Arc Welding

INTRODUCTION:

SHIELDED METAL ARC WELDING (SMAW), commonly called stick, or

covered electrode, welding, is a manual welding process that uses a
welding power supply to create an electric an arc between a flux-
covered consumable electrode and the work piece to melt the metals
at the welding point. The process uses the decomposition of the flux
covering to generate a shielding gas and to provide fluxing elements to
protect the molten weld-metal droplets and the weld pool. They can
use either direct (DC) or alternating (AC) current, and consumable or
non-consumable electrodes. The process uses the decomposition of
the flux covering to generate a shielding gas and to provide fluxing
elements to protect the molten weld-metal droplets and the weld pool.

Figure 1: SHIELDED METAL ARC WELDING

THE SMAW PROCESS

The SMAW process is the most widely used welding process. The arc is initiated
by momentarily touching or "scratching" the electrode on the base metal. The
resulting arc melts both the base metal and the tip of the welding electrode.
The molten electrode metal and flux is transferred across the arc (by arc forces)
to the base-metal pool, where the welding region is usually protected by some
type of shielding gas, vapor, and/or slag.

HOW TO STRIKE AND ESTABLISH AN ARC?

A welding arc is maintained when the welding current is forced across a gap
between the electrode tip and the base metal. A welder must be able to strike
and establish the correct arc easily and quickly. There are two general methods
of striking the arc.

1. SCRATCHING:
The scratching method is easier for beginners and when using an AC machine.
The electrode is moved across the plate inclined at an angle, as you would strike
a match. As the electrode scratches the plate an arc is struck. When the arc has
formed, withdraw the electrode momentarily to form an excessively long arc,
then return to normal arc length.

Figure 2: Scratch method arc starting

2. TAPPING:
In the tapping method, the electrode is moved downward to the base metal in a
vertical direction. As soon as it touches the metal it is withdrawn momentarily
to form an excessively long arc, then returned to normal arc length.
 Figure 3 : Tapping method of arc starting.

Welding Circuit
The circuit diagram for the SMAW process is shown in Fig. 4. The equipment
consists of a power source, electrode holder, and welding cables that connect
the power source to the electrode holder and the work piece. Alternating
current (ac), or direct current, electrode negative (DCEN), or direct current,
electrode positive (DCEP) can be used, depending on the electrode coating
characteristics. The DCEN source is also called dc straight polarity, whereas the
DCEP source is also called dc reverse polarity.

Figure 4 : Welding Circuit

THE ELECTRODE HOLDER:

It is held by the welder, firmly grips the electrode and transmits the welding
current to it. Electrode holders are available in several designs, such as the
 pincher type and the collet, or twist, type, shown in Fig. 3. Each style has its
proponents and the selection is usually a personal preference. Electrode holders
are designated by their current capacity. Selection factors, such as the current
rating, duty cycle, maximum electrode size, and cable size, are shown in Table 1.
The most lightweight holder that will accommodate the required electrode size
is usually desired. All electrode holders should be fully insulated. Because they
are used in proximity to the arc and are exposed to high heat, they will
deteriorate rapidly. It is extremely important to maintain electrode holders to
ensure that they retain their current-carrying efficiency, their insulating
qualities, and their electrode gripping action. Manufacturers supply spare parts
so that the holders can be rebuilt and maintained for safe and efficient.

ELECTRODES

The electrodes used in the SMAW process have many different compositions of
core wire and a wide variety of flux- covering types and weights. Standard
electrode diameters of the core wire range from 1.6 to 8 mm. Electrode length
usually ranges from 230 to 455 mm (9 to 18 in.); the shorter lengths are
associated with the smaller diameter electrodes. A bare, uncoated end of the
electrode (the grip end) is provided for making electrical contact in the
electrode holder.

POWER SOURCES:

Welding power sources are also known as welder, and welding machines.
All welding machines are designed to change the high voltage alternating
current main supply into a safe, low voltage, heavy-current supply,
suitable for arc welding.
Arc welding machines produce either a constant current or a constant
voltage. Manual metal arc welding process requires a constant current
welding machine to minimize the changes in current whenever a welder
changes the arc length.
Constant current welding machines are classified into three types. They
are:
 1-Ac transformer
 2-Dc generator
 3-Ac /Dc Transformer-rectifier

Brief descriptions of these types are given below.

Types of
Types of current
Application
machine available at the
arc
Used for both light and heavy steel fabrications
Transformer AC
and for TIG welding of aluminum
As listed above plus light and heavy stainless
Transformer steel fabrication .TIG welding of stainless steel,
AC and DC
rectifier copper and nickel alloys using dc and aluminum
using ac.
Motor Light and heavy fabrications made from low
DC
generator carbon steel and stainless steel
Engine As for motor generator but where main supply
DC
generator of electricity is not available