Chapter
6
Shielded Metal Arc
Welding
Objectives
• Describe how and why electricity flows in an
electrical circuit and list the three variables in Ohm’s
law.
• Demonstrate your ability to correctly complete a
safety inspection on an arc welding station.
• Plan and list all the hand tools, personal safety
equipment, and clothing required for a given
welding task.
• Demonstrate your ability to select the correct
electrode, current, and polarity for welding with the
SMAW process in a given welding position.
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Objectives
• Demonstrate your ability to strike a welding arc and
produce acceptable stringer and weaving beads.
• Demonstrate your ability to correctly restart the arc
and blend the new and old beads.
• Demonstrate your ability to use the SMAW process
to create acceptable welds on all five basic joints in
all positions.
• Describe all types of weld defects and demonstrate
your ability to inspect and differentiate between
acceptable and unacceptable welds.
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Objectives
• Successfully pass a safety test as related to arc
welding work areas, equipment, clothing, tools, and
correct welding procedures in all positions.
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Shielded Metal Arc Welding
• Shielded metal arc welding (SMAW) is a commonly
used welding process
• Both alternating and direct current can be used for
SMAW
• With the correct size electrode, the heat generated
can melt any weldable metal
• SMAW is used in many industries and applications
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Direct Current Arc Welding Fundamentals
• Arc welding is a group of welding processes that
melt the base metal using heat from an electric arc
• SMAW is done by producing an arc between the
base metal and a consumable, flux-covered metal
electrode
• Dc arc welding power sources are called welding
machines
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Direct Current Arc Welding Fundamentals
• Ohm’s law for electricity
states that voltage in a
closed circuit has a constant
relationship to the current
and the resistance of the
current
• This illustration shows a
diagram of a DCEN arc
welding circuit
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Constant Current Power Sources
• Constant current power sources are drooper-type
power sources
• A welder using SMAW must try to keep a constant
arc length
• The current changes slightly as the arc length
changes
• To make a good quality weld, the welder must find
and keep the proper arc length
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Constant Current Power Sources
• The welding arc is seen to
be divided into two parts:
the stream and the arc
flame
• The vaporized metal in the
arc stream appears yellow
• Liquid metal in the arc
stream appears green
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
DCEN and DCEP Fundamentals
• In a direct current electrode negative (DCEN)
circuit, the electrons flow from the negative terminal
of the machine to the electrode
• This process was formerly called direct current
straight polarity (DCSP)
• It is sometimes necessary to reverse the polarity in
the arc welding circuit
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
DCEN and DCEP Fundamentals
• When the electrons flow from the negative pole of
the arc welding machine to the base metal, this
circuit is direct current electrode positive (DCEP)
• This was previously called direct current reverse
polarity (DCRP)
• The choice of when to use DCEN or DCEP is
determined by the electrode being used
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
DCEN and DCEP Fundamentals
• DCEP produces better
penetration than DCEN
• Base metal thickness will
affect which polarity is
required
• This illustration shows a
diagram of a DCEP arc
welding circuit
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Alternating Current Arc Welding
Fundamentals
• Several types of arc welding
machines are used
– Transformer-type, as shown in
the illustration
– Inverter
– Motor- and engine-driven
generator
(Century Mfg. Co.)
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Alternating Current Arc Welding
Fundamentals
• The current’s frequency
is measured in cycles
per second, or hertz
(Hz)
• The current in the
U.S.A. is 60Hz current
• In most parts of the
world, 50Hz current is
used
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Alternating Current Arc Welding
Fundamentals
• A method used to stabilize the ac arc is to increase
the ionization of the material in the arc
• Arc welding requires electrodes designed for use
with alternating current
• Welds performed with ac electrodes show good
penetration
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Selecting an Arc Welding Machine
• Selecting the type of current to use should be done
after considering the advantages and
disadvantages
• Characteristics of a dc constant current-type arc
welding machine
– The ability to choose DCEP or DCRP
– Can be used in positions other than flat
– Electrodes designed to weld nickel, aluminum, and
copper generally use DCEP
– The ability to choose DCEN or DCSP
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Selecting an Arc Welding Machine
• A disadvantage is that a dc arc welder is generally
more expensive than a similar ac arc welding
machine
• Advantages of ac constant current arc welders
– Welds have moderate penetration
– Greater filler metal deposition rates and faster welding
speeds
– Machines are generally less expensive than similar dc arc
welding machines
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Selecting an Arc Welding Machine
• The major disadvantage of ac arc welding machines
is that not all SMAW electrodes can be used with
alternating current
• Welding machines capable of both ac and dc
operation are available
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Inspecting an Arc Welding Station
• The arc welding station includes several parts
– Arc welding power source
– Electrode lead and terminals
– Workpiece lead and terminals
– Electrode holder
– Workbench
– Ventilation
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Inspecting an Arc Welding Station
• Before beginning to weld, check all parts of the arc
welding station
• Check that the electrode and workpiece leads are
tightly attached to the machine
• Inspect the electrode holder and make sure the
handle is not cracked
• Turn on the ventilation system to see that it is
working
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Safety, Protective Clothing, and Shielding
• Arc welding should be performed using the proper
safety equipment
• There are several hazards to be avoided
– Radiation, such as ultraviolet rays, from the arc
– Flying sparks and small pieces of molten metal
– Electric shock
– Fumes
– Burns
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Safety
• Helmets or handheld face shields with approved
lenses must be worn to protect eyes from arc
radiation
• Never look at an arc from any distance unless
your eyes are protected by approved filter lenses
• Wear gloves and protective clothing to shut out the
rays from the arc
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Safety, Protective Clothing, and Shielding
• The arc welding operation should be shielded so
that no one can look directly at the arc
• It is advisable to wear suitable clothing to protect
against flying sparks
• Electric shock hazards can be avoided by working
on a dry floor and wearing dry gloves
• The health hazard from fumes can be avoided by
using proper ventilation equipment
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Safety, Protective Clothing, and Shielding
• To protect against burns
from hot metal, welders
should wear leather gloves
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Safety
• Do not carry flammable materials, such as
matches or lighters, when welding
• Wear high shoes with safety toes
• Avoid using arc welding equipment in wet or damp
areas
• Perform welding in an area that is well ventilated
• Handle hot metal with tongs or pliers
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Safety
• Before beginning to weld, inspect the complete arc
welding station to make certain it is safe for use
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Arc Welding Power Source
• An arc welding machine should never be started or
stopped under load
• Arc welding machines powered by ac are easy to
start and stop using an on-off switch or buttons
• Constant current-type arc welding machines are
used for manual arc welding processes
• The desired current is set on the machine
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Arc Welding Power Source
• Amperage controls vary
in appearance, location,
and operation on
various machines
• Some machines have
both coarse and fine
current adjustments
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Selecting the Proper Electrode
• Several factors should be considered when
selecting an electrode for SMAW
– Weld groove design
– Required tensile strength
– Base metal composition
– Position of the weld joint
– Rate at which to deposit weld metal
– Type of arc welding current used
– Penetration required
– Metal thickness
– Experience of the welder
– Specifications for the weld to be made
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Selecting the Proper Electrode
• When a groove weld
is made, the electrode
must be small enough
to manipulate at the
root of the weld
• The metal composition
of the base metal will
determine the metal
composition of the
electrode used
(American Welding Society)
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Selecting the Proper Electrode
• The welding position will determine the electrode
used
• Electrodes are made to be most effective with one
type of welding current
• Whenever a qualified welding procedure
specification is used, the diameter and type of
electrode are specified
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Striking the Arc
• To strike an arc, the electrode must first touch the
base metal to complete the circuit
• The electrode is then pulled back and the current
jumps to gap to create the arc
• First attempts to strike an arc may cause the
electrode to stick
• Another problem may occur from withdrawing the
electrode too far
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Striking the Arc
• There are two common
methods of striking an arc
– Use a glancing or
scratching motion with the
end of the electrode
– Use a straight down-and-up
motion or pecking motion
with the electrode
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Running a Bead
• The first skill that a welder must master is the ability
to run (form) a bead
• The arc length must be varied slightly as different
electrode diameters are used
• When small, solidified metal drops are seen on the
base metal surface, spattering is occurring
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Running a Bead
• Stringer beads are narrow
weld beads made without
oscillating the weld pool
• Weave beads are wide
weld beads made by
moving the weld pool side
to side as it progresses
along the joint
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Running a Bead
• The arc should always be struck about 3/8″ ahead
of where the bead should begin
• The speed of forward motion is judged by two
factors when welding
– The bead width
– The bullet-nose shape of the ripples at the rear of the
molten weld pool
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Running a Bead
• Weld reinforcement is the amount of buildup above
the surface of the base metal
• The proper current setting is important to make a
quality weld or bead
• A practical application of weld beads is the
rebuilding of worn surfaces
• Another application of bead work is hard-surfacing
or wear-resistant surfacing
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Restarting and Finishing a Bead
• When a SMAW bead is stopped prior to completion,
a deep crater is left in the base metal
• Restarting the arc and completing the bead must be
done with care
• When a SMAW electrode is stopped, it may be easy
or difficult to restart an arc with the electrode
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Restarting and Finishing a Bead
• Low-hydrogen electrodes are more difficult to restart
• There are two ways to finish a bead without leaving
a crater
– Use a run-off tab
– Reverse the electrode direction as the end of the weld is
reached
• A weld bead can be started on a run-on tab and
continued onto the weldment
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Cleaning the Bead
• When shielded metal electrodes are used, a brittle
slag coating is left on the weld bead
• This slag must be removed prior to restarting a
bead
• If the slag is not removed, the resulting weld will
have slag inclusions
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
DC Arc Blow
• A dc arc may have a tendency to wander from the
weld line
• This wandering is called arc blow and is one of two
types
– Forward arc blow
– Backward arc blow
• If the arc blow is very strong, preventive or
corrective measures can be taken
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
DC Arc Blow
• A welder can use the backstep method to create a
continuous weld by performing a number of short
welds
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Arc Welding Joint Designs
• Shielded metal arc welding can be done on any of
the basic joint designs
• Weld joints may be in any position
– Flat welding position
– Horizontal welding position
– Vertical welding position
– Overhead welding position
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Weld Flaws and Defects
• Completed welds may have a variety of flaws or
imperfections
• If a flaw is large, it is called a defect
• A weld may have a properly contoured face or an
undercut condition
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Weld Flaws and Defects
• If the bead has a number of small pit holes, this
indicates porosity
• Other surface flaws may be seen during a visual
inspection
– Spatter
– Slag inclusions
– Cracks in the weld bead or weld crater
• If a defect is found, the weld must be repaired
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
SMAW Welding Techniques
• Shielded metal arc welding is a skill
• A number of variables must be controlled to make a
good weld
– Arc length
– Travel speed
– Travel and work angles
– Electrode motion
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Edge Joint in Flat Welding Position
• An edge joint may be welded in any position
• On thin metal, no edge preparation is needed
• On thicker pieces of metal, the edge should be
prepared to provide a bevel- V-, U-, or J-groove
• A piece of the same metal being welded should be
used for practice
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Edge Joint in Flat Welding Position
• Run test beads and reset
the arc welding machine
current until the desired
bead is achieved
• A tack weld is a small,
well-fused weld used to
hold parts in proper
alignment
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Lap Joints in Flat Welding Position
• Lap joints are commonly made in flat or horizontal
welding positions
• Fillet welds are used with lap joints
• To weld a lap joint, the electrode should have a 20
drag travel angle and about a 45 work angle
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Lap Joints in Flat Welding Position
• The fillet weld on a lap joint is
made on the edge of one
piece and the surface of the
other piece
• The finished bead should
have the proper contour, be
straight, and have a
consistent width
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Corner and T-Joints in Flat Position
• Inside corner joints are often
made by butting two base
metals together to form a
square-groove joint
• An outside corner joint is
similar to a butt joint
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Corner and T-Joints in Flat Position
• A T-joint is formed by
placing one piece of base
metal on the other to form
a T-shape
• This joint can be welded
from one or both sides
• Be certain to melt both
surfaces on an inside
corner joint
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Butt Joints in Flat Welding Position
• It is suggested that a butt weld be practiced on low
carbon steel 1/4″ to 3/8″ thick
• The root pass in a butt joint must melt both pieces
of metal and obtain complete penetration
• For thin base metal, only one pass is required
• Thick metal requires additional passes
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Butt Joints in Flat Welding Position
• Use the keyhole method to
ensure complete
penetration in a groove
weld
• Many weld joints require
more than one electrode to
complete the weld
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Butt Joints in Flat Welding Position
• Some weld beads require re-melting the existing
crater before resuming the weld
• The welder must clean the bead before attempting
to add another bead
• The weld should have no small cavities and should
have good fusion
• A wandering arc will result in incomplete fusion and
a nonuniform weld bead
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Butt Joints in Flat Welding Position
• The final beads used to fill the joint should be built
above the original top surface
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Safety
• Always wear safety goggles when removing slag
and cleaning metal
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
SMAW in Horizontal Position
• A butt, edge, or outside
corner joint can be made in
the horizontal welding
position
• The electrode should be
pointed upward at an angle
of about 20
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
SMAW in Horizontal Position
• A short arc length and lower welding current should
be used
• Be sure to eliminate undercutting at the edge of the
bead
• For a T-joint or inside corner joint, the electrode is
inclined 20 in the direction of travel
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
SMAW in Horizontal Position
• When making a fillet weld on
a horizontal lap joint, the
electrode should point more
toward the surface than
toward the edge
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
SMAW in Vertical Position
• Welding in the vertical position may be done in
either or two directions
– Uphill (also called vertically up)
– Downhill (also called vertically down)
• The weld must be made so that slag is not
entrapped in the weld metal
• The material should not run or drip
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
SMAW in Vertical Position
• The uphill method of
welding is generally
preferred
• With downhill welding,
the slag has a tendency
to run into the molten
weld pool
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
SMAW in Vertical Position
• To control the weld pool heat and allow the metal
time to cool, a whipping motion is used
• Vertical butt, edge, and outside corner joints can be
prepared using square-, V-, bevel-, J-, or U-groove
edges
• In a vertical weld, the bead must be straight with a
uniform width
• The weld must be properly fused
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
SMAW in Overhead Position
• Overhead arc welding is
generally the most difficult
• Most electrode holders have
jaws designed to allow the
electrode to be held in a variety
of positions
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
SMAW in Overhead Position
• A covered electrode should never be bent to
change its angle for welding
• Bending a covered electrode will crack the covering
and cause it to fall off
• It is important to keep metal in the molten weld pool
from falling due to gravity
• A whipping motion is used to keep an overhead
weld pool cool enough to control
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Safety
• A welder’s helmet, cap, leather cape or coat, and
leather gloves should be worn when overhead
welding
• Coveralls must be buttoned at the collar
• All pockets should have closed flaps on them
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Review of Safety in SMAW
• Safety rules must be carefully observed to prevent
welding accidents
– Protect your eyes and face with an approved helmet
– Wear recommended clothing and shoes
– Avoid open pockets and cuffs
– Keep the floor of the welding area dry
– Work on electrical power connections only if you are an
experienced electrician
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Review of Safety in SMAW
• Safety rules continued
– Wear heavy, gauntlet-type gloves
– Cover all skin during arc welding to prevent burns
– Protect against harmful fumes by having good ventilation
or a source of filtered air
– Always use equipment approved by NEMA
– Never operate an ac welding machine with the welding
cables wrapped around the welding machine
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
Safety
• Protect your eyes and face from harmful rays and
sparks by wearing an approved helmet
• The floor on which the welder stands should be
kept dry to reduce the chance of an electrical
shock
• Never use homemade or unapproved transformer
equipment, which may be dangerous
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only.
