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Chapter 5:
SMAW: Equipment and Supplies
Chapter 6:
SMAW: Equipment Assembly and
Adjustment
Chapter 7:
SMAW: Electrodes
Chapter 8:
SMAW: Flat Welding Position
Chapter 9:
SMAW: Horizontal, Vertical, and
Overhead Welding Positions
Chapter 10:
Surfacing
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51
Chapter 5 SMAW: Equipment and Supplies
Chapter
Chapter 5
SMAW:
Equipment
and Supplies
SMAW:
Equipment
and Supplies
After studying this chapter, you will be able to:
Describe the differences between direct current
(dc) and alternating current (ac).
Interpret American Welding Society (AWS)
abbreviations regarding welding current polarity.
Identify the equipment and accessories used in
shielded metal arc welding (SMAW).
Identify factors to consider when selecting an arc
welding machine.
Shielded Metal Arc Welding
Principles
Shielded metal arc welding (SMAW) is a weld-
ing process in which the base metals are heated to
fusion or melting temperature by an electric arc. The
arc is created between a covered metal electrode and
the base metal. A shielding gas protects the base
metals, arc, electrode, and weld from the atmos-
phere during welding. The shielding gas is created
as the flux covering on the electrode melts. When
the flux solidifies, it forms a protective slag over the
weld bead. The melting electrode wire furnishes
filler metal to the weld. See Figure 5-1.
alternating current (ac)
bridge rectifier
chipping hammer
constant current (CC)
constant voltage (CV)
cover plate
cycle
diode
direct current (dc)
direct current electrode
negative (DCEN)
direct current electrode
positive (DCEP)
direct current reverse
polarity (DCRP)
direct current straight
polarity (DCSP)
droop curve machines
Technical
Terms
bjectives
Learning droopers
duty cycle
electrode holder
electrode lead
filter lens
flash goggles
frequency
gauntlet gloves
helmet
hertz
input power
inverter
lug
open circuit voltage (OCV)
polarity
primary current
rated output current
secondary current
shielding gas
shielded metal arc
welding (SMAW)
silicon-controlled
rectifier
slag
step-down transformer
terminals
voltage drop
welding outfit
welding station
wire brush
work booth
workpiece lead
This sample chapter is for review purposes only. Copyright The Goodheart-Willcox Co., Inc. All rights reserved.
The temperature of the arc in SMAW can be over
9000F (5000C). With the correct diameter electrode,
the heat created by the arc is enough to melt any
weldable metal. Mild carbon steel melts at slightly
above 2800F (1540C).
Shielded metal arc welding is used to construct
buildings, ships, truck chassis, pipelines, and other
weldments. SMAW equipment is fairly inexpensive. It
is widely used on farms and in small repair shops.
SMAW Current and Polarity
In SMAW, electrical current flows across an air
gap between the covered electrode and base metal. An
electric arc is formed as the current flows across the
air gap. The arc creates the heat required for welding.
The electrical current for welding is supplied by
an arc welding machine. Welding machines, also
called power sources, produce two types of current:
direct current (dc) and alternating current (ac).
An electrical current is actually the flow of elec-
trons within a circuit. The direction that the electrons
flow is referred to as the polarity. Electrons flow from
a negatively charged (polarized) body to a positively
charged body. Direct current may flow from the
electrode to the base metal. When the current flows
in this direction, the electrode has negative polarity
and the base metal has positive polarity. It is called
direct current electrode negative (DCEN). Direct current
electrode negative is also known as direct current
straight polarity (DCSP). See Figure 5-2. The current
direction may be reversed to flow from the base metal
to the electrode. When the current flows in this
direction, the base metal has negative polarity, and the
electrode has positive polarity. It is called direct current
electrode positive (DCEP). Direct current electrode
positive is also known as direct current reverse polarity
(DCRP). See Figure 5-3.
The direction selected is determined by the
metal thickness, joint position, and type of electrode
used. The selection of polarity is covered later in
this chapter.
Welding Technology Fundamentals 52
Electrode
wire
Direction
of travel
Shielding
gas
Arc flame
Slag
Base metal
Depth of
penetration
Flux
covering
Welding arc
Weld pool
Figure 5-1. In shielded metal arc welding, slag covers the weld
bead while it cools. Shielding gas is formed as the flux covering
is burned.
Electrode
holder
Electrode
()
Arc
gap
Workpiece
(+)
Figure 5-2. A diagram for a direct current electrode negative
(DCEN) arc welding circuit. Notice the current is traveling
from the negative electrode to the positive base metal.
Electrode
holder
Electrode
(+)
Arc
gap
Workpiece
()
Figure 5-3. A diagram for a direct current electrode positive
(DCEP) arc welding circuit. In DCEP, the current travels
from the negative base metal to the positive electrode.
53
Chapter 5 SMAW: Equipment and Supplies
Direct Current
Direct current (dc) flows in only one direction.
Current flows from one terminal of the welding
machine to the base metal. It then flows back to the
second terminal of the welding machine. On some
welding machines, the electrical leads are manually
reversed on the machine terminals. This changes the
direction of current flow. On other machines, a polar-
ity switch is flipped to electrically reverse the terminal
leads within the machine. See Figure 5-4. Welding
must be stopped and the electrode insulated from
the circuit whenever the polarity is changed.
The circuit polarity affects the selection of the cov-
ered electrode and how the covered electrode will
perform. Direct current electrode positive (DCEP)
used with the proper electrode produces deeper pen-
etration than direct current electrode negative
(DCEN). Most electrodes use DCEP.
Direct current electrode negative (DCEN) is used
with electrodes that do not produce deep penetration.
Asmall electrode using DCEN and a low-current setting
will produce a soft arc with only minimal penetra-
tion. Thus, DCEN, with proper electrodes, is used for
welding thin metals. DCEN is also used with some
electrodes to deposit weld metal quickly. DCEN can
melt an electrode more rapidly and deposit filler
metal at a faster rate than DCEP.
When limited to a certain polarity, the selection of
the electrode will depend on the type of polarity. If
only certain electrodes are available, the electrode will
determine the type of polarity. The polarity and the
electrode must always agree.
Alternating Current
Alternating current (ac) generally operates at 60
cycles per second in the United States. Acycle is a set
of repeating events, such as the flow and reversal of
flow in an electrical circuit. Alternating current flows
in one direction for 1/120 of a second, then reverses
its direction and flows for 1/120 of a second to form
one complete cycle. See Figure 5-5. The total time for
a cycle is 1/60 of a second:
1/120 sec + 1/120 sec = 1/60 sec
Frequency is a term used to describe the number
of cycles per second there are in ac power. Frequency
is measured in hertz (Hz). One cycle per second is the
same as one hertz. Thus, ac power at 60 cycles per sec-
ond is also called 60-hertz power.
Welding with ac and with ac electrodes produces
a medium depth of penetration. Many electrodes (but
not all) will work with alternating current. See
Chapter 7 and manufacturer's recommendations for
more information on electrodes.
SMAW Outfit
SMAW requires the use of proper protective
clothing and various tools, supplies, and equipment.
The welding outfit includes equipment required to
actually create a weld. The welding station includes
tools, supplies, and other items required to make
welding safe and comfortable. A complete SMAW
outfit includes the following:
Welding machine/power source (dc, ac, or ac/dc).
Electrode and workpiece leads.
Electrode holder.
Selects alternating
current
Selects direct current
electrode positive
Selects direct current
electrode negative
Figure 5-4. This polarity switch has positions for DCEP, AC,
and DCEN.
Maximum
C
u
r
r
e
n
t
1/120 sec
1/60 sec
One cycle or hertz (Hz)
Time
Maximum
0
0
1/120 sec + 1/120 sec = 2/120 sec = 1/60 sec
Figure 5-5. Alternating current plotted against time results in
an ac sine wave. The current increases from zero and returns to
zero. It then increases in the opposite direction and returns to
zero. The complete process is one cycle and takes 1/60 second.
A complete SMAW station, Figure 5-6, includes
the SMAW outfit plus the following:
Ventilation.
Welding table.
Welding booth with an opaque (solid) or filtered
transparent plastic screen.
Covered electrodes.
Chipping hammer and wire brush.
Arc Welding Machine
Arc welding machines produce either a constant
current (CC) or a constant voltage (CV). Manual
welding processes, such as SMAW, require a constant
current (CC) welding machine. If a CC welding
machine is not used, large changes in current occur
whenever a welder changes the arc length slightly.
Since it is impossible to manually maintain a constant
arc length without any variation, a CC welding
machine is used.
CC welding machines are also called droopers or
droop curve machines. This name is derived from the
voltage versus amperage curve produced by the
machines. Figure 5-7 shows the curve shape for a CC
welding machine.
Examine Figure 5-7 closely. An increase from 20
volts to 25 volts is a 25% increase in voltage. This
change in voltage results in an increase in current
from 125 amps to 130 amps, only a 4% increase. If the
welder varies the arc length, it causes a change in volt-
age. However, the amperage changes very little with
a CC welding machine. Although the current varies
slightly, these welding machines are considered con-
stant current. Both ac and dc welding machines are
available as constant current machines.
Selecting an Arc Welding Machine
Ac welding machines meet most welding require-
ments. They are easy to use and generally cost less
than comparable dc welding machines. Therefore,
they are widely used on the farm and in the home
shop. See Figure 5-8.
Because the polarity can be changed, dc welding
machines are more versatile than ac machines. The
ability to change the polarity allows the welder to
make out-of-position welds and to weld thin metal
more easily. It also allows the welder to vary the heat
applied to the metal. DCEP provides deep penetration
for welds on thick metal; DCEN deposits filler metal
faster. DCEN is used more easily on thin metal.
Some arc welding machines are combination
ac/dc machines. These machines can be used as ac
welding machines and then can easily be switched to
Welding Technology Fundamentals 54
Figure 5-6. This is a well-equipped shielded metal arc welding
station.
V
o
l
t
s
80
70
60
50
40
30
20
10
0
0 25 50 75 100 125 150 175 200
Amperes
Figure 5-7. A volt-amp diagram for a constant current
machine. The constant current (CC) welding machine is called
a drooper because of this curve. A 25% change in voltage
results in only a 4% change in amperage. The current change
is so slight that the current is considered constant.
55
Chapter 5 SMAW: Equipment and Supplies
dc welding machines. Combination machines have a
greater flexibility in their use. However, they are more
expensive than ac or dc machines.
Machine designs can be different types. The most
common are:
Transformerused for ac.
Transformer-rectifierused for ac and dc.
Inverter power supplyprovides ac and dc
options.
Motor generatorused to create dc power.
Motor alternatorused to create ac power; with
addition of a rectifier, can produce dc power. See
Figure 5-9.
The function of a power supply is to take the high-
voltage, low-current supplied power and change it
into the low-voltage, high-current power needed for
welding. Welding transformers are called step-down
transformers because the voltage is reduced.
Alternating current is supplied to one side of a
transformer. This is called the primary current. The cur-
rent coming out of the transformer, which is used for
welding, is called the secondary current. Alternating
current is used as the input to the transformer. The
output of the transformer is also alternating current,
but at a higher amperage and lower voltage.
To obtain direct current, the alternating current
is passed through a set of diodes or silicon-controlled
rectifiers (SCRs). Diodes and silicon-controlled rectifiers
are electrical devices that allow current to flow in only
one direction. (Remember, alternating current flows in
two directions.) Abridge rectifier is a group of diodes or
SCRs used to transform ac into dc. Figure 5-10 shows a
bridge rectifier circuit.
Another type of power supply is an inverter.
Inverter machines are very small and lightweight.
Current range
selector
Current adjustment
dial
Figure 5-8. An ac shielded metal arc welding machine has two
current ranges. The desired current is set by selecting a current
range and setting the desired current using the adjustment
dial. (Miller Electric Mfg. Co.)
Generator
engine
AC/DC
polarity
switch
Figure 5-9. A portable engine-driven ac/dc welding power
source has a switch used to select ac or either dc polarity.
(Lincoln Electric Company)
Transformer
Inductor
SCR SCR
SCR SCR
Controls
+