1.

INTRODUCTION

I. ELECTRIC ARC
An electric arc, or arc discharge, is an electrical breakdown of a gas that produces
an ongoing electrical discharge. The current through normally a non conductive
medium such as air produces a plasma , the plasma may produce visible light. An
arc discharge is characterized by a lower voltage than a glow discharge and relies
on thermionic emission of electrons from the electrodes supporting the arc. The
electric arc is produced when two conductors are touches together and then
separated by a small gap of 2 to 4 mm, such that the current continues to flow,
through the air.

II. ARC WELDING

Arc welding is a welding process that is used to join metal to metal by
using electricity to create enough heat to melt metal, and the melted metals when
cool result in a binding of the metals. It is a type of welding that uses a welding
power supply to create an electric arc between an metal stick ( electrode ) and the
base material to melt the metals at the point-of-contact. Arc welders can use
either direct (DC) or alternating (AC) current, and consumable or non-
consumable electrodes.The welding area is usually protected by some type
of shielding gas, vapor, or slag. Arc welding processes may be manual, semi-
automatic, or fully automated. First developed in the late part of the 19th century, arc
welding became commercially important in shipbuilding during the Second World
War. Today it remains an important process for the fabrication of steel structures and
vehicles.
2.SHIELDED ARC WELDING (SMAW)

I. WORKING PRINCIPLE
II. LIST OUT THE GMAW APPARATUS/EQUIPMENT USED IN
THE WORKSHOP

GMAW machine Shielding Gas Supply Work Lead

Wire Reel GMAW gun

III. CONSUMABLE RELATED TO SMAW PROCES
Consumable that are related to smaw process is

 Contact Tips

 Nozzles

 Liners

 Filler wire
IV. SAFETY MEASURES TO BE ADHERED TO WHEN CARRYING
OUT

Darker welding filters

The primary concern in regard to safety is the open arc and intensity, which is much
greater than that associated with MMAW electrodes. Thus a darker welding filter
than is normally used is required for GMAW – a filter one shade darker than that
used for welding at the same amperage with the MMAW process is required.
For example:
 up to 200 amps – a shade 11 is recommended
 200−300 amps – a shade 12 is recommended.
Clear safety glasses must be worn at all times, due to the high emission of UV
radiation, resulting in more frequent and severe arc flashes.

Body protection
This same arc intensity will also require the operator to ensure their body is
completely covered with protective clothing. Even extraneous light from the arc (ie
UV radiation bouncing from a reflecting wall) can result in a rather uncomfortable ‘ray
burn’. Experience has shown that cotton materials have less resistance to ultraviolet
rays than woollen materials. Cotton, and particularly synthetics, quickly break down
and eventually disintegrate. Consequently, it is preferable to wear leather or woollen
materials.

Ventilation
When arc welding, a toxic gas called ozone (O3) is given off from the arc. Processes
which employ higher current densities produce more ozone. Although ozone is not
dangerous under most conditions, it is advisable when working in confined spaces
(where ventilation is restricted) to use exhaust extraction. Natural ventilation and
exhaust fans can also be advantageous. Any ventilation system used must not
interfere with the gas shielding of the weld zone.
3.ADVANTAGE AND DISADVANTAGES OF SMAW PROCESS

Advantages The major advantage of the GMAW process is its high deposition rate
compared with the manual metal arc, and gas tungsten arc welding processes. This
is brought about by the automatic wire feed, the high ratio of current to wire
diameter, and the removal of the need to change electrodes, chip slag etc. The
advantages of this include:
 high deposition rates when compared to manual metal arc welding
 high operating factor
 no wastage from electrode stubs
 elimination of slag removal
 has a wide range of applications
 low hydrogen deposit
 reduced distortion on thin materials.

Limitations/disadvantage Whilst GMAW is a popular and versatile welding process

offering the advantages listed above, it is also limited by the following.
 High initial equipment cost.
 High maintenance requirements and low mechanical reliability.
 Cannot be used in windy conditions Australian Standard® AS/NZS 1554.1
Structural steel welding – Welding of steel structures, limits the use of gas
shielded processes where the wind velocity exceeds 10 km/hr. This makes
the process generally unsuitable for site work.
 Lack of fusion defects can be a major problem under some circumstances.
 More variables to set.
4.EFFECT OF POLARITY IN SMAW PROCESS
DCEP Polarity - For DCEP the source of the heat is from the plate coming to the
electrode so the plate is in the hot side therefore it make the weld hotter and make
deep penetration into the base metal.The thickness of the bead is quit low but more
length in width.DCEP polarity when being used ,the welding will produce much
spatter

DCEN Polarity – For DCEN the heat source is coming from the electrode then
transfer to the plate,it melting the wire of but not enough to penetrate the base metal
thus producing shallow penetration.The thickness of the bead quite high but low in
width.Otherwise DCEN polarity when being used ,the welding will produce less
spatter
5.COMMON DEFFECT IN SMAW PROCESS

Porosity

Defined as a pore or group of gas pores in the weld metal. Porosity may be
conveniently differentiated according to size and distribution

Lack of fusion

Defined as portions of the weld deposit which do not fuse to the surface of the metal
or the edge of the joint.

Lack of root penetration

Lack of root penetration is Defined as the failure of the weld metal to completely fill
the root of the joint
Excessive penetration

Defined as excess weld metal protruding through the root of a butt weld. This defect
normally only occurs on thin (sheet) materials or when the spray mode of transfer is
used.

Contour defects

Contour defects may be in the form of overroll or overlap, excessive convexity or

excessive concavity of the bead, or simply a rough, uneven appearance

Undercut

Undercut Defined as a groove or channel in the parent metal, occurring continuously

or intermittently along the toes or edge of a weld.
Cracking

Cracking Defined as discontinuities produced either by the tearing of metal in the

plastic condition (hot cracks) or by fracturing when cold (cold cracks).

Stray arcing

Stray arcing Defined as damage on the parent metal resulting from the accidental
striking of an arc away from the weld, or the accidental striking of an arc away from
the weld.

Excessive spatter

Excessive spatter Defined as the metal particles expelled onto the surface of the
parent metal or weld, during welding, and not forming part of the weld.