Exp 2.
Principles of Shielded Metal Arc
Welding
Aim:
To understand the basic principles of the Shielded metal arc
welding process
Introduction
Shielded Metal Arc Welding (SMAW), usually referred to as
manual metal arc welding is widely used in structural connections,
pressure vessels, and maintenance and repair activities. This
process is employed in numerous industrial applications because
it is flexible, easy to use, and can be administered indoors and
outdoors. The weld bead produced by SMAW is highly effected by
the skill of the operator. In addition, the quality of the weldment is
heavily influenced by input process parameters like current,
voltage, arc gap, welding speed, electrode orientation, etc. The
electrode consists of a wire of the same composition as that of the
workpiece and it is coated with a layer of flux.
Theory:
Working Principle: In a shielded metal arc welding process, an
electric circuit that supports a welding arc is used to convert
electrical power into heat. The intense and highly focused heat
from the welding arc rapidly melts a section of the workpiece and
the tip of the electrode. The electrode is gently touched to the
workpiece and then slightly pulled back to start the arc. The
welder controls the arc length by maintaining a consistent gap
between the electrode and the workpiece. The heat generated by
the arc leads to the melting of the electrode and workpiece and a
weld pool is formed in the workpiece. The coated electrode melts
during the welding process, the flux coating breaks down,
releasing shielding gases and molten slag. The shielding gases
and slag protect the weld area from airborne contaminants. After
solidification of the slag, it has to be chipped away to expose the
finished weld.
Fig. 1 Schematic of the SMAW
In Fig. 1 schematic of the SMAW is shown. The electrode and the
base material are connected to the power supply. There are two
separate output terminals on the power supply. A connection is
established to the workpiece through one terminal and the
electrode using another terminal. When a DC power supply is
used, the needed polarity for that type of electrode determines the
appropriate terminal for electrode connection. During AC power
supply, the electrode can be connected to any port. In case of DC
power supply, the electrode is usually connected to the positive
terminal also termed reverse polarity.
Fig. 2 Schematic of Shielded Metal arc welding Process
This welding process can be used to join metals in a variety of
welding positions. The four main welding positions used in SMAW
are flat position, horizontal position, vertical position, and
overhead position.
1. Flat Position: This is the easiest position to weld in SMAW.
The weld is made on a horizontal plane with the axis of the
electrode perpendicular to the workpiece. The electrode is
held at a slight angle to direct the molten metal onto the joint.
In this position, the molten metal tends to flow evenly and
smoothly, resulting in a flat, uniform bead.
2. Horizontal Position: In this position, the weld is made on a
horizontal surface with the workpiece tilted at an angle of 45
degrees. The electrode is held at a slight angle to direct the
molten metal into the joint. The molten metal tends to flow to
one side of the joint, creating a "crown" or convex weld
bead.
3. Vertical Position: This position involves welding on a
vertical surface with the axis of the electrode perpendicular
to the workpiece. In this position, the molten metal tends to
flow downwards, creating a "V" shaped groove. The direction
of welding can be either uphill or downhill, depending on the
joint design and welding parameters.
4. Overhead Position: This position involves welding on the
underside of a horizontal surface. It is the most difficult
welding position in SMAW because the molten metal tends
to sag and fall off the joint. A smaller diameter electrode is
typically used in this position to reduce the heat input and
prevent the molten metal from sagging.
Polarity in SMAW
The polarity used depends on the electrode and desired weld
characteristics.
1. Direct Current Electrode Positive (DCEP / Reverse Polarity)
o Electrode → positive (+) terminal
o Produces deeper penetration
o More heat at the electrode tip
o Used for many structural and low-hydrogen electrodes
(e.g., E7018)
2. Direct Current Electrode Negative (DCEN / Straight Polarity)
o Electrode → negative (–) terminal
o Higher deposition rate, lower penetration
o Used for special electrodes like E7014 (in some cases)
3. Alternating Current (AC)
o Electrode can be connected to any terminal
o Used for welding magnetized workpieces
o Low-cost and widely available
o Suitable for E6013, E7014, and some E7018 electrodes
Types of Flux Coatings in SMAW Electrodes
The electrode coating determines arc characteristics, slag
behavior, and weld quality. SMAW electrodes are classified based
on the chemical composition of the flux coating.
1. Rutile (Titania-Based) Coating
o Smooth, stable arc
o Easy slag removal
o Good weld appearance
o Suitable for AC and DC
o Example: E6013
2. Cellulosic Coating
o High CO and H₂ gas generation
o Deep penetration
o Excellent for vertical-down welding and pipelines
o Fast-freezing slag
o Examples: E6010, E6011
3. Basic (Low-Hydrogen) Coating
o Coating contains CaCO₃, CaF₂
o Produces low hydrogen content → reduces hydrogen
cracking
o Strong and ductile welds
o Requires baking before use
o Example: E7018
4. Iron Powder Electrodes
o Contain iron powder to increase deposition rate
o Higher productivity
o Used for fillet welds in flat/horizontal position
o Examples: E7014, E7024
Different types of Electrodes used in SMAW
Electrodes are classified by AWS based on tensile strength,
welding position, and coating type.
1. E6010
o Cellulosic coating
o Deep penetration
o Suitable for root passes, pipes
o DC only
2. E6011
o Cellulosic coating
o Deep penetration
o AC or DC
o Good for rusty or contaminated surfaces
3. E6013
o Rutile coating
o Smooth arc, easy slag removal
o Good for sheet metal
o AC or DC
4. E7018
o Low-hydrogen basic coating
o Strong, ductile welds
oUsed in structural and pressure vessels
o Requires electrode baking
o AC or DC+
5. E7014
o Iron-powder rutile coating
o Higher deposition rate
o Suitable for fillet welds
o AC or DC
6. E7024
o High iron powder content
o Very high deposition rate
o Used for flat/horizontal welding
Process parameters:
Electrode diameter: the diameter of the electrode is an
essential factor in SMAW. A larger diameter electrode
increases the current carrying capacity of the arc and also
increases the heat input. The correct electrode diameter
should be selected based on the thickness of the material to
be welded and the current settings.
Electrode type: The choice of electrode type is vital for
SMAW. An electrode with a low-hydrogen core wire and an
appropriate flux coating should be selected for the
application. Low hydrogen electrodes reduce the risk of
hydrogen cracking in the weld.
Welding current: The welding current should be set
correctly for the application. Too much current can cause
excessive spatter and undercut, while too little Current can
cause incomplete fusion and porosity.
Welding speed: The travel speed of the electrode is a
crucial factor in SMAW. A Welding speed that is too fast can
result in an undercut and poor fusion, whereas a slow
welding speed can result in excessive heat input and
distortion.
Arc Length: The arc length should be kept short for SMAW.
A short arc length increases the stability of the arc and
reduces the risk of porosity formation in the weld bead.
Welding Equipment:
1. Power supply: The welding power source in a shielded
metal arc welding (SMAW) is a critical component of the
welding system. It provides the electrical energy needed to
generate the arc that melts the electrode and base metal to
form the weld. Two welding power sources are used in
SMAW: alternating current (AC) and direct current (DC). The
welding power source in SMAW typically has a control panel
that allows the operator to adjust the welding current and
voltage to optimize the welding process for the specific
electrode and metal being used. Some welding power
sources also have features such as over-voltage and
overcurrent protection to prevent damage to the equipment
and improve safety. A constant current power source with at
least a 60% duty cycle at the maximum current is preferred
for shielded arc welding. Since, Output electrical properties
of Shielded metal arc welding require the welder to maintain
constant arc length, which is almost impossible, a constant
voltage power source is not employed. Constant current
(CC) power sources are used in SMAW to maintain a
constant current output regardless of changes in arc length.
Fig.3. Power supply Transformer for SMAW
2. Electrode: An electrode consists of metal filler wire coated
with various materials to provide shielding, deoxidizing, and
alloying elements. The composition of electrode coating and
the type of metal filler wire determines the welding
characteristics of the electrode, including its welding current,
electrode polarity, and the kind of metal being welded.
Electrode coating may include rutile, calcium fluoride,
cellulose, iron powder, etc. The flux layer provides shielding
gases such as CO2, CO, and H2 to protect the weld pool from
atmospheric oxidation. The flux layer also contributes to the
slag formation and helps stabilize the arc.
3. Electrode Holder: This holds the electrode and provides a
means of conducting the electric current to the electrode.
4. Ground clamp: This provides a path for the return current
from the workpiece to the power source.
5. Welding helmet: This protects the welder’s face and eyes
from the welding arc's bright light and dangerous radiation.
6. Welding cables: These conduct electric current from the
power source to the electrode holder.
7. Chipping hammer and wire brush: These are used to
remove slag from the surface of the weld.
Advantages:
1. The apparatus is reasonably simple and portable.
2. Shielding gas and granular flux are not needed.
3. The SMAW electrode provides the filler material and
insulation needed to create a strong weld.
4. The method is adaptable and can be used for various joint
types and welding positions.
5. The method is appropriate for the majority of regularly used
metals and alloys.
Limitations:
1. Shielded metal arc welding is not suitable for metals with low
melting temperatures, such as lead, tin, and zinc, and their
alloys.
2. The heat generated within the SMAW electrode will be
excessive if the current is too high.
3. Stub loss is also a drawback of shielded metal arc welding.
4. The weld bead appearance produced by SMAW can be
irregular and unattractive, making it less suitable for
cosmetic applications.
5. SMAW produces fumes and Smoke during welding, which
can harm the welder without protective gear and proper
ventilation.