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No. 1
PETRONAS CARIGALI Rev.0
Date 22/9/2020
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CLIENT:

PROJECT TITLE:
(BVF 1234 WELDING AND INSPECTION)

DOCUMENT TITLE:

SHIELDED METAL ARC WELDING (SMAW)

CONTRACT NO:
001

PROJECT NO:
EXERSICE 1

GROUP INFORMATION: SECTION:

NADZRUL AFIQ BIN MOHD ASRI VA19021

MUHAMMAD ZULHAIRIE BIN MAT ZAM VA19018
HAZIQ BIN ROSLAN VA19024
MOHAMAD FARIS ADLI BIN ADANAN VA19025
MUHAMAD SYARULNIZAM BIN DON VA19005
DOCUMENT STATUS CODE
CODE 1 CODE 2 CODE 3 CODE 4 CODE Z
WORK MAY PROCEED REVIEW AND RESUBMIT.
REVISED AND RESUBMIT. REVIEW NOT REQUIRED. SUPPLIER CERTIFIED FINAL/
NO MORE SUBMISSION FOR WORK MAY PROCEED SUBJECT
WORK MAY NOT PROCEED ONLY FOR INFORMATION AS BUILT/ACCEPTED AS FINAL
REVIEW REQUIRED TO INCORPORATED OF CHANGES
Name/Sign/Date
Code 1 , Code 2 and Code Z endorsed on Supplier data by Contractor and/or Company Shall not relieve the Supplier from full responsibility for any errors or
omissions, therein, or limit the S pplier obligations for conformance to Specification and Purchase Order or Contract Requirements.

0 22/9/2020

Prepared by Checked by Approved by Approved by Approved by

Name/Sign/Date Name/Sign/Date Name/Sign/Date Name/Sign/Date Name/Sign/Date
Rev. Date Description
GROUP NAME PPLV PLV

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PETRONAS CARIGALI Rev.0
Date 22/9/2020
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RECORDS OF AMMENDMENTS

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ABSTRACT

Shielded Metal Arc Welding or known as manual metal arc welding or flux shielded arc
welding is a process that uses a flux-coated electrode to form the weld. 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 contamination from atmospheric gasses
in he eld. Thi ce i fai l im le and d e n e i e in he way of specialized
equipment. For safety requirements, like any tool, welding equipment must be respected but
not feared. Any type of arc welding involves high voltage and amperage electricity which can
be dangerous if the proper precautions are not taken. Burns from heat of the torch or electrical
conduction can be serious and even life threatening if electricity passes through the heart. To
protect ourselves while welding, basic personal protective equipment must be worn. This
includes at minimum, heavy leather gloves, a long-sleeve jacket or coverall and a welding
helmet. Ultraviolet light released during the welding process can cause retinal burns and
e manen e e damage if he fil e in he helme face la e d e n ec e e.
Additionally, the welding process can release gasses that can be harmful to your health, so
providing sufficient ventilation is important.

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1.0 INTRODUCTION

There are few type of welding are commonly used but in this exercise we using SMAW or
Shielded Arc Welding. SMAW is one of famous type because it can be used on variety of
applications, including maintenance and repair, construction, industrial fabrication and many
more. To complete the course learning in this subject, student needs to apply the knowledge
and inf ma i n hand n . And a ma icall , den ill lea n h e he igh
current welding machine based on situation and type of power source (AC & DC). Before that,
all welders need to prepare the material to complete and perform the task or or more precisely
to complete the Tee joint. Student also need to prepare the right place to perform the task or
find a safe work station. By using a right technique, student will able to weld the Tee joint by
using SMAW with proper step and guideline from lecture. For this exercise, we using a SMAW
code number 1 which is its means we can use all position to perform the task and student are
able to choose a position that suitable with type of welding for example like Tap and Z.

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2.0 OBJECTIVE
1. To identify the principles of and set up.
2. To demonstrate basic SMAW welding applications.
3. To demonstrate welding common to joint material.
4. Apply a proper guideline before, during and after welding.
5. Inspection and identify the defect welding surface and near surface.

3.0 BILL OF MATERIAL

BILL MATERIAL FUNCTION

1
As power supply to make
electric arc between an
electrode
and base material

Alternating current ( AC )
2
Is a tools for holding
the electrode safely in any
position

Electrode Holder
3
To make sure the
electrical circuit to be
closed with the
welding power source and
the base material.
Work clamp

5
4

As a material to melt
between steel

Electrode
5
To protect the
eyes, face and neck from
electrode sparkling,
ultraviolet light, infrared

Welding shield light, and heat.

6
Used for to remove slag
from a weld
and welding
spatter from side welds.
Chipping hammer
7
As a heat resistant to
protect hand from hazard
like sparkling and head
during perform the
welding

Leather Glove
8
To protect you and your
clothing from hot metal
and slag that is generated
while welding, grinding
Welding apron or using a cutting torch.

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 9
For remove the slag and
clean the weld and surface

Wire brush

4.0 METHODOLOGY

Preparetion of Side plate Clamping a

material preparation workpiece

Check the
Start welding
welding Spot weld
work
product

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LIST FIGURE DESCRIPTION

1 Preparation of material:

1. Mild steel: 150mm X 50mm X

6mm

2. Mild steel: 150mm X 50mm X

6mm

2 Side plate preparation:

1. Prepare side plate to create flat

surface

2. Use file or grinder to get flat

surface

3 Clamping a workpiece:

1. Use the clamp to fix the

position using a clamp tool.

4 Spot weld:

1. Spot weld is to hold the tee

joint from slip.

2. To hold the work piece from

move after clamp tool is
removed

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5 Start welding work:

1. Use electrode E6013

2. Use any of weaving pattern

3. To weld a tee

6 Check the welding result:

1. Smoothness

2. Straightness

3. Reinforcement-3mm height

4. Overlap- no overlap

5. Uniform bead

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 5.0 RESULT

Before During After

a. Prepare two plate and put a. Use a suitable electrode to a. Check and inspect
magnet to hold the plates. weld. the result of the joint.
b. Tacking on each end of b. Start the spot weld. b. The tee joint is done.
the tee.

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6.0 DISCUSSION

1. What is the preparation work to weld T-joint?

Prepare your metal for welding by grinding off the mill scale finish. Grind off the mill
finish where you intend to weld. Use magnets that will hold your plate to one another
while making your first few tacks. Start by tacking each end, placing a tack weld on
either side of the tee. Complete a tack in the centre, before tacking the opposite side of
the tacks you already placed in the centre. Finish by tacking the back side of your
previous centre tack.
2. To produce a good bead, what is the technique or step in welding work
To improve the weld bead size, the weight of metal deposited per linear of the weldment
must be changed. Set a proper welding current and control the travel speed. A decrease
in travel speed will result in an increase in the weld bead height and width.
3. Why we have weaving technique?
Weaving technique is used to control heat in the weld puddle. In addition, this technique
is used to pause on each side of the weld to achieve good tie in and prevent undercutting
of the edges.
4. Complete the blanks callout in Figure 7
First blank: Electrode coating
Second blank: Core wire
Third blank: Shielding atmosphere
Fourth blank: Arc

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5. What are the advantages and disadvantages of SMAW process?

Advantages Disadvantages
Cheapest common arc welding equipment Consume bigger electric current.
to purchase.
All position welding. Dirty work finish.
Relative simplicity and portability of Root pass is lower than MIG and TIG.
equipment.
Auxiliary gas shielding or granular flux is Prone to slag inclusions.
not required.
The process is flexible and can be applied Weld deposits is prone to blue holes.
to a variety of joint configuration and
welding positions.

6. Lists 5 common discontinuities in SMAW process?

a. Porosity
b. Inclusions
c. Inadequate joint penetration
d. Incomplete fusion
e. Overlap

7. Complete the figure 8 below:

SMAW Number System: E7018
E= electrode
70= 70,000 psi tensile strength
1= welding in all positions
8= low hydrogen

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7.0 CONCLUSION

As a conclusion, Shielded Metal Arc Welding (SMAW) is a standard in most industries because
it has so many benefits over other types of welding. One of the benefits is it is highly portable.
Besides that, it can be used in many different environments, in a fabrication shop or outdoors
on a construction site or a ship. The skill of the welder is an important factor in SMAW.
However, fortunately most welders get trained in SMAW in their first stages of education,
meaning that most skilled welders are familiar with the process. It is also one of the most trusted
processes in welding because of its simplicity and versatility. It can be used with carbon steel,
stainless steel, cast iron and more. SMAW can also be done in any position as well as on
different thickness of materials. Many times, the skill of the welder determines what can
actually be accomplished and where it can be used.

8.0 REFERENCE

1. Lesson, S. (2020, May 17). Working principles of SMAW, its advantages and
disadvantages. Retrieved September 30, 2020, from
https://studentlesson.com/working-principles-of-smaw/
2. Buel, Z. (2019, January 24). What Are Welding Discontinuities? Retrieved September
30, 2020, from https://www.tws.edu/blog/welding/what-are-welding-discontinuities/
3. STI Group - Industrial, Midstream & Fabrication Services. (2016, April 07). The Use
of SMAW in Industrial Fabrication. Retrieved September 30, 2020, from
https://setxind.com/fabrication/role-smaw-plays-industrial-fabrication/
4. Audreyobscura, & Instructables. (2017, September 23). Welding Class. Retrieved
September 30, 2020, from https://www.instructables.com/lesson/Welding-Joints/

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