Shielded Metal Arc Welding

Safe practices when Arc Welding

 Don’t stand in water
 Discard frayed cords and wires
 Keep flammable liquids away from heat

 Don’t look at the arc with out a number 10

lens.
Dress Code
 Wear properly fitted clothes.
 When welding, sleeves should be buttoned and
gloves should be worn.
 Wear boots or high top; Tightly laced shoes.
 Do not wear loose clothing, shirt tails, and
unbuttoned sleeves around power equipment.
 Do not wear clothes that you do not want to get
dirty.
The Arc

 When electrons jump through the air

 When the pressure overcomes resistance

 V=A X R
Parts of the Arc
 Arc stream
 Vaporized metal

 Appears yellow

 Liquid metal

 Appears green

 Arc flame
 Natural gases surrounding arc stream

 Pale red
Arc Control

 Length

 Angle
Reverse Polarity
(DCEP)

 Electrode positive

 Better penetrated welds

Straight Polarity
(DCEN)
 Electrode Negative

 Used when a high rate of filler metal is

required.

 EXX2X Electrodes
Alternating Current
 Stops and starts
 Must have enough voltage restart arc

 Good penetration

 Less expensive
Classification of Steel Electrodes
 Electrode designated by “E” followed by a
4- or 5- digit number
 First two or three digits - minimum tensile
strength as-welded deposited weld metal
expressed in thousands of pounds per
square inch (1000psi)
 E-60xx - 60,000psi TS

 E-120xx - 120,000 psi TS

Classification of Steel Electrodes
 Third or fourth digit refers to the welding
position.
 E-xx1x - all positions

 E-xx2x - flat and horizontal fillet

positions
 E-xx3x - flat position only
Classification cont.
 The fourth or fifth and last digit indicates the type
of welding current and the type of flux covering
 E-xx10 - DC reverse polarity (electrode

positive) only (cellulose sodium).

 E-xx11 - AC or DC reverse polarity (cellulose

potassium ) Fast freeze, cutting

 E-xx13 - AC or DC straight polarity (titania

potassium)
Factors of Electrode Selection
 Type of metal to be welded
 Thickness of metal
 Position of weld
 Type of power (DC or AC)
 Cleanliness of metal
 Weld bead appearance desired
Flux
 Improves the performance in handling, storage
and operation of the electrode
 Floats out impurities
 Directs arc stream (stabilizer)
 Insulator
 Prevents oxidation (slag or gas)
 Holds in heat
 Iron-powder improves striking ability and
increases metal deposition rate
Striking the Arc
 Pecking  Scratching
 Touching electrode to
 Moving electrode
the base metal and
moving away to proper across base metal
arc distance. Moving then moving
electrode in a vertical
motion.
electrode away to
 Can start precisely
the proper arc
where the weld is to distance.
be.  Dose not work
good in tight places
Common Striking Problems
 Sticking  Arc is extinguished
 Lift electrode and  The electrode is

metal moved to far away

 Break electrode from the base metal
from metal after the arc is
 Remove electrode
struck.
from clamp
Arc Length
 Longer arc  Shorter arc
 Increases  Decreases

Resistance Resistance
 Increases Voltage  Decreases Voltage

 Decreases Current  Increases Current

 Decreases filler  Increases filler

consumption consumption
Arc Length

 Should be no more then ¼ inch

 The sound of the arc should sound like eggs

frying
Bead Width
 Stringer bead  Weaving bead
 Only motion is in the
direction of travel
 About 3 times the
width of the electrode
 With 1/8 inch electrode
should be 3/8 inch
 Motion side to side
as well as forward
 About 6 times the
width of the
electrode
 With 1/8 inch
electrode should be
3/4 inch
Stringer Bead
Weaving Bead
Electrode Angle

 Should be 15° to 20° tipped forward in the

direction of travel

 Stringer bead should be at 90° from the base

metal
Travel Speed

 Bead width

 Bullet-nose-shaped ripples
Restarting
 Strike ark 3/8 inch in front of previous weld

 Move back to crater

 Move forward to finish weld

Restarting