CSWIP 3.

1 Welding Inspection

Manual Metal Arc Welding

or
Shielded Metal Arc Welding

Copyright © TWI Ltd 2008

TWI Training & Examination Services

Course Reference WIS 5

Course notes section reference 11
Shielded Metal Arc Welding Introduction

The SMAW welding Process was first developed in the late

19th century using bare wire consumables.
• SMAW is a simple process in terms of equipment
• The process can by used in AC, DC+ or DC-
• The process is a manual process and demands a high

Copyright © TWI Ltd 2008

skill from the welder.
• The process is widely used throughout the welding
industry both for shop and site working conditions
SMAW - Principle of operation

Copyright © TWI Ltd 2008

 SMAW welding

Main features:
• Shielding provided by decomposition of flux covering
• Electrode consumable
• Manual process

Welder controls:
• Arc length
• Angle of electrode

Copyright © TWI Ltd 2008

• Speed of travel
• Amperage settings
 Shielded Metal Arc Welding Basic Equipment

Control panel Power source

(amps, volts)

Electrode Holding oven

oven
Electrodes Inverter power

Copyright © TWI Ltd 2008

source
Return lead
Electrode holder
Welding visor
filter glass Power cables
 SMAW Welding Plant

Transformer:
• Changes mains supply voltage to a voltage suitable for welding.
Has no moving parts and is often termed static plant.
Rectifier:
• Changes a.c. to d.c., can be mechanically or statically achieved.
Generator:
• Produces welding current. The generator consists of an armature
rotating in a magnetic field, the armature must be rotated at a

Copyright © TWI Ltd 2008

constant speed either by a motor unit or, in the absence of
electrical power, by an internal combustion engine.
Inverter:
• An inverter changes d.c. to a.c. at a higher frequency.
 ARC CHARACTERISTICS

Constant Current/Amperage Characteristic

Large change in voltage =

OCV Smaller change in amperage

Volts
Large arc gap
Welding Voltage

Copyright © TWI Ltd 2008

Small arc
gap

Amps
 SMAW Welding Variables

Voltage
• The arc voltage in the MMA process is measured as close to
the arc as possible. It is variable with a change in arc length
O.C.V.
• The open circuit voltage is the voltage required to initiate, or
re-ignite the electrical arc and will change with the type of
electrode being used e.g 70-90 volts
Current

Copyright © TWI Ltd 2008

• The current used will be determined by the choice of
electrode, electrode diameter and material type and
thickness. Current has the most effect on penetration.
Polarity (Cực, CHIỀU PHÂN CỰC)
• Polarity is generally determined by operation and electrode
type e.g DC +ve, DC –ve or AC
 SMAW Welding Checks
OCV open circuit volts
•A check should be made to ensure that the equipment can
produce the OCV required by the consumable and that any
voltage selector has been moved to the correct position
Current & polarity
•A check should be made to ensure the current type and range
is as detailed on the WPS
Other variables
•Checks should be made for correct electrode angle, arc gap

Copyright © TWI Ltd 2008

and travel speed
Safety
Check should be made on the current carrying capacity, or
duty cycle of the equipment and all electrical insulation is
sound and in place. Correct extraction systems should be in
use to avoid exposure to toxic fume.
 SMAW Welding Checks
The welding equipment
A visual check should be made on the equipment to ensure it
is in good working order
The electrodes
Checks should be made to ensure that the correct
specification of electrode is being used, the electrode is the
correct diameter and in good condition.

Copyright © TWI Ltd 2008

Basic fluxed electrodes ensure the correct heat treatment is
being carried out before use
Rutile electrodes do not require pre-baking but should be
stored in a dry condition.
Cellulosic electrodes should not be dried
 SMAW electrode holder

Copyright © TWI Ltd 2008

“Tongs” type with
Collet or twist type spring-loaded jaws
 SMAW welding parameters

Welding current
– approx. 35 A/mm of diameter
– governed by thickness, type of joint and welding position

Welding
Too low current Too high

•poor starting •spatter

Copyright © TWI Ltd 2008

•slag inclusions •excess
•weld bead contour too penetration
high •undercut
•lack of •burn-through
fusion/penetration
 SMAW welding parameters

Arc length = arc voltage

Arc
Too low voltage Too high

•arc can be extinguished •spatter

•“stubbing” •porosity
•excess
penetration

Copyright © TWI Ltd 2008

•undercut
•burn-through

• Polarity: DCEP generally gives deeper penetration

 SMAW welding parameters

Travel speed

Travel
Too low speed Too high

•wide weld bead contour •lack of root fusion

•lack of penetration •incomplete root
•burn-through penetration
•undercut

Copyright © TWI Ltd 2008

•poor bead profile,
difficult slag removal
 SMAW welding parameters

Type of current:
• voltage drop in welding cables is lower with AC
• inductive looses can appear with AC if cables are coiled
• cheaper power source for AC
• no problems with arc blow with AC
• DC provides a more stable and easy to strike arc, especially
with low current  better positional weld, thin sheet applications
• welding with a short arc length (low arc voltage) is easier with

Copyright © TWI Ltd 2008

DC  better mechanical properties
• DC provides a smoother metal transfer  less spatter
 SMAW - Troubleshooting

Copyright © TWI Ltd 2008

MMA quality (left to right) - current, arc length and travel speed
normal; current too low; current too high; arc length too short;
arc length too long; travel speed too slow; travel speed too high
 SMAW welding typical defects
Most welding defects in MMA are caused by a lack of welder
skill (not an easily controlled process), the incorrect settings
of the equipment, or the incorrect use, and treatment of
electrodes
Typical Welding Defects:
•Slag inclusions
•Arc strikes

Copyright © TWI Ltd 2008

•Porosity
•Undercut
•Shape defects (overlap, excessive root penetration, etc.)
 Shielded Metal Arc Welding (SMAW)
Advantages:
• Field or shop use
• Range of consumables
• All positions
• Portable
• Simple equipment
Disadvantages:
• High welder skill required

Copyright © TWI Ltd 2008

• High levels of fume
• Hydrogen control (flux)
• Stop/start problems
• Comparatively uneconomic when compared with some
other processes i.e MAG, SAW and FCAW
 Any Questions

Copyright © TWI Ltd 2008