This is a simple butt weld joint that i weld up with 7018 18. In here will be share about what is shield metal arc welding, stick welding machine parts, electrode, stick welding technique, smaw welding parameter, polarity ac dc in smaw welding, and other. As this arc forms, both the electrode and the metal melt. Shielded metal arc welding smaw is an arc welding process in which coalescence of metals is produced by heat from an electric arc that is maintained between the tip of a consumable covered electrode and the surface of the base metal in the joint being welded.
Arcwelding introduction arc welding is the fusion of two pieces of metal by an electric arc between the pieces being joined the work pieces and an electrode that is guided along the joint between the pieces. Smaw is a wellestablished form of welding used extensively in commercial and. Shielded metal arc welding definition and general description shielded metal arc welding smaw is an arc welding process in which coalescence of metals is produced by heat from an electric arc that is maintained between the tip of a consumable covered electrode and the surface of the base metal in the joint being welded. Shielded metal arc welding smaw or the conventional arc welding process is particularly dominant in structural joints. The cap weld does have some common problems that are easily solved. Teaching of asme ix code to students of gtaw, gmawfcaw, smaw and saw welding processes. Syllabus introduction to shielded metal arc welding smaw. The electrode and work circuit is electrically live whenever the output is on. Always use a split bead technique always work from the bottom up 5g position. Aug 18, 2016 millerwelds provide great guidelines for shielded metal arc welding. Improving your smaw welding technique lawrence lerias. Do not weld where flying sparks can strike flammable material.
The welding technologystandards were validated with the adoption of the nationally recognized standards approved by the american welding society. Shielded metal arc welding smaw, or manual metal arc welding was first invented in russia in 1888. The welding machine is hooked up to a power source, which creates either alternating current ac or direct current dc to form an arc between the electrode and the metal. Engineering standards manual welding standards manual volume 3 welding procedure specifications wps no api rev. Depending upon the process, the electrode is either consumable, in the case of gas metal arc welding or shielded metal arc welding, or nonconsumable, such as in gas tungsten arc welding. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Applying shielded metal arc welding smaw techniques a ncient welders and tools have been seen depicted on egyptian tombs.
Shielded metal arc welding smaw, also known as manual metal arc welding mma or mmaw, flux shielded arc welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode covered with a flux to lay the weld. Click on a document, and you can download the pdf to your pc. Pdf modified short arc gmaw techniques for welding a. This process produces coalescence of metals by heating them with an arc between a covered metal electrode and the base metal work piece. Stick welding is a manual arc welding process in which a covered metal stick electrode is. It was produced with a great deal of help and guidance from professional welders. Tig welding pipe welding techniques on how to walk the cup. Most of the time, welding work is conducted with the materials to be joined placed in flat or horizontal positions. This subject is very complicated and only these precautions related to arc welding will be discussed in this brochure. D do not use ac weld output in damp, wet, or confined spaces, or if there is a danger of falling. Techniques for welding fill and cap passes the exact procedure for welding fill and cap passes is dependent on the characteristics of the pipe wall thickness, temperature, and position on the pipe, the skill of the welder, as well as the characteristics of the welding machine. This document is not an application manual and does not contain a complete statement of all factors pertaining to those topics. Before the gtaw welding process starts, all grease, oil, dirt, rust and other contaminants should be removed from the areas to be.
In arc welding an electrode is used to conduct current through a work piece to fuse two pieces together. The use of a wrong welding parameter or mishandling the welding equipment will result in unacceptable weldments that contain welding defects. It gives less spatter than most other rutile electrodes, the slag is easy to remove and the weld bead is smooth and even. Smaw welding techniques smaw welding techniques weld bead a weld resulting from a pass passes weld pass a single progression of welding along a joint. Welding spats made of chrome leather and protects the feet from spatter. Tungsten also called wolfram is a metal with a fusion point of more than 3300oc, which means more than double the fusion point of the metals which are usually welded. Here is a guide on tig welding for beginners to make the process quick and safe for everyone gtaw welding techniques and tips. When performing smaw, the ideal outcome is for the electrode cores material to be deposited onto the work surface in a uniform, even layer. The welding and metal fabrication technology program prepares students for entry level welder positions as structural welders.
Welding shieldhelmet used to protect our face and eyes from the arc rays and heat, and the spatter from the molten metal. Shielded metal arc welding smaw is the most common form of arc welding. Applying shielded metal arc welding smaw techniques. The purpose of the welding handbook for maritime welders is to provide guidance in modern welding and related processes and to provide the welder with a source of practical information on the right solution to specific onboard welding problems. Essential factors in gas shielded metal arc welding. Students develop key fundamental skills during the initial courses and learn to apply these skills using different and more complex welding procedures. A central group of chapters then assesses the main welding techniques. Overview of specialized welding processes including narrow. Scribd is the worlds largest social reading and publishing site. Shielded metal arc welding smaw, also known as manual metal arc welding mma or mmaw, flux shielded arc welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode covered with a flux to lay the weld an electric current, in the form of either alternating current or direct current from a welding power supply, is used to form an electric arc.
An introduction to smaw shielded metal arc welding. Developments in the welding process and discoveries in metallurgy have led. Pipe rotated, electrode is always at the top either a split bead or weave technique may be used. The slag is removed by tapping the weld with a chipping hammer or chisel and cleaned off with a wire brush.
Tig welding method and application tig welding definition the designation tig comes from usa and is an abbreviation of tungsten inert gas. This guide, and all the information contained within, is intended to provide you with. Stick welding techniques and tips 7018 butt weld youtube. Shielded metal arc welding smaw is the simplest, least expensive, and mostly widely used arc welding process figure 2. Guidelines for shielded metal arc welding smaw miller. When welding from left to right, maintain a 0 to 15degree angle tilted towards the direction of travel. S s w single pass multi pass m cleaning andor grinding. The facilitators manual is to be used as a reference tool for teachers to plan lessons related to the smaw units of study. The actual welding technique utilized depends on the electrode, the composition of the workpiece, and the position of the joint being welded. Unlike gas metal arc welding gmaw, in which you basically point and shoot, smaw requires a higher skill level and a mastery of certain techniques. It involved a bare metal rod with no flux coating to give a protective gas shield.
Shielded metal arc welding an overview sciencedirect. Lesson a56 applying shielded metal arc welding smaw techniques unit a. This chapter presents the basic principle of arc welding processes with focus on. Shielding is obtained from decomposition of the electrode covering. Smaw welding, which stands for shielded metal arc welding, is one of the worlds most popular welding processes. Weld bead a weld resulting from a pass stringer bead weave bead 3. If this is not possible, tightly cover them with approved covers. Stick welding properly known as shielded metal arc welding or smaw requires use of a covered stick electrode, a metal rod thats coated with a material called flux. The modified short arc gmaw techniques offer a number of advantages over the conventional welding methods gmaw, gtaw and smaw when welding root passes from a. It is easy to strike and restrike and therefore also good for tack welding. A main objective became to develop and maintain a range of welding equipment that is suitable for onboard welding, backed by a. The choice of electrode and welding position also determines the welding speed. In the video i explain how i go about the weld as well as showing the welding.
Teaching of asme ix code to students of gtaw, gmawfcaw, smaw and saw welding processes article pdf available in journal of materials education 3912. Pdf teaching of asme ix code to students of gtaw, gmawfcaw. Today, resistance mash seam welding and laser welding are the main fabrication techniques, and the expression tailorwelded blanks is now common terminology. The metal must be free of dirt, grease, rust, paint, or other impurities which may combine with a molten weld bead and cause it to be weakened. P roject c oordinator alex kyser, educati on programs professional skilled and technical sciences office of career, technical and adult education nevada department of education. The following lesson plans are based around the lesson slides in the smaw powerpoint presentations and should be used in conjunction with the units of study.
Stick welding tips for beginners trades for careers. Aug 14, 2009 when welding from left to right, maintain a 0 to 15degree angle tilted towards the direction of travel. The input power circuit and machine internal circuits are also live when power is on. It is the primary type of welding used in the maintenance and repair industry. Smaw stick welding machine parts, parameter and tips.
Describe how to select shielded metal arc welding equipment and supplies. Mechanical ventilation is an effective method of fume control for many welding processes. To receive a shock your body must touch both sides of the welding circuit electrode and work. Sep 05, 20 into this the melting alloy center of the welding rod is deposited completing the weld.
This process uses a consumable electrode covered with flux. Five steps to improving your stick welding technique. Prequalified process smaw process type manual positions flat, horizontal base metals only steels in category a of table 3. Electricity arc welding shielded metal arc welding smaw.
If you need to use a work clamp, make sure to place it as close to the area being welded as safety permits. Electricity, as it jumps a gaseous gap between two conductors. Also known as stick welding, flux shielded arc welding and manual metal arc welding mmaw, this is a relatively uncomplicated process as it uses simple equipment and its fairly straightforward to learn. Applying smaw techniques free download as powerpoint presentation. Source extraction local exhaust is a mechanical device used to capture welding fume at or near the arc and filter contaminants out of the air. Reinforcement weld metal, at the face or root, in excess of the metal. Because of its flexibility and mobility, gas welding is widely used for. Any welder should know gtaw welding techniques and tips to ensure a good weld. When arc welding in a confined area, such as a boiler, tank, or the hold of a ship, bear in mind that all the hazards associated with normal arc welding are amplified, so the precautions mentioned here are even more important. Welding the cap on a pipe is no different than walking the cup on any other surface.
Energy dispersive spectrometry eds was found to be an effective technique for evaluating the elemental composition of welding fume, and the results of the elemental analyses. Learn the five basic elements of stick welding technique to significantly improve your stick welding results. The most popular processes are shielded metal arc welding smaw, gas metal arc welding gmaw and gas tungsten arc welding gtaw. Shielded metal arc welding smaw shielded metal arc welding smaw is the most extensively used manual welding method for general welding applications.
Depending on the type shielding gas, this process is of also known as co. The essential factors in gas shielded metal arc welding states specific technologies needed to accomplish gsmaw successfully, focusing on the welding procedures in which solid wires and fluxcored. It is often referred to as stick welding or manual metal arc welding. Larger size electrodes may be used for fill and or cap passes of the thicker material. Passes weld pass a single progression of welding along a joint. This tutorial is intended to offer practical advice to beginner arc welders. Be alert that welding sparks and hot materials from. This installation, operation, and maintenance of arc welding equipment and the. The intense heat of the arc melts the tip of the electrode and the surface of the work close to the arc. Pipelines welding handbook welding techniques welding consumables. Develop your own style by observing others, practicing and noting which techniques produce the best results.
Basic elements to improve results for many people, especially those who are new to it or perhaps dont weld every day, stick welding, otherwise known as shielded metal arc welding smaw, is one of the more difficult processes to learn. Welding may be viewed as an ancient art, but the science of shielded metal arc welding and other welding processes is relatively new. Flat welds require the least operator skill and can be done with electrodes that melt quickly but solidify slowly. History of welding the art of welding is an ancient one but the science of shielded metal arc welding is relatively new. Welding glovesgauntlet made of chrome leather and protects the hands from heat, spatter, and radiations. This edition of the unitor welding handbook builds upon all the earlier editions. In arc welding processes a number of potential electrocution sources can be. In august 1985, thyssen stahl ag began butt welding two pieces of hotdipped galvanized steel to make a blank wide enough for the floorpan of the audi 80. Guidelines for shielded metal arc welding smaw warning this document contains general information about the topics discussed herein. Arc welding, shielded metal arc welding, shielding in smaw. The numerical code can be used for other electric arc welding techniques as gtaw or fcaw.
Welding hand tools chipping hammer tong steel brush angle grinder steel file 14. Protect yourself and others from flying sparks and hot metal. Pdf optimization of shielded metal arc welding smaw process. Shielded metal arc welding, otherwise known as manual metal arc welding or flux shielded arc welding, is a process that uses a fluxcoated electrode to form the weld. Pdf teaching of asme ix code to students of gtaw, gmaw.
An introduction to the shielded metal arc welding process. Shielded metal arc welding smaw also known as stick welding is an arc welding process which produces coalescence by heating with an electric arc between a covered metal electrode and the surface of the base metal. D use ac output only if required for the welding process. Smaw welding is a process which uses a consumable electrode which is covered with a flux.
Smaw welding is same with stick welding, manual metal arc mma, and flux shielded arc welding. Before switching on your power supply, make sure that your workpiece is clean and free of dust. Each welder manipulates the electrode a little differently. As electricity passes through the electrode, the flux forms a gas, which shields the electric arc in the space between the electrode and the metal being welded, preventing. Emphasis placed on power sources, electrode selection, oxyfuel cutting, and various joint designs. Stick welding, unlike point and shoot types of welding, requires a higher level of skills and mastery of some techniques.
Engineering standards manual welding standards manual volume 3 welding procedure specifications api rev 0 page 3 of 3 date. Welding commences when an electric arc is struck by making contact between the tip of the electrode and the work. The following are free downloadable pdfs available to all users. Arc welding is usually used to weld iron and steel, although it can also be used for alloys aluminum, nickel, etc. Whether you prefer stick welding or wire welding the welding process you use is most likely the one you have the most experience with or have the equipment for. For welding vertical up, use a push or forehand technique and tilt the top of the electrode 0 to 15 degrees away from the direction of travel. However, creating a good weld is not always easy, especially for a beginner. Welding guide 1 welding buyers guide 1 the welding process 1 what to look for when choosing a welder 1 common welding processes 2 shielded metal arc welding smaw stick 2 gas metal arc welding gmaw mig 3 flux cored arc welding fcaw gasless 4 gas tungsten arc welding gtaw tig 5 multiprocess welders 6 inverter welders 6. One of the most important and most often neglected parts of the welding job is preparation of the metal for welding. Describe the procedures and techniques for shielded metal arc welding. Ideally you want to ratchet the cup but if you are not there yet just wobble the cup. Tleia shielded metal arc welding smaw for grades 710. One thing to be careful of as youre welding this rod is being consumed. Camtech has prepared this handbook on welding techniques by compiling useful information from various sources and books available on the subject.
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