The document discusses Shielded Metal Arc Welding (SMAW) process. It describes the basic SMAW process where an electric arc is struck between a consumable electrode and the base metal. As the electrode melts, the flux coating allows for the transfer of molten filler metal across the arc to form the weld pool. The document provides details on SMAW equipment, power sources, electrodes, baking of electrodes, and important welding terminology like preheating, post heating, inter-pass temperature etc. to minimize cracking in the weld.
The document discusses Shielded Metal Arc Welding (SMAW) process. It describes the basic SMAW process where an electric arc is struck between a consumable electrode and the base metal. As the electrode melts, the flux coating allows for the transfer of molten filler metal across the arc to form the weld pool. The document provides details on SMAW equipment, power sources, electrodes, baking of electrodes, and important welding terminology like preheating, post heating, inter-pass temperature etc. to minimize cracking in the weld.
The document discusses Shielded Metal Arc Welding (SMAW) process. It describes the basic SMAW process where an electric arc is struck between a consumable electrode and the base metal. As the electrode melts, the flux coating allows for the transfer of molten filler metal across the arc to form the weld pool. The document provides details on SMAW equipment, power sources, electrodes, baking of electrodes, and important welding terminology like preheating, post heating, inter-pass temperature etc. to minimize cracking in the weld.
The document discusses Shielded Metal Arc Welding (SMAW) process. It describes the basic SMAW process where an electric arc is struck between a consumable electrode and the base metal. As the electrode melts, the flux coating allows for the transfer of molten filler metal across the arc to form the weld pool. The document provides details on SMAW equipment, power sources, electrodes, baking of electrodes, and important welding terminology like preheating, post heating, inter-pass temperature etc. to minimize cracking in the weld.
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Shielded Metal Arc Welding
By L D Poyyara
1 What Is Welding ? • Process of joining metals / alloys
• The process performed by Heat with or without
Pressure
• Filler metal may or may not be used
• The joint will be homogeneous
2 Classification Of Welding 1 Pressure Welding – With Heat & Pressure
2 Fusion Welding – With Heat & mostly
with Filler
3 Pressure Welding Process • Metal parts heated to forging temperature • Heating by Oven, Oxy fuel flame or Electric Resistance • Pressure applied on heated parts – by Hammer, Hydraulic Press or Mechanical liver. • The Parts remain permanent homogeneous joint 4 Types Of Pressure Welding
5 Types Of Fusion Welding • Shielded Metal Arc Welding- SMAW • Gas Tungsten Arc Welding - GTAW • Gas Metal Arc Welding - MIG / MAG • Submerged Arc Welding – SAW • Gas welding – Oxy Fuel Gas • Electron Beam Welding - EBW • Thermit Welding 6 Fusion welding Process • Metal parts locally heated to melt along the joint.
• Heating by oxy fuel flame or electric Arc.
• Invariably filler metal added to molten pool.
• On cooling, molten puddle solidifies to permanent
homogeneous joint. 7 Shielded Metal Arc Welding Process Core Wire • An electric Arc struck between electrode and base metal joint • Base metal melts under arc Flux Coating
• Electrode tip melts in drops and
transfers to molten pool of BM • Electrode with Arc moves along the joint keeping constant arc Pool Arc length • On cooling pool solidifies Base Metal
8 Equipment, Accessories & tools • Power Source
• Welding Cables, Holder & Earthing Clamp
• Head Screen, Hand gloves, Chipping
Hammer & Wire Brush
9 Types Of Power Source • Inverter- DC
• Thyrester – DC
• Motor Generator – DC
• Rectifier – DC
• Transformer - AC
10 Characteristic Of Power Source Manual welding Machine welding Drooping – Cons. A Linear – Cons. V V V V1 Vertical Horizontal V2 Curve Curve V1 V2
A A A1 A2 A1 A2
11 Electrode • Consumable
• Metallic Wire Coated with Flux
• Conducts Current and generates Arc
• Wire melts & deposited as filler in joint
12 Flux Coating On Electrode • Sodium Chloride • Potassium Chloride • Titanium Dioxide • Sodium Silicate • Ferrosilicon • Iron Powder • Alloying Elements • Binding Material 13 Function Of Flux In welding • Stabilizes Arc • Prevents contamination of weld metal • Cleans the weld from unwanted impurities • Increases fluidity of molten metal • Generates inert gas shielding while metal transfers • Forms slag after melting & covers weld • Allows deposited metal to cool slowly • Introduces alloying elements in the weld • Increases deposition efficiency • Minimizes the spatter generation • Helps in even & uniform bead finish
14 CS & LAS Electrode Sizes & Recommended Currents Core Wire in mm No Gage Dia Length Time required for Current burning in seconds
1 2 300 14 40 – 60 A 50-55 2 2.5 350 12 60 – 85 A 60-65 3 3.15 450 10 100 – 130 A 80 -85 4 4 450 8 130 – 180 A 85-90 5 5 450 6 150 – 210 A 90-95 6 6.3 450 4 240 – 250 A 95-100
15 ASME Classification Of Electrodes
SFA 5.1 E 7018 E = Electrode 70 = UTS in 1000 psi ( 60/70/80/90/100/ 110) 1 = Position (1= all, 2= 1G, 1F & 2F, 3= 1G & 1F) 8 = Type of coating (0,1,2,3,5,6,8)
16 Baking Of Basic Coated Electrodes
• Bake the loose electrodes in a baking Oven
• Baking Temperature 250° C to 300° C • Baking Time 2Hrs to 3 Hrs • Reduce the temperature to 100 ° C to 150 ° C • Hold the electrodes at this temperature till use • Unused / left over electrodes to be re-baked
17 Why Baking
• To remove the moisture (H2O) from
coating to avoid possible cracking of weld
18 How Does Moist Electrode Generate Crack Within Weld?
• Moist electrodes introduce atomic hydrogen at high
temperature in weld • On cooling, atomic hydrogen try to form molecules • The reaction results in stresses and fine cracks • Cracks occur within hardened metal - HAZ • Known as “Hydrogen Embrittlement” or “Under Bead Crack” or Delayed Crack
19 Important Terminology used in Critical Welding
• Preheating • Post Heating or Dehydrogenation • Intermediate Stress leaving • Inter pass Temperature • Post Weld Heat Treatment
20 What Is Preheating? • Heating the base metal along the weld joint to a predetermined minimum temperature immediately before starting the weld. • Heating by Oxy fuel flame or electric resistant coil • Heating from opposite side of welding wherever possible • Temperature to be verified by thermo chalks prior to starting the weld
21 Why Preheating? • Preheating eliminates possible cracking of weld and HAZ • Applicable to Hardenable low alloy steels of all thickness Carbon steels of thickness above 25 mm. Restrained welds of all thickness
• Preheating temperature vary from 75°C to 200°C
depending on hardenability of material, thickness & joint restrain
22 How does Preheating Eliminate Crack?
• Preheating promotes slow cooling of weld and
HAZ • Slow cooling softens or prevents hardening of weld and HAZ • Soft material not prone to crack even in restrained condition
23 What Is Post Heating? • Raising the pre heating temperature of the weld joint to a predetermined temperature range (250° C to 350° C) for a minimum period of time (3 Hrs) before the weld cools down to room temperature. • Post heating performed when welding is completed or terminated any time in between. • Heating by Oxy fuel flame or electric resistant coil • Heating from opposite side of welding wherever possible • Temperature verified by thermo chalks during the period
24 Why Post Heating? • Post heating eliminates possible delayed cracking of weld and HAZ • Applicable to Thicker hardenable low alloy steels Restrained hardenable welds of all thickness • Post heating temperature and duration depends on hardenability of material, thickness & joint restrain
25 How does Post Heating Eliminate Crack? • SMAW introduces hydrogen in weld metal • Entrapped hydrogen in weld metal induces delayed cracks unless removed before cooling to room temperature • Retaining the weld at a higher temperature for a longer duration allows the hydrogen to come out of weld
26 What Is Intermediate Stress Relieving? • Heat treating a subassembly in a furnace to a predetermined cycle immediately on completion of critical restrained weld joint / joints without allowing the welds to go down the pre heat temperature. Rate of heating, Soaking temperature, Soaking time and rate of cooling depends on material quality and thickness • Applicable to Highly restrained air hardenable material
27 Why Intermediate Stress Relieving?
• Restrained welds in air hardenable steel highly
prone to crack on cooling to room temperature.
• Cracks due to entrapped hydrogen and built in stress
• Intermediate stress relieving relieves built in stresses
and entrapped hydrogen making the joint free from crack prone 28 What Is Inter- Pass Temperature? • The temperature of a previously layed weld bead immediately before depositing the next bead over it • Temperature to be verified by thermo chalk prior to starting next bead • Applicable to Stainless Steel Carbon Steel & LAS with minimum impact
29 Why Inter Pass Temperature? • Control on inter pass temperature avoids over heating, there by Refines the weld metal with fine grains Improves the notch toughness properties Minimize the loss of alloying elements in welds Reduces the distortion
30 What Is Post Weld Heat Treatment? • Heat treating an assembly on completion of all applicable welding, in an enclosed furnace with controlled heating/cooling rate and soaking at a specific temperature for a specific time. • Rate of heating, Soaking temperature, Soaking time and rate of cooling depends on material quality and thickness • Applicable to All type of CS & LAS 31 Why Post Weld Heat Treatment?
• Welded joints retain internal stresses within the
structure • HAZ of welds remains invariably hardened • Post Weld Heat Treatment relieves internal stresses and softens HAZ. This reduces the cracking tendency of the equipment in service
32 Common Defects In SMAW 1. Cracks 2. Lack Of Fusion 3. Slag 4. Porosity 5. Pinhole 6. Piping 7. Undercut 8. Overlap 9. Lack Of Penetration 10. Excess Penetration 11. Spatters 12. Suck Back 13. Under Flush 14. Burn Through 15. Uneven Bead 16.Stray Arcing 33 Crack Cause Remedy 1) Wrong Consumable 1) Use Right Electrode 2) Wrong Procedure 2) Qualify Procedure 3) Improper Preheat 3) Preheat Uniformly 4) Excessive Restrain 4) Post heating or ISR
crack
34 Lack Of Fusion
Cause Remedy 1) Inadequate Current 1) Use Right Current 2) Wrong Electrode angle 2) Train /Qualify welder 3) Improper bead placement 3) Train/Qualify Welder
Lack Of Fusion
35 Slag Cause Remedy 1) Inadequate Cleaning 1) Clean each bead 2) Inadequate Current 2) Use Right Current 3) Wrong Electrode angle 3) Train / Qualify welder 4) Improper bead placement 4) Train / Qualify Welder
Slag
36 Porosity Cause Remedy 1) Damp Electrode 1) Bake the electrodes 2) Damaged coating 2) Replace the electrodes 3) Wet surface of BM 3) Clean & warm the BM 4) Rusted core wire 4) Replace the electrodes
Porosity . .
37 Pinhole
Cause Remedy 1) Damp Electrode 1) Bake the electrodes 2) Damaged coating 2) Replace the electrodes 3) Wet surface of BM/WM 3) Clean & warm the BM 4) Rusted core wire 4) Replace the electrodes
Pinhole •
38 Piping Cause Remedy 1) Damp Electrode 1) Bake the electrodes 2) Damaged coating 2) Replace the electrodes 3) Previous beads wet 3) Clean & warm the weld 4) Rusted core wire 4) Replace the electrodes
Piping •
39 Undercut
Cause Remedy 1) Excess Current 1) Reduce the Current 2) Excess Voltage 2) Reduce Arc length 3) Improper Electrode angle 3) Train & Qualify the Welder 4) Eccentric Coating 4) Replace the electrode
2) Excess Current 2) Reduce Current 3) Inadequate root face 3) Increase Root face 4) Wrong Electrode angle 4) Train / Qualify Welder * Applicable to SSFPW
Excess Penetration 43 Spatters Cause Remedy 1) Excess Current 1) Reduce to Right Current 2) Excess Voltage 2) Reduce Arc length 3) Wrong Polarity 3) Correct the polarity 4) Wet Electrodes 4) Use Baked electrodes 5) Rusted BM surface 5) Clean BM surface 6) Rusted Core wire 6) Replace the electrodes 7) Eccentrics coating 7)
Spatters • ••
44 Suck Back* Cause Remedy
1) Excess weaving in root 1) Reduce weaving
2) Excess Current 2) Reduce Current 3) Inadequate root face 3) Increase Root face 4) Wrong Electrode angle 4) Train / Qualify Welder * Applicable to SSFPW in 4G, 3G & 2G
Suck Back 45 Under flush Cause Remedy 1) Inadequate weld beads in 1) Weld some more beads final layer in final layer 2) Inadequate understanding on 2) Train / Qualify welder weld reinforcement requirement 3) Wrong selection of Electrode 3) Train / Qualify Welder size for final layer
Under flush
46 Burn through* Cause Remedy 1) Excess Current 1) Reduce the Current 2) Excess Root opening 2) Reduce root 3) Inadequate Root face opening 4) Improper weaving 3) Increase root face 4) Train / Qualify Welder *Applicable to root pass Burn trough
47 Uneven Bead Finish Cause Remedy 1) Improper bead placement 1) Train & Qualify the Welder 2) Excess Voltage 2) Reduce Arc length 3) Excess / inadequate 3) Train & Qualify the Welder current
Uneven bead finish
48 Stray Arcing Cause Remedy 1) Wrong Arc Striking Practice 1) Train the Welder 2) inadequate Skill of Welder 2) Train the Welder
Arc Strikes
49 Good Engineering Practices in
Shielded Metal Arc Welding
50 Good Engineering Practices In SMAW • Do Welding with properly baked electrodes • Basic coated CS electrodes to be baked to 250° to 300° C for two hours • Baked electrodes to be directly used on job or to be retained in a hold over oven at 100° C to 150° C until use • Unused balance electrodes shall be returned to baking oven
51 Good Engineering Practices In SMAW • Do not weld with damp Electrodes • Do not try to heat electrodes by touching the job (Short circuiting) • Do not use electrodes with damaged coating • Do not use electrodes with cracked coating • Do not bend the electrodes after holding it in the holder
52 Good Engineering Practices In SMAW • Do not weld on groove / surface with mill scale or rusting • Prior to welding, clean the weld groove with power wire wheel • Do not weld with unidentified electrodes • Do not leave balance electrodes unattended on shop
53 Good Engineering Practices In SMAW • All connections with earthing and welding cables shall be tight fitted • Earthing clamp shall always be tightly connected to the job • Burn the full length of electrode till 37 mm stub length
54 Good Engineering Practices In SMAW • Earthing cable shall directly connect to the job with an earthing clamp. • Tacks for set up shall be minimum 5 times the electrode diameter • Weaving shall be limited to three times the electrode diameter. • Only trained & qualified welders shall be employed for welding
55 Good Engineering Practices In SMAW • Do not direct fan or blower to welding arc • Remove paint if any from the area near welding • While welding in open, area shall be covered to protect from rain water & breeze • Weld edge preparation shall be free from serrations
56 Good Engineering Practices In SMAW • Use poison plates between the job material & structural supports. • Do not damage parent metal while removing temporary supports. • Locations where from temporary supports are removed shall be touched up by welding / grinding and PT checked.
57 Good Engineering Practices In SMAW • Remove visible defects from welds before placing the subsequent beads • Do not weld over a visible crack • Electrodes kept out side more than 2 Hrs shall be returned to baking oven • Maximum 15 electrodes at a time shall be taken from oven for welding
58 Good Engineering Practices In SMAW • When preheat is required, heat from opposite side of welding. • Use temperature indicating crayons for checking temperature • Do not Weld more than specified weld size- Fillet / Reinforcement.
59 Safety Precautions in
Shielded Metal Arc Welding
60 Safety Precautions In SMAW • Welders shall use safety devises – Hand gloves, Head screen with right glass & Safety shoes • Welders shall use full sleeve boiler suit • Use welding glass-DIN 11/12 up to 250 Amps and 13 above 250 Amps • Do not look at the arc with naked eyes
61 Safety Precautions In SMAW • Do not throw Stubs on ground. They shall be placed in stub collector. • Do not keep electrode in the holder when work is not in progress • Do not touch the electrode held on holder and the the job when the power source is on • Keep welding cables duly wound near power source when no welding is done
62 Safety Precautions In SMAW • Do not breath welding fumes • When working in confined area, ensure adequate ventilation / exhaust • Gas cutting torch / preheating burner shall not be taken inside confined area unless the flame is lit • When not in use, switch off the the power source from electric supply
63 Safety Precautions In SMAW • Acetone / inflammable liquids (Chemical for dye penetrant test) shall not be brought near welding • Gas cutting unit / fuel gas cylinders shall be away from welding area • Wet safety Shoes or wet hand gloves shall not be worn while welding
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