INTRODUCTION TO ARC

WELDING
(SMAW)

Terms & Definitions

Welding - Joining of two or more
pieces of metal together by the fusion
process
NOTE: In arc welding, heat is produced by the
electric arc created.

SMAW - Shielded Metal Arc Welding

Electrode - Metal rod which conducts
a current from the electrode holder to
the base metal
Base Metal - Metal to be welded

Continued
Bead Weld - Made by one pass of
the electrode
Bevel Type of edge preparation
containing an angle
Butt Joint - Weld located between
the two edges of metal.
Crater - Depression at the end of a
weld

Safety precautions in SMAW

welding
Never look at the arc with the naked eye.
Use a welding hood that is in good
condition and has a #12 shade.
Wear suitable clothing to protect all parts
of the body. (PPE) personal protective
equipment

Long sleeved shirt

Leather gloves
Collar buttoned

Continued
Cuffs turned down
High topped shoes or boots

Do not strike an arc or weld until

you are sure those in the vicinity
have protective equipment or will
look in the other direction.
(Note) Yell cover before striking an arc.

Continued
Do not weld around combustible
or flammable materials.
Do not pick up hot metal with
the hands.
(NOTE) Use a pair of pliers

Do not weld in confined places

without ventilation

Continued
Always turn off main switch or
disconnect plug when checking over
a welder.
Do not leave electrode holder on the
welding table or in contact with
grounded metal.
Do not use worn or frayed cables.

Continued
Stand on dry footing when welding.
Keep area around welder clean.
Keep tools and metals in proper
location.

Types of Arc Welders

A.C. (Alternating current) Welder
current alternates direction 120
times per second.
D.C. (Direct current) Welder
current flows in the same direction.
TIG (Tungsten Inert Gas) Welder
may use either A.C. or D.C. with a
non-consumable tungsten electrode
and an inert shielding gas.

Continued
MIG (Metal Inert Gas) May use
A.C. or D.C. with a base wire filler
material that is fed automatically into
weld; also has an inert shielding gas.

Common SMAW Tools

Welder
Electrode Holder
Ground clamp
Shield or helmet
Gloves
Chipping hammer
Safety goggles or glasses
Wire brush
Electrodes

Types of Electrodes
Mild Steel
High Carbon Steel
Hard Surfacing
Alloys special purpose

Electrode Characteristics
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

Electrode Characteristics continued

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

Common Sizes of Electrodes

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.

AWS Classification

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

Electrode Coating Functions

To Provide Deoxidizers & Scavengers
To Produce Shielding Gases
To Produce a Slag Covering
To Provide Mechanical and Physical
Properties
To Increase Deposit Rates

Effects of Raising & Lowering

Current
Raising current
Produces more heat

Lowering current
Produces less heat

(Note: On thicker metals more heat is

necessary in order to get penetration
of the weld.)

Methods of Establishing an Arc

Scratching
Similar to striking a match

Tapping
Straight down and up

Characteristics of Proper Arc

Length
End of electrode is the same distance
from the base metal as the diameter
of electrode.
1/8 electrode = arc length 1/8

Correct arc length makes a steady

hum of the welder.
Correct arc length makes a frying
sound at the arc
Like bacon frying in a pan

Parts of the welding process

Electrode
Wire core
Coating (flux)
Arc
Gaseous shield
Weld
Slag

Parts Continued
Heat lines
Base metal
Penetration
Crater
15 30 degree angle
Direction of travel

Principles of the SMAW

Process

Kinds of Welds
Fillet
Groove
Bead

Fillet Weld

Groove Welds

Continued

Types of Weld Joints

Butt Joint
Lap Joint
Tee Joint
Corner Joint
Edge Joint

Square Butt Joint

Tee Joints
A- plain tee
B- single beveled
C- double beveled
D- single J
E- double J

Lap Joints
A- single lap joint,
one weld.
B- single lap joint,
two welds.
C- offset lap joint.

Corner Joints

Edge Joints

Weld Positions

Flat - 1F&1G
Horizontal 2F&2G
Vertical-3F&3G
Overhead_4F&4G

Reason for Poor Welds

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

Equipment Arc Welding