Shielded Metal Arc Welding Principles

Objectives
1. 2.

3. 4.

List the percentage of usage of SMAW in the industry. Name the components that make up the schematic representation of the shielded metal arc. Know the maximum arc temperature of an SMAW electrode. List the four constant current welding machines.

Objectives
5. 6. 7. 8. 9.

List the common type and uses of constant current welding machines. Name the power supply ratings. Name the characteristics of the four basic types of welding machines. Choose the correct cable size based on the application. List the welders safety equipment.

Shielded Metal Arc Welding (SMAW)

y Manual arc welding y Also Called stick electrode welding y Combustion and decomposition of electrode creates gaseous

shield
y Protects electrode tip, weld puddle, arc, and highly heated work from

atmospheric contamination
y Heat for welding generated by electric arc established between flux

covered consumable metal rod (electrode) and work

y Additional shielding provided by covering of molten slag

(flux)
4

SMAW

American Welding Society

Process Capability
y Shielded metal arc welding one of most used of various electric

arc welding processes

9% 13% 42% 2% SMAW GMAW/FCAW GTAW SAW Others

34%
6

SMAW Advantages
y Equipment less complex, more portable and less costly y Can be done indoors or outdoors, in any location and any

position y Electrodes available to match properties and strength of most base metals
y Not used for welding softer metals y Not as efficient in deposition

SMAW Operating Principles

y Sets up electric circuit
y Includes welding machine, work, electric cables, electrode holder

and electrodes, and a work clamp

y Heat of electric arc brings work to be welded

and consumable electrode to molten state

y Heat intense: as high at 9,000F at center

Welding Process
y Electric arc started by striking work with electrode y Heat of arc melts electrode and surface of base metal y Tiny globules of molten metal form on tip of electrode and

transferred by arc into molten pool on work surface y After weld started, arc moved along work

SMAW Operating Principle

American Welding Society

10

Welding Power Sources

y Each type of power source has fundamental electrical

differences that best suit particular processes y Welding machine

y Must meet changing arc load and environmental conditions

instantly y Must deliver exact amount of electric current precisely at right time to welding arc
y Available in wide variety of types and sizes

11

Welding Power Sources

y Also known as power supplies and welding machines y Two classifications
y Output slope y Whether constant current or constant voltage y Power source type y Transformer y Transformer rectifier y Inverter y Generator

12

Type of Output Slope

y Two basic types
y Constant current
y Referred to as variable voltage

y Constant voltage
y Referred to as constant potential

13

Output Slope
y Relationship between output voltage and output current

(amperage) of machine as current increased or decreased

y Also called volt ampere characteristic or curve

y Largely determines how much welding current will change

for given change in load voltage

y Permits welding machine to control welding heat and maintain

stable arc

14

Output Slope
y Indicates type and amount of electric current designed to

produce y Each arc welding process has characteristic output slope

y SMAW and GTAW require steep output slope from constant

current welding machine y GMAW and FCAW require relatively flat output slope from constant voltage power source y Submerged arc welding adaptable to either slop

15

Typical Output Slopes

16

Four Types of Power Source

y Engine driven generators
y Powered by gas or diesel combustion engine y Can be found with a.c. or d.c. electric motor y No longer being manufactured and rarely found

y Transformer rectifiers
y Use basic electrical transformer to step down a.c. line power

voltage to a.c. welding voltage y Welding voltage then passed through rectifier to convert a.c. output to d.c. welding current y May be either d.c. or a.c. d.c. machines

17

Four Types of Power Source

y A.C. transformers
y Used to step down a.c. line power voltage to a.c. welding

voltage
y Inverters
y Increases frequency of incoming primary power y Constant current, constant voltage, or both y Produce a.c. or d.c. welding current

18

Power Sources
y Important to select right power source for each job y Table 1 "Common types and uses of arc welding machines"

should be studied y Study of job indicates whether a.c. or d.c.

y Shielded metal arc welding and gas tungsten arc welding must

use constant current machine y Gas metal arc prefers constant voltage machine

19

Constant Current Welding Machines

y Used for shielded metal arc welding and gas tungsten arc

welding
y Current remains fairly constant regardless of changes in arc

length y Called drooping voltage, variable voltage, or droopers

y Load voltage decreases as welding current increases

20

Constant Current Output Slope

y Constant current welding machines
y Steep output slope y Available in both d.c. and a.c. welding current

y Steeper the slope, the smaller current change y Enables welder to control welding current in specific range

by changing length of arc

21

Constant Current Output Slope

Some jobs require steep volt ampere curve Other jobs use less steep volt ampere curve

22

Open Circuit Voltage

y Voltage generated by welding machine when no welding

being done
y Machine running idle

y Arc voltage
y Voltage generated between electrode and work during welding

y Load voltage
y Voltage at output terminals of welding machine when arc is

going y Combination of arc voltage plus voltage drop in welding circuit

23

Open Circuit and Arc Voltage

y Open circuit voltage runs between 50 100 volts
y Drops to arc voltage when arc struck

y Arc voltages
y Range: 36 volts (long arc) to 18 volts (short arc) y Determined by arc length held by welder and type of electrode

used
y Arc lengthened, arc voltage increases and current decreases

24

Open Circuit and Arc Voltage

y Open circuit voltage on constant current machines higher

than on most constant voltage machines y Arc voltage depends on physical arc length at point of welding and controlled by welder
y Shielded metal arc welding y Gas Tungsten arc welding

y Arc voltage much lower than open circuit voltage

25

Motor Generator Welding Machines

y Usually supply only direct current
y Can be made to supply a.c.

y Most constant current type y Used chiefly for shielded metal arc welding and gas tungsten

arc welding

26

Motor Generator Welding Machine

Sturdy steel lifting eye Large voltmeter Calibrated dial for easy, fine adjustment of heat and relation between voltage and current Outer wheel and dial for selecting desired welding range Stop button
Hobart Brothers Co.

27

Motor Generator Welding Machine

Ground cable connector Optional steel guard Pressed steel bearing cap Heavy duty ball bearings Arc welded copper squirrel cage rotor Motor stator Heavy steel fan
Hobart Brothers Co.

28

Motor Generator Welding Machine

Steel frame Fourpole "Multi Range" generator Heavy duty metallic graphite brushes Large commutator Heavy duty ball bearings Pressed steel bearing cap
Hobart Brothers Co.

Arc welded steel frame

29

Motor Generator Welding Machine

Removable steel covers Heavy duty single unit steel shaft Welding cable connector Polarity switch Large ammeter Steel turret top with removable cover

Hobart Brothers Co.

30

Motor Generator Welding Machine for SMAW

Variable voltage control Instruction on the Name plate

Polarity switch Constant voltage

The Lincoln Co.

Toggle switch Current control

31

External Construction of d.c. Motor Generator Welding Machine

The Lincoln Electric Co.

32

Internal Construction of a D.C. Motor Generator Welding Machine

The Lincoln Electric Co.

33

Motor Generator Desirable Characteristics

y Have forceful penetrating arc y Versatile
y Can be used to weld all metals that are weldable by arc process

y Flexible
y With proper electrode, can be used in all positions

y Durable and have long machine life

34

Generators
y Classified by type of motor that drives generator y Consists of a.c. motor, d.c. generator, and exciter built on single

shaft

Generators used in the field

Miller Electric Mfg. Co. The Lincoln Electric Co.

35

Sizes
y Determined on basis of amperage y Range
y 100 ampere rated for home y 1,500 ampere rated for use with automatic submerged arc

welding equipment
y Manual welding machine idle sometimes y Automatic power supply units 100% duty cycle
y Should not be used at or beyond max over extended period

36

Maintenance
y Contacts of starter switch and control rheostat should be

inspected, cleaned frequently and replaced when necessary y Brushes need frequent inspection for wear
y Check commutator for wear or burning y Rewound and turned on lathe

y Main bearings on shaft inspected and greased at each 6 month

period
y Clean old grease out of bearing housings

37

Start and Stop Buttons

y Purpose of starting and stopping the motor y Start button black y Stop button red y Important buttons be engaged firmly

38

Polarity Switch
y Electrode negative and electrode positive used in d.c.

welding y DCEN (d.c. electrode negative)

y Electrode connected to negative terminal of power source and

work connected to positive terminal

y DCEP (d.c. electrode positive)
y Electrode connected to positive terminal of power source and

work connected to negative terminal

y Switch changes to either electrode positive or electrode

negative

39

Volt Ampere Meters

y Sometimes serve dual purpose
y Can indicate polarity as well as current y Others, individual meters for volts and amperes y Some, single meter that indicates both volts and amperes y Button engaged to get individual readings y Would need second person for monitoring

y Increased demand for additional devices so meters have been

discontinued by some manufacturers

40

Current Controls
y Amperage
y Quantity of current y Determines amount of heat produced at weld

y Voltage
y Measure of force of current y Determines ability to strike an arc and maintain its consistency

y Two types of dual control generators

y Tapped step current control y Continuously variable current control

41

Dual Tapped Current Control

y Coarse adjustment dial selects current range
y Called steps or taps y Impossible to secure current value between two

steps by setting dial between them

y Fine adjustment dial trims current between steps
y Whether set high or low depends on type and

size of electrode, thickness of metal, soft or digging arc required, arc starting, restricting characteristics, and Position of welding

42

Dual Continuous Control

y Coarse adjustment dial continuously adjusts current y Fine dial adjusts both current(amperage) and open circuit voltage
y Operator adjusts output slope for given current setting by

manipulating both coarse and fine adjustment dials together

y Wheel or knob on both amperage and voltage setting devices

gives welder continuous control of both

43

Engine Driven Generator

Miller Electric Mfg. Co.

Capable of SMAW, GTAW, SMAW, FCAW and PAC.

Miller Electric Mfg. Co.

44

Remote Control
y Welding machines may be installed in remote part of plant y Welder may adjust current without leaving job y Timesaving on work
y Welder does not have to leave fabrication to readjust current

45

Air Filters
y Wear in arc welding machines costly
y Cost of replacement parts and labor y Loss of production due to nonuse of machine

y Bearing wear critical

y May be reduced through use of air filter fitted on suction end of

motor generator machine

y Filter cleaned regularly
y High pressure air, commercial solvent or steam

46

D.C. Transformer Rectifier Welding Machines

y Have many designs and purposes y Flexibility one reason for wide acceptance
y Deliver either DCEN or DCEP

y May be used for:

y y y y y

Stick electrode welding Gas tungsten arc welding Submerged arc welding Multi operator systems Stud welding
Miller Electric Mfg. Co. The Lincoln Electric Co.

47

Transformer Rectifier Machines

y Have two basic parts
y Transformer for producing and regulating alternating current

that enters machine y rectifier that converts a.c. to d.c.

y Third important part is ventilating fan
y Keeps rectifier from overheating

y Design improves arc stability and makes it easy to hold short

arc which is soft and steady y No major rotating parts so consume little power

48

A.C. D.C. Transformer Rectifier Welding Machines

y Permit welder to select either a.c. or d.c. and electrode negative

or electrode positive y Switch

y Permits welder to use only transformer part of machine for a.c.

welding y Flipping switch then output current directed through rectifier which converts it to d.c. welding
y High frequency arc starting devices, water/gas flow

controls, balance controls for a.c. operation, remote control often built into machine

49

A.C. D.C. Transformer Rectifier Welding Machines

A 300 amp model shown in use

Miller Electric Mfg. Co.

A 300 amp a.c. d.c. GTAW/SMAW machine.

50

The Lincoln Electric Co.

The Lincoln Electric Co.

Portable SMAW/GTAW welding machine

A.C. Transformer Welding Machines

y Most popular a.c. welding machine y Function of transformer
y Step down high voltage of input current to high amperage, low

voltage current required for welding

y Especially suited

for heavy work

Miller Electric Mfg. Co

The Lincoln Electric Co.

51

Advantages of a.c. Power Sources

y Reduces tendency to arc blow y Can use larger electrodes
y Resulting in faster speeds on heavy materials

y Lower cost y Decreased power consumption y High overall electrical efficiency y Noiseless operation y Reduced maintenance

52

D.C. and A.C. D.C. Inverter Welding Machines

y Portable, lightweight, and versatile y May be either constant current, constant voltage or both y Can perform several different processes

Miller electric Mfg. Co.

The Lincoln Electric Co.

53

Cost Comparisons: Arc Power Sources

y Three main areas
y Cost of purchasing equipment (nearly equal) y Operating efficiency y Motor generator machine: 52 65% y Transformer rectifiers: 64 72% y Inverters: 85% y Maintenance y Motor generator machine: replacing parts, lubrication y Transformer rectifiers and inverters have no moving parts

54

Multiple Operator Systems

y Can be installed away from work site and be connected to control

panels close to welding operator y When using direct current, all welders must weld with same polarity

Most installations are d.c. Power: 600 2,500 amperes Cost less, saves space and cable, lowers operating cost
55
Miller Electric Mfg. Co.

Power Supply Ratings

y Standards set
y The National Electrical manufacturers Association y Occupational Safety and Health Administration

y Provide guidelines for manufacture and performance of

power sources y Rated by

y Current output y Open circuit voltage y Duty cycle

Efficiency of output Power factor

56

Current Output
y Rated on basis of current output in amperes y Amperage range
y 200 amperes or less for light or medium work y Over 2,000 amperes for submerged arc welding

57

Open Circuit Voltage

y Maximum allowable used for manual welding
y 80 volts for a.c. or a.c. d.c. machines y 100 volts for d.c. machines y Very smooth output (less than 2% ripple)

y Automatic machine welding

y Some constant current machines rated up to 125 y Constant voltage types normally rated from

15 to 50

58

Duty Cycle
y Percentage of any given 10 minute period that machine can

operate at rated current without overheating or breaking down

y Rating of 100% means machine can be used at rated amperage

on continuous basis
y Required by continuous, automatic machine welding

y Rating of 60% means machine can be used at its capacity 6 out

of every 10 minutes without damage

y Satisfactory for heavy SMAW and GTAW

59

Efficiency
y Relationship of secondary power output to primary power

input
y Indicated in percent

y Determined by losses through machine when actually

welding at rated current and voltage y Average efficiencies

y Motor generator welding machines: 50% y Transformer rectifier: 70% y Inverter: 85%

60

Power Factor
y Measure of how effectively welding machine makes use of

a.c. primary line power

y Primary power used divided by amount total drawn y Expressed in percent

y Three phase d.c. transformer rectifiers: 75% y Single phase a.c. power units: 55% y Welding machines can be purchased with power factor

correction

61

Power Cable
y Conductors of ample capacity and adequately insulated for

voltage transmit power y Necessary to ground frame of welding machine

y Portable cable with extra conductor fastened to machine frame

on one end and solid ground on other

y Important cable adequately insulated with tough abrasion

resisting insulation
y Stand up under rough usage in welding shops

62

Electrode and Work Cable

y Required to complete electric circuit between welding

machine and work

y Electrode cable (welding cable) attached to electrode holder y Work cable attached to work

y Rubber covered multi-strand

copper cable generally used

y Must have high flexibility

The Lincoln Electric Co.

63

Cable Core Construction

y
y

Woven of thousands of very fine copper wire

Greater the number of strands the more flexible

Components
Wires stranded for extra flexibility Paper wrapping around wires allows conductor to slip within robber covering when bent C. Extra strength from open braided reinforcement of extra cotton cords D. Special composition and curing of heavy rubber covering
A. B.

64

Work Cable
y Not necessary to have flexibility of electrode cable
y Usually same cable used

y Important considerations
y Amperage of welding machine y Distance from work

y Larger cable
y Greater the amperage and greater the distance y Resistance increases as diameter of cable decreases

65

Cable Lugs
y Required on both electrode cable and work cable
y Soldered or fastened mechanically y Connections MUST be tight and secure

66

Work Clamps
y Variety of structures to be welded; many types of clamps may be

used
y Copper hook, heavy metal weight, C clamp y Specialized work clamps

This clamp stops twisting and turning of welding cable where work rotates. Clamp welded to part, thus permits work clamp to be attached in seconds. It is generally used in fabricating Spring loaded C clamp tanks, pressure vessels, and on weld positioners.
Lenco dba NLC. Inc. Lenco dba NLC. Inc.

Rotary type

Lenco dba NLC. Inc.

67

Quick Connector
y Attached to ends of different lengths of cables y Allow quick and easy attachment to any length cable

Lenco dba NLC. Inc.

This connector has cam type action that ensures positive stop and lock and cannot come loose or accidentally fall apart.
68

Metal Electrode Holders

y Device used for holding electrode mechanically y Conveys electric current

from welding cable to electrode y Insulated handle protects hand from heat y Jaws of holder grip electrode at any angle y Made of metal with high electrical conductivity and ability to withstand high temperatures

Lenco dba NLC. Inc.

69

Metal Electrode Holders

y Jaws can be replaced with new ones y Should be light in weight, well balanced and have

comfortable grip y Size of holder must be in line with size of welding machine y Fully insulated so stays cool even with high duty cycles

70

Spring Type Electrode Holder

Lenco dba NLC. Inc.

71

Short stub Electrode Holder

One ton pressure contact High welding current conductance Special extruded copper alloy body Cable connections

Bernard Welding Equipment Co.

Entirely insulated Holds electrodes burned to very short stub. Lifeguard insulation Twist type locking device permits electrode gripping power in excess of 2,000 pounds.
72

Angle head Electrode Holder

Shorter and lighter than other holders of comparable capacity.

Jackson Products Co.

Available in sizes of 400 and 600 amperes and takes electrodes from 1/16 through 5/16 inch in diameter.
73

Hand and Head Shields

y Brilliant light caused by electric arc contains two kinds of invisible

rays which injure eyes and skin

y Ultraviolet y Infrared

y Rays affect eyes within 50 feet;

and skin any distance within 20 feet

Fibre Metal Products Co.

Hand shield so person may hold shield in front of face

74

Hand and Head Shields

y Also called hood or helmet
y Attached to adjustable headband y Allows it to be moved up or down as wearer desires

y Dependable protection
y Both hands free to grasp electrode holder

y Partial protection
y Must also wear leather or

nonflammable cap for adequate protection

Fibre Metal Products Co.

75

Fibre Metal Products Co.

Hand and Head Shields

y Constructed of heat resisting, pressed fiber

insulating material y Shields fully molded at top and bottom to protect head and neck y Usually black to reduce reflection with window frame to hole protective lens

Fibre Metal Products Co.

Chrome leather helmets ideal for hard to get into areas. Flip front welding helmet permits welder to inspect and brush weld without lifting the hood.
76
Wilson Products

Head Shield Lens

y Sizes: 2 x 4.5 or 4.5 x 5.25 y Colored to screen out ultraviolet, infrared rays, and most of

visible rays y Variety of shades of color

y Density depends on brilliance of arc y Varies with size of electrode and volume of current

y Side exposed to weld pool protected by clear polycarbonate

plastic cover lens

y Protect costly filter lens from molten metal spatter and

breakage (replaced when pitted and clouded)

77

Auto darkening Electronic Filter Helmet

y Useful when working close quarters, doing high

production work, or avoiding inadvertent arc . strikes y Single shade or variable shades y Filter can switch from light to dark in less than 1/10,000 of a second y Battery powered
y May have solar battery booster

Jackson Products Co.

78

Safety Glasses
y Should be worn y Also behind hood to prevent severe arc flash reaching eyes y Can Absorb more than 99.9% harmful

ultraviolet rays y Worn by others who work with welders y Light in weight, well ventilated, and comfortable y Lenses have light tint (Not dark!) and tented side shields
79
RobCrandall/The Image Works

Protective Clothing
y Gloves to protect hands y Made of leather or some other type of fire resistant material y Leather capes, sleeves, shoulder

garments with detachable bibs, aprons y Split type apron if sitting down
y No place to collect hot particles

y High top shoes y Leggings and spats

Department of Labor

80

Protective Clothing
y 100% cotton or wool y Thick enough to prevent

injurious untraviolet rays from penetrating to skin y Long sleeves y Shirts buttoned to neck y Shirttails tucked y Cuffless pants long enough to cover top of leather boots
Miller Electric Mfg. Co.

81

Protective Clothing

82

Further Protection
y Ear Protection
y Full ear muffs that cover entire ear or ear plugs y Dangers y Noise y Hot weld spatter or slag entering ear canal

y Fume Protection
y Always use proper ventilation to keep head out of fume plume

83

References
http://www.aws.org/ American Welding Society http://www.ewi.org/Welding and Joining Information Network http://www.lincolnwelding.com Lincon Electric (welding supply co.) http://www.weldingengineer.com/ Welding Procedures and Welding Techniques http://www.efunda.com/processes/metal_processing/welding_inertg
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