HISTORY

It is an first invented in arc welding family

MANUAL ARC WELDING
Started with bare electrode welding

SHIELDED METAL ARC WELDING

Developed With flux coated electrode

 Electric arc started by striking work with electrode

Consumable electrode Process
Heat of arc melts electrode and surface of base
metal
Tiny globules of molten metal form on tip of
electrode and transferred by arc into molten pool
on work surface
After weld started, arc moved along work

American Welding Society

Shielding (Gas)
Flux
coating
Electrode

Travel direction
Weld Puddle
Shielding
Gas

6
6

Slag

43

Slag
Weld Puddle

2
2

Arc

Arc

Solidified WeldSolidified
Metal Weld Metal

 Is a consumable - it gets
melted during the welding
process
Is composed of two parts
Core Rod (Metal Filler)
Carries welding current
Becomes part of the weld

Flux Coating
Produces a shielding gas
Can provide additional filler
Forms a slag

 An arc occurs when the electrode comes in

contact with the work-piece and completes the
circuit like turning on a light!
The electric arc is established in the space
between the end of the electrode and the work
The arc reaches temperatures of 10,000F which
melts the electrode and base material

 As the core rod, flux

coating, and work
pieces heat up and
melt, they form a
pool of molten
material called a
weld puddle
The weld puddle is
what a welder
watches and
manipulates while
welding

1/8 E6013 at
125 Amps AC
8

 As the molten weld

puddle solidifies, it
forms a joint or
connection between
two pieces of base
material
When done properly on
steel, it results in a
weld sound with the
surrounding base metal

 Slag is a combination of the flux coating and impurities

from the base metal that float to the surface of the
weld.
Slag quickly solidifies to form a solid coating
The slag also slows the cooling rate of the weld
The slag can be chipped away and cleaned with a wire
brush when hard

10

Arc column and weld puddle

Shielding (Fumes)

A shielding gas is formed when the flux coating

melts.
This protects the weld puddle from the atmosphere
preventing contamination during the molten
stateThe shielding gas protects the molten puddle from
the atmosphere while stabilizing the arc

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Flux melt in arc column and it deposit as slag over the weld
metal to protect the weld metal till the metal cools
Slag shall be removed before depositing another layer

12

 A.C. (Alternating current) Welder current

alternates direction 120 times per second.
D.C. (Direct current) Welder current flows in the
same direction.

 Two basic types

Constant current
Referred to as variable voltage
Constant voltage
Referred to as constant potential

 Settings on the
machine
Polarity : AC, DC+, DC Amperage Output

Operator Controlled
Variables

Work Angle
Travel Angle
Arc Length
Travel Speed

A straight AC machine will

not have a polarity switch
like this AC/DC machine
16

17

Improper power selection

Machine adjustment too hot or too cold
Electrode size too large or too small
Improper movement of electrode
Improper angle of holding electrode
Improper base metal preparation
Arc length too long or too short

ANSI/AWS - 5.1 : Specification for Covered Carbon Steel

ANSI/AWS - 5.5 : Specification for Low Alloy Steel
ANSI/AWS - 5.4 : Specification for Corrosion Resistant Steel

AWS Website:
http://www.aws.org

E70XX-H4R
Electrode
Tensile in Ksi
Welding Position:
1 = All Position, 2 = Flat & Horizontal

Type of Current and Coating

*Hydrogen:
H4 = Less than 4ml/100g weld metal, H8 = Less than
8ml/100g Weld Metal
or H16 = Less than 16ml/100g weld metal
*Meets Requirements of Absorbed Moisture Test
*Optional Designators

AWS
Class

Covering

Current
Requirements

Position

Characteristics

EXX 10

Cellulose
Sodium

DCEP

All

Deep Penetration,
With Ripples

EXX 11

Cellulose
Potassium

AC, DCEP

All
Flat Decking

Deep Penetration,
With Ripples

EXX22

Rutile
Sodium

DCEN, AC

Flat, Horiz. Fillet

Deep Penetration,
With Ripples

EXX 24

Rutile
50% Iron
Powder
Mineral
50% Iron
Powder

EXX 27

AC, DCEP, DCEN Flat, Horiz. Fillet

High Deposition
Shallow Penetration

AC,DCEP, DCEN Flat, Horiz. Fillet

High Deposition
Shallow Penetration

AWS
Class

Covering

Current
Requirements

Position

Characteristics

EXX 12

Rutile
Sodium

DCEN, AC

All

Mild to Medium Penetration

EXX 13

Rutile
Sodium

AC, DCEP, DCEN

All

Mild Penetration

EXX 14

Rutile
30% Iron
Powder
Low-Hydrogen
30% Iron
Powder
Low-Hydrogen
50% Iron
Powder

AC, DCEN

All

Medium Penetration

DCEP, AC

All

Medium Penetration

AC, DCEP

Flat, Horiz. Fillet

High Deposition

EXX 18

EXX 28

 1/8
5/32
Sizes of electrodes range from 1/16 to 3/8.
Electrode size is determined by the diameter of
the wire core.

Coating Materials -Partial List

Arc Stabilizers
Titania TiO2
Gas-Forming Materials
Wood Pulp
Limestone CaCO3
Slag-Forming
Materials
Alumina Al2O3
TiO2
SiO2
Fe3O4

Slipping Agents to Aid Extrusion

Clay
Talc
Glycerin
Binding Agents
Sodium Silicate
Asbestos
Starch
Sugar
Alloying and Deoxidizing Elements
Si, Al, Ti, Mn, Ni, Cr

 Understand and follow all safety precautions listed in Safety in Welding,

Cutting, and Allied Processes (ANSI Z49.1) and Arc Welding Safety (E205)
Understand and follow all warning labels and material safety data sheet
found On welding equipment, consumables, tools
Wear suitable clothing to protect all parts of the body. (PPE) personal
protective equipment, fire resistant, shock resistant, light filter
Never look at the arc with the naked eye. The applicable shade shall be
used it ranges from 7-14
Fumes and Gases can be dangerous
Keep your head out of the fumes
Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases
from your breathing zone and the general area
The SMAW process can withstand wind and exhaust near the arc from ventilation
equipment
Electric Shock can kill to receive a shock your body must touch the electrode
and work or ground at the same time
Do not touch the electrode or metal parts of the electrode holder with skin or wet
clothing
Keep dry insulation between your body and the metal being welded or ground
Arc Rays can injure eyes and skin - Choose correct filter shade (See chart below
25

Equipment less complex,

more portable, Flexible
Low initial cost
Less sensitive to drafts, dirty parts, poor fit-up
Electrodes Readily available for most base metals
Less operator training
Easy to change between many base materials

Low Deposition Rates Low Productivity

Operator Dependent
Difficult to weld very thin materials
Frequent restarts
Lower operating factor
Higher operator skill required for SMAW than
some other processes
Electrode need baking and storing for long time
not advisable

END

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