Smaw Manual

BRAINWARE UNIVERSITY
KOLKATA-7000124
DEPARTMENT OF COMPUTER SCIENCE ENGINEERING
REPORT ON
SHIELDED METAL ARC WELDING
SUBJECT CODE :
NAME………………………………….
ROLL NO………………………………
YEAR…………………………………..
SESSION………………………………
SEMESTER……………………………
DEFINITION:
Welding is a method of producing local coalescence of two or more similar or dissimilar

metals by achieving sufficient proximity and/or activity between them. It can be produced by
the application of heat or pressure alone or by suitable condition of the both.
Principle of SMAW:
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 between the electrode and the metals to be
joined. The work piece and the electrode melts forming the weld pool that cools to form a
joint. As the weld is laid, the flux coating of the electrode disintegrates, giving off vapours
that serve as a shielding gas and providing a layer of slag (ceramic), both of which protect the
weld area from atmospheric contamination.
Equipments:
1. Source of power: AC/DC

2. Cable
3. Electrode holder
4. Ground clamp
5. Chipping hammer
6. Wire brush
7. Tong
8. Eye shield
9. Apron(leather)
10. Hand Gloves(leather)
11. Shoes
12. Fire Extinguisher Cylinder
Difference Between AC & DC Welding Machine:
AC TRANSFORMER DC GENERATOR
No polarity option; both poles distribute Both Straight(electrode “-Ve“) & Reverse
equal temperature (electrode”+Ve”) polarity distributes 33.5%
& 66.5% heat respectively.
Only ferrous metal can be welded Ferrous & non-ferrous metal can be welded
Only flux covered electrode is used Both flux covered & bear wire electrode is
used
All positions cannot be satisfactorily welded. All positions can be satisfactorily welded.
Arc stability less Arc stability more
Arc blow less Arc blow more
No noise; breakdown possibility less Noisy machine; breakdown possibility more
POLARITY OF DC WELDING MACHINE:
AC TRANSFORMER:
Classification of Electrode:
Electrode coating ingredients and their function (function of flux):-
The covering/ coating on the core wire consists of many materials which perform a number
of functions as listed below:
1. Slag forming ingredients, like silicate of sodium, potassium, magnesium, aluminium,

iron oxide, china clay, mica etc. form a layer on the molten metal and protect the
same from atmospheric contamination.
2. Gas shielding ingredient, like cellulose, wood flower, calcium carbonate etc. form a
protective gas shield around the electrode end.
3. De-oxiding element, like ferro-manganese and ferro-silicon, refine the molten metal.
4. Arc stabilizing , like calcium carbonate, potassium silicate, titanates, magnesium
silicate etc, add to arc stability.
5. Alloying element like ferro alloy of magnesium, molybdenum may be added to impart
suitable properties and strength to the weld metal and to make up the loss of some of
the elements.
6. Iron powder in the coating improve arc behavior and bead appearance.
Standard Size Electrode:
 No.  Diameter(mm)  Length(inch)  Required

Amps
16 1.6 9 25-40
14 2.3 9-14 45-70
12 2.6 9-14 55-85
10 3.15 14-18 90-130
8 4 18 140-180
6 5 18 180-300
4 6 18 220-320
2 7 18 350-400
Electrode Classification:
Oxide coating , Rutile coating , cellulose coating, Basic Coating, Acid Coating.
Type of Coated Electrodes & Their Application:
i. Light coated Electrode: maximum spatter loss, low penetration, plug or deposited
on surface.
ii. Medium Coated Electrode: Weld metal is strong and flexible,
iii. Heavy coated electrode: stable arc, deep penetration and flexible, 5G 6G position
is better.
iv. Super heavy coated electrode: super deep penetration, no other welding defect,
extra iron powder is added with flux.
Electric Arc:
An arc is a constant spark or an electric discharge across a gap, which is called the arc-
gap.The arc is started by momentarily touching the electrode on the plate and then
withdrawing it about 2 to 3 mm from the plate. When the electrode touches the plate current
flows, and when it is withdrawn from the plate the current continues to flow in the form of
“spark” across the very arc gap. Thus the arc is formed with a high temperature.
SMAW JOB:-
Two mild steel plate are welded by both side” T” joint(fillet group) in downhand position.
Procedure:
1. Clean the two MS plate ( 100×50×5 and 100×40×5 mm) with wire brush.
2. Setting of AC welding Machine according to the job thickness i.e. 50/65 OCV and
120 Amps.
3. Select the ferrosped Medium coated electrode, size 3.15 mm , dia ( 10 No. SWG.)
4. And to take personal safety, job safety and plant safety.
Setting of job:
a. The larger plate is placed horizontally on the table, and thereafter the smaller one is
placed vertically at the middle position facing 5 mm side.
b. Two tacking are made conjoining the plates at the end edges.
c. Check the perpendicularity of the job and reset if necessary.
Method of Welding:
i. Hold the electrode with holder and maintain an angel of 45 degree to start as well
as continue the welding.
ii. Scratch of electrode on the plate , sparks will be generated thereon maintain the
gap 2 to 3 mm to stable the arc .
iii. Deposit the electrode metal uniformly spreading on the both plate.
iv. Clean the slag with chipping hammer and wire brush after the welding job is
naturally cooled in air.
Advantages of SMAW:
1. Flux shielded manual metal arc welding is the simplest of all the arc welding process
2. The equipment can be portable and the cost is fairly low
3. The process can be very well employed for hard facing and metal deposition.
4. Welding can be carried out in any position with highest weld quality
Limitation(s) of SMAW:
5. Because of the limited length of each electrode as compared to MIG continuous

welding can not be done.
6. As the electrode is flux coated , there is more possibility of slag inclusion
(entrapment) inside the welding bead.
7. Because the fumes and other slag particles, the visibility is much less and the welding
control is more difficult.
8. High pressure welding is not done now-a –days to avoid chances of slag inclusion,
porosity , blowhole, crater foramation. (MIG welding is preferred)
Assignments:
1. Define SMAW/MMAW.
2. Principle of SMAW.
3. Write short notes on limitation of SMAW.
4. What is “duty cycle”?
5. Why a welding machine is designed to give a higher current at low voltage.
6. Discuss the advantage and disadvantage of welding transformer over the motor
generator.
7. Mention the names of hand tools/ accessories used by SMAW and write their
application in brief.
8. What is open and close circuit voltage.
9. What is an electric arc.
10. Define electrode classification.
11. What is the role of electrode coating in SMAW.

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BRAINWARE UNIVERSITY

DEPARTMENT OF COMPUTER SCIENCE ENGINEERING

SHIELDED METAL ARC WELDING

Welding is a method of producing local coalescence of two or more similar or dissimilar

1. Source of power: AC/DC

Difference Between AC & DC Welding Machine:

Electrode coating ingredients and their function (function of flux):-

1. Slag forming ingredients, like silicate of sodium, potassium, magnesium, aluminium,

Standard Size Electrode:

 No.  Diameter(mm)  Length(inch)  Required

Type of Coated Electrodes & Their Application:

5. Because of the limited length of each electrode as compared to MIG continuous

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