
Adds strength to the weld (alloying elements.)

48. Electrode Sizes:
1/16
3/32
1/8
5/32
3/16 of an inch in diameter

49. Approximate Amperage Settings

50. Fundamentals of arc welding:
Amperage: dependent on mental thickness
Arc length: equal to the diameter of the bare end of the electrode
Angle of the electrode: degrees in the direction of travel.
Rate (Speed) of travel: bead width should equal 2 ½ times the diameter of the bare end of the electrode.

52. Arc Welding hints: (procedure)
Methods of striking an arc:
scratching
tapping
Starting a bead- long arc (more heat)
Finishing a bead: shorten arc then stop completely and let eye cool for one or two seconds and deposit a spot of weld directly in the crater (to fill it up)
Starting a new rod in the middle of the bead: Strike arc one inch ahead of crater. Move back into crater with long arc and proceed to weld as usual.

53. Arc Length

54. Electrode Angles

55. Travel Speed

56. Starting The Arc

57. Bead Initiation

58. Techniques Stringer Weave Beads Narrow and No Motion D. Box Weave
A. Circles
B. Crescent
C. zig zag
E. Double J

59. Bead Formation

60. Bead Termination

61. Restarting Interrupted Bead
1. Strike Arc Here
2. Move Electrode to Crown of Crater
3. Resume Travel Forward

64. Sample Beads For Quality Welding

65. Trouble Shooting: Undercut: a. too long of arc b. excessive amperage
Overlap:
a. too low amperage
Narrow bead:
low amperage
too fast rate of travel
Wide bead:
too slow rate of travel
excessive amperage
Splatter:
a. long arc
b. excessive amperage
Electrode Sticks:
a. too short of an arc
b. too low amperage

66. Methods of identifying metals:
Surface appearance
Sound
Spark test
high carbon: many short sparks
low carbon: longer shaft like appendages

67. Controlling distortion:
Distortion: forces of expansion and contraction pushing and pulling in metal being welded until it will not return to its original shape or position.
Control methods:
proper preparation
tacking
clamping
avoid excessive amperage
intermittent welding
don’t over weld
peening
use fewer passes
back step method
weld down hill (sheet metal)

68. Safety Rules For ARC Welding
Secure services of a competent electrician when making electrical installations for an arc-welding machine.
Inspect primary and secondary cables regularly. Repair or replace defective cable at one and use only parts that are rated for the welder.
Do not run machinery over or under cables.
Stand on a dry board while welding if the ground or floor is wet.
Make sure that all electrical connections including the power line, arc welding machine cable, electrode and ground clamp are firmly attached before beginning to weld.
Wear good quality gauntlet leather gloves.
Use electrode holders, which are fully insulated.
Protect face and eyes from flying particles of slag by wearing safety glasses, and placing your hand in front of your face to deflect particles when chipping the bead.
Wear high top leather shoes to protect feet and ankles from burns caused by weld spatter.

69. Safety Rules For ARC Welding
Wear skullcaps under helmet to protect head from particles or spatter.
Keep buttoned parts of clothing such as collar, shirtsleeves, and pockets. Have cuffs of pants turned down in order to avoid catching weld spatter. Avoid wearing ragged clothes while welding.
Avoid handling hot metal.
Twist electrode free or remove holder, before removing your helmet, if electrode should “freeze” in welding.
Do not strike the arc without first covering the face and eyes with the protective shield or helmet.
Give the word “cover” to all people standing nearby when ready to strike an arc. Do not weld around small children, as they tend to look directly at the arc.
Examine the head shield or helmet and color lens, making sure that there are no cracks, which will permit leakage of light rays.

70. Safety Rules For ARC Welding
Wear protective clothing when welding, and keep all parts of the body covered. The arc flash will penetrate lightweight clothing such as T-shirts.
Treat eyes with butyn preparation to prevent inflammation, in case a direct flash is received from the arc at close range. (Also milk, potato water, cool boric acid, or 5% argyrols solution).
Keep shop well ventilated when welding steel or cast iron in order to insure comfort of welding operator.
Use ventilating fan, or work in the open when welding metals containing zinc lead (galvanized metals).
Use forced ventilation when welding in a confined area such as a tank.
Drink sweet milk to over come nausea resulting from welding where zinc-oxide fumes are present.
Clean the shop frequently, especially in areas where welding is done. (Fire hazard)
Never weld where uncovered containers holding combustible or flammable materials are in the shop.
The best first aid for minor burns is to immerse the injured area in cold water for several minutes.