Welding Research Institute

Manual
metal arc
welding
process

HISTORY OF WELDING
1782- PRO.G.LICHTENBERG- ELECTRIC
FUSION
1801- Sir HUMPHERYDAVY- ARC TWO
POLES
1860- WILDE - ELECTRIC WELDING
1907- OSCAR KJELLBROG-FLUXCOATED
1909- STROH MENGER
- HEAVY
COATED
1912- US PATENT

Shielded Metal Arc

Welding
Process Capabilities:
Versatile process
Indoor & Outdoor welding
Multi-position welding
Equipment is simple & portable
Universal process for repair welding
Limitations:
Productivity is less
> Fixed length of electrode
> Deslaging

LIMITATIONS OF SMAW PROCESS

>> Less metal deposition Cannot be
used for heavy fabrication welding
>> Requires more number of welders
>> Control of distortion is difficult
>> Continuous & automatic Welding
is not possible
>> More strain to the welders

TYPES OF COVERING
Based of covering:
> Rutile electrodes
> Basic coated electrodes
> Cellulose coated electrode
>Iron powder,iron oxide electrodes
Based on application:
> carbon-manganese steel electrodes AWS A5.1
> Stainless steel electrodes A5.4
> Low alloy steel electrodes A5.5
> Copper & Copper alloy electrodes A5.6
> Aluminium & Aluminium alloy electrodes A5.10
> Nickel & Nickel alloy covered electrodes A5.11
> Hardfacing electrodes A5.13
> Covered electrodes for cast iron A5.15

CHARACTERISTICS OF ELECTRODES
Rutile Electrodes:
Electrode:

Cellulose

Quite & smooth arc

> Forceful &
noisy arc
> Excellent slag removal
> Friable slag
> Fine ripples
> Coarse ripples
> Medium penetration
> Deep
penetration
> Thick slag
> Thin
slag cover
> Good running
> More
gas shield
>

PURPOSE OF FLUX COATING

>> Gas shielding of arc
>> Stabilizes the arc
>> Provides slag blanket
>> Alloying element will improve the
mechanical properties
>> Gives good appearance & penetration
>> Welding in all position is easy
>> Compensates for oxidation loss

COMPOSITION OF FLUX IN THE ELECTRODE COATING

1.

Organic substance or Cellulose material:

Wood, Flour & Cellulose
High arc force
Large volume of gas mostly hydrogen

2. Rutile:
Found in sand
Arc stabilizer
Good slag former
3. Ball Clay:
Compound of silica & alumina
Slag former & Gives plasticity in the wet paste

COMPOSITION OF FLUX IN THE ELECTRODE COATING

4.Iron powder:
Gives good operating characteristics
Improves arc stability
Makes the coating electrically conducting
5.Oxidizing Substance:
Makes the weld metal flow freely
Oxidizing substance are: iron oxide, Lamitite, Magnetite
6.Reducing Substances:
They compensate for manganese Ferro Silicon
Substances: Ferro Manganese, Ferro Silicon, Ferro Titanium

COMPOSITION OF FLUX IN THE ELECTRODE COATING

7. Ionizing Substances:
Used for stabilizing the arc
Substances : Chalk, Marble
8.Binding substance:
Help the coating to grip firmly around the core wire
Substances: Sodium Silicate, Potassium Silicate

CLASSIFICATION OF ELECTRODES (AWS 5.1)

E6010
Electrode
60 Psi
70
80
90
100
110
120

Welding
position

Coating and
current conditions

CLASSIFICATION OF ELECTRODES (AWS 5.5)

Electrode
80,000 Psi
All position

E8018-B1H4RMoisture
Difful. H
SUF

1-F,H,V,OH 2-F,H , 4-F,H,VD,OH

0

CELLULOSE SODIUM

DCEP

CELLULOSE POTASSIUM

AC/DCEP/DCEN

TITANIA SODIUM

AC/DCEN

TITANIA POTASSIUM

AC/DCEP

IRON POWDER TI

AC/DCEN/DCEP

LOW HYDROGN Na

DCEP

LOW HYDROGEN K

AC/DCEP

Fe POWDER Fe OXIDE

AC/DCEP/DCEN

Fe POWDER LOW H2

AC/DCEP

%Mn

%Ni

Resistant
%Cr

A1

%Mo

1/2

B1

B2

1-

B3

2-1/4 1

C1

2-1/2

C2

3-1/4

C3

D1&
D2

%V

1.2 2.00

0.50

0.15

.25 .35

0.30

0.20

0.10

Metal Transfer
Factors influencing metal transfer:
> Surface tension
> Force of gravity
> Magnetic forces
> Metallurgical factors
Surface tension forces:
> Holds the liquid metal droplet to the tip.
Force to be overcom
Force of gravity:
> Position of welding
Flat --- Helps in metal transfer
Overhead--Negative influence oppose metal transfe
Magnetic forces:
>Lorentz & Pinch forces.
Metallurgical factors:

Common Welding Elements

For electrically-based welding processesSMAW,GMAW,FCAW & GTAW the
common elements are:
Joint types

joint edge preparation

parts of a weld
selection of joint preparation
welding positions
other types of weld
welding terminology
welding cables & grounding clamps
safety equipment
safety practices

SAFETY ACCESSORIES
>> Welding hand screens & helmet
>> Chipping goggles.
>> Apron
>> Jacket
>> Gloves
>> Sleeves
>>

Leggings

>>

Shoes

>>

Cap

RECOMMENDED COPPER CABLE FOR ARC WELDING

Cable

diameter(mm)

Length of cable in Mts.

Current capacity in Amps.

---

015Mts

15--30Mts

30-75Mts

24

600 Amps 600 Amps

400 Amps

21

500 Amps 400 Amps

300 Amps

19

400 Amps 350 Amps

18

300 Amps
300 Amps 300 Amps 200 Amps

16.5

250 Amps 200 Amps

175 Amps

15

200 Amps 195 Amps

150 Amps

14.5

150 Amps 150 Amps

100 Amps

13.5

125 Amps 100 Amps

75 Amps

EQUIPMENT AND ACCESSORIES USED IN THE

PROCESS
>> Power source
>> Electrode holder
>> Ground cable
>> Welding cable
>> Lugs

POWER SOURCE
Either AC or DC may be used for SMAW process.
Factors to be considered for SMAW:
>>

Type of current---- AC or DC

>>

Current requirement

>>

Positon of welding

>> Primary power available at the work

station

RECOMMENDED SHADE NUMBER OF THE

COLOURED GLASSES

Shade No.

Range of welding
current(Amps)

8--9

Upto 100 Amps

10--11

100300 Amps

12--14

Above 300 Amps

ELECTRODE MANUFACTURE:

>> Wire procurement

>> Wire drawing(mm)
> Wire straightening &
> Weighing machine
> Sewing
> Dry mixer
> Wet mixer
> slug press
> Extruder
> Conveyor
> Eccentricity
> End chamfering
> Name printing
> Backing & drying

- 8mm wire
- 6.3, 5, 4, 3.15 & 2
cutting

> packing

WELDING TECHNIQUES
>> Touch & Retract method
>> Scratch method
>> Maintaining the arc
>> Stopping the arc
>> Re-start or Re-strike the arc
>> Stringer Beads
>> Weaving Beads

Welding Positions
GROOVE WELD

Flat position(1G)

Horizontal position(2G)

Vertical position(3G)

Overhead position(4G)

FILLET WELD

Flat position(1F)
Horizontal position(2F)

Vertical position(3F)

Overhead position(4F)

EFFECT OF VARIATION OF
PARAMETERS
1.CURRENT TOO LOW:
Uneven bead height
Poor penetration
Slag inclusion
Irregular ripples

2.CURRENT TOO HIGH:

Wide & flat beads in uneven shape

Excessive penetration parent metal
More spatter
Poor ripple appearance
Porosity
Undercut

EFFECT OF VARIATION OF
PARAMETERS
3.ARC TOO SHORT:

4.

Irregular ripple
Burn through
Unequal width & height of bead
Electrode freezing the job

ARC TOO LONG:

Unequal height of bead

Wide ripple
Crater with blow holes
More spatters

EFFECT OF VARIATION OF
PARAMETERS
5 . TRAVEL TOO LOW:
More width & height of the bead
Slag inclusion

6. TRAVEL TOO FAST:

Narrow width of the bead
Porosity
Elongated ripples

TYPES OF WELD DEFECTS IN ARC WELDING

PROCESSES
1.POROSITY:
Blow holes,worm hole, gas pockets,aligned porsity,
clustered
porosity, scattered porosity, surface
porosity, starting porosity.
2.INCLUSIONS:
Metallic inclusions, oxide inclusions, slag inclusions,
wagon tracks, interpass inclusions, stringer inclusion,
fingernail inclusion.
3.LACK OF FUSION:
Lack of root fusion, lack of interpass fusion, lack of side
wall fusion.
4.MISMATCH
5.BURN THROUGH
6.DISTORSION:
Longitudional distortion, Angular distortion, Transverse
distortion.

TYPICAL DEFECTS IN SMAW

9.CRACKING:
Branch cracking, Longitudional cracking, Radiating
cracking(star cracking), Toe cracking, Under bead
cracking, Lameller tearing, Root cracking, Center line
cracking, Hot cracking, Cold cracking, Micro fissuring,
Crater cracking. Disconnected cracking. Reheat cracking,
Hydrogen cracking, Solidification cracking, Inter granular
cracking, Burning or Liquation cracking.
10.UNDER CUT:
External, Internal(Root undercut)
11.WELD REINFORCEMENT:
Excessive reinforcement, Insufficient reinforcement,
Root reinforcement.
12.OVER LAPPING
13.LACK OF PENETRATION:
Excessive penetration, incomplete penetration,
14.ARC STRIKES
15.CRATER PITS

TYPICAL DEFECTS IN SMAW

CRACKS:
Linear ruptures of metal under stress.Three major
classification are Hot cracking, Cold cracking & Micro
fissuring.
HOT CRACKING:
Occurs at elevated temp.( above 540 C ) during
cooling after the weld metal has been deposited &
started
to solidify from the molten state. Related to Hot
CAUSES
shortness.Generally
1.Stresses in WM. associated with2.grain
Poorboundary
joint
liquation
or inter granular or interdendritic fissures,
configuration.
Under
severe
or shrinkage conditions.
3.Poor
weldstress
bead shape.
4. Use of These
fissures
canfixtures
grow.
restraint
5. Improper weld technique.
6. High
heat input
7.Too large weld puddle.
8. Repeated
reheating.
9. Segregation of liquid phases.

TYPICAL DEFECTS IN SMAW

CAUSES
10. S,B,P,As, Sn, Sr, Cu.
11.C above 0.15% & Mn/S ratio below 22:1.
12. < 3% FeB to coating for 2.25 Cr-1Mo alloy steel.
13. Insufficient ductility
14. C/Cb ratio 14-15
in ASS.
15.Variation in dilution.
16.Diffusion of
atmospheric H, O, or N.
17.Differences of over 5% composition dissimilarities.
18. Differences in the coefficient of expansion.
19. Non ferrite composition.
20. Hot shortness.
21. Low thermal conductivity.
REMEDIES
1.Slightly convex bead.
2. Slow welding until
elliptical bead.
3.Improve joint configuration. 4. Suitable welding
sequence.

SELECTION OF ELECTRODES
>> Composition or Strength of BM.
>> Penetration requirement
>> Position of welding
>> Fit-Up condition
>> Skill of the welding personnel
>> Cost of the welding operation
>> Service requirement of weld joint.

ADVANTAGES OF SMAW PROCESS

>> Light & heavy gauge metals can be
welded.
>> Fabrication welding, Construction
welding & Maintenance welding
>> All types of metals ( Ferrous, Nonferrous & alloys) can be welded
>> Welding operation is quick & easy
>> More suitable for short length welds
>> Less expensive
>> Less sensitive
>> It is portable

APPLICATIONS OF SMAW PROCESS

>>

Used for welding thin & thick gauge metals

>>

Used in welding bridges, bus bodies,domestic

items like grills for gates, windows, chairs,
doors .

>>

Used in welding roof structure for workshop,

broken & cracked castings

>>

Whenever welding is done in outdoor work, this

process is very useful as a diesel generator
welding set can be used.

>>

Used for hardfacing & repair welding

Electrode Pilot
Plant

10

11

12

13

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

Thank you