SMAW (Shield Metal Arc Welding)
Qualification: NC II
Sector: Metal & Engineering
3 Competencies
*Basic
*Common
*Core
Basic
1. Participate in workplace communication.
2. Work in team environment.
3. Practice career propessionalism.
4. Practice occupational health and safety procedures.
Common
1. Apply safety practices.
2. Interpret drawing & sketches.
3. Perform industry calculations.
4. Contribute to quality system.
5. Use hand tools.
6. Prepare weld materials.
7. Set-up welding equipments.
8. Fit-up weld materials.
9. Repair welds.
Core
1. Weld carbon steel plates and pipes using SMAW.
Welding - is a process of joining two metal by heating or melting to form one. It is a practical skills that
requires continual practice and careful attention to the variables that the welder control to improve the
Golden Rule "Practice Makes Perfect" applies to welding in that the more you do. As long as you or
someone evaluates your welds, The better you become.
Hazardous effect of welding in our health and safety
1. Electric shock can kill
a. Do not touch live electric parts.
b. Wear dry, hole insulating gloves and body protection.
c. Turn off all equipment when not in use.
d. Do not use worn, damaged, undersize or poorly splice ce. Do not drape cables on your body.
f. Use only well maintained equipment. Repair or replace damage part at once.
2. Fumes and gases can be hazardous
a. keep your head out of the fumes, do not breath the fumes.
b. If inside, ventilate the area to remove fumes and gases.
3. Arc days can burn eyes and skin
a. wear approve welding helmet with proper shades of filter lenses to protect your eye and face when
welding.
b. Wear approve safety glasses w/ and shield under your helmet.
c. Use protective screens or barriers to protect others from flash, glare and spark.
d. Wear protective clothing made from durable flame resistant material and foot protection.
4. Flying metals can injure
a. Welding, chipping, wire brushing and grinding cause spark and flying metals as weld can throw of slag.
You sent
5. Hot parts can cause severe burns.
a. Do not touch hot parts bare handed.
b. To handle hot parts use proper tools. Wear heavy insulated welding glove and clothing to prevent
burns.
6. Noise can damage hearing
a. Wear approve ear protection if noise level is high
PPE - Personal Protective Equipments
1. Welding gloves
2. Welding mask
3. Safety Shoes
4. Goggles/ safety glasses
5. Apron
6. Long sleeves or jacket
7. Ear plug or ear maps
8. Pants
Tools
Grinder
Chipping hammer
Angle square
Lever bar
Pull push rule
Bench vise/gato
Plier
Screw driver
Steel saw
Materials
Electrode
Grinding disc
Cutting disc
Steel brush
Chalk stone
Buffing brush
Equipment
Welding machine
Cut off machine/ speed cutter
Acetylene
Branches of Welding
SMAW - Shielded Metal Arc Welding
GMAW - Gas Metal Arc Welding
GTAW - Gas Tungsten Arc Welding
FCAW - Flux Cord Arc Welding
OAW - Oxy Acetylene Welding
5 Parameters
C - Current settings
L - Length of Arc
A - Angle of electrode
M - Manipulation
S - Speed of travel
If you're just learning the stick process, technically called shielded metal arc welding (SMAW),
remembering these five points will improve your welding technique
Stroke
Stringer or Strainth
Circular or Rotary
Cresent or Half Moon
Zigzag
Size of Electrodes
Inches
1. 1/16
2. 3/32
3. 1/8
4. 5/32
5. 3/16
6. 1/4
mm
2
2.5
3.2
4
5
6
Welding Electode Position
1. All position
2. Flat and horizontal
3. Flat position
4. Vertical
Welding Position
1G - Flat position
2G - Horizontal position
3G - Vertical position
4G - Overhead position
E-6013 - all purpose electrode
The E-6013 electrode is best used for light to medium penetration on thin or sheet metal pieces. 6013
electrodes are commonly used in manufacturing truck frame bodies, metal furniture, storage tanks, farm
implementations, or where aesthetics are critical.
E-6011 - is used for root passing for deep penetration.
E 6011 electrode is a general-purpose electrode performs welding in all positions and efficiently in
vertical-up and over-head positions; it is used mainly for sheet metal welding and low silicon deposit
application. The electrode arc is easy to control and produces a flat weld bead with light slag formation.
E-7018 - is used for hot pass, filling pass, and capping
E-7018 stick welding rods are highly suitable for welding carbon steel and ideal for structural
applications and jobs within the retail welding industry. Common 7018 welding rod applications include:
Bridges. Military vessels.
Classification
The welding industry has adopted the American Welding Society’s classification number series for
welding rod electrodes.
The electrode identification system for steel arc welding is set up as follows:
1. E – indicates electrode for arc welding.
2. The first two (or three) digits – indicate tensile strength (the resistance of the material to forces
trying to pull it apart) in thousands of pounds per square inch of the deposited metal.
3. The third (or fourth) digit – indicates the position of the weld. 0 indicates the classification is not
used; 1 is for all positions; 2 is for flat and horizontal positions only; 3 is for flat position only.
4. The fourth (or fifth) digit – indicates the type of electrode coating and the type of power supply
used; alternating or direct current, straight or reverse polarity.
5. The types of coating, welding current, and polarity position designated by the fourth (or fifth)
identifying digit of the electrode classification are listed in Tables 5-4 below.
Mathematical Computation and Mesnsuration
1m = 3.28ft
1ft = 12inches
1inch = 2.54cm
1cm = 10mm
1m = 100cm
1m = 1000cm
Convert the ff Measurements
4.3m
2.71m
5.63m
3.80m
1.95m
6.8m
7.45m
8.32m
9.95m
10.35m
ft.
14.10
8.89
18.47
12.467
6.39
22.31
24.44
27.29
27.29
33.95
inch.
169.29
106.69
221.65
149.60
76.77
267.71
293.30
327.55
327.55
407.48
cm.
430
271
563
380
195
680
745
832
995
1035
mm
4300
2710
5630
3800
1950
6800
7450
8320
9950
10350
DCEP(Direct Current Electrode Positive) - Reverse Polarity
The direction of current flow through a welding connected to the positive terminal of the power
source and the work is connected to the negative terminal.
DCEN(Direct Current Electrode Negative) - Straight Polarity
The direction of current flow through a welding circuit when the electrode lead is connected to the
negative terminal of the power source and the work is connected to the positive terminal. Sometimes
referred to as straight polarity
AC – (50-50) What is AC Welding?
An alternating current is an electric current that reverses its direction many times per second. A
60-hertz current will change its polarity 120 times per second. With AC welding, because the
magnetic field and current rapidly reverse -direction, there is no net deflection of the arc.
1. D
2. B
3. A
4. D
5. B
6. C
7. C
11. A
12. B
13. C
14. B
15. D
16. D. 38. B
23. B
24. B
25. C
36. A
37. A
Welding Trouble Shooting
Porosity - small cavities on holes resulting from gas pockets in weld metal.
Porosity is the presence of cavities in the weld metal caused by the freezing in of gas released from the
weld pool as it solidifies. The porosity can take several forms: distributed. surface breaking pores
Possible cause
1. Arc length to long
2. Work piece dirty
3. Damp Electrode
4. High wind velocity
Corrective actions
1. Reduce arc length
2. Remove all grease, oil moisture, rust, paint coating, slag and dirt from work surface before welding.
3. Use dry Electrode
4. Use barrier or cover
Excessive spatters - scattering of molten metal particles that cool to solid form near weld beads
This is typically caused by the amperage and voltage settings used during welding. If the voltage is too
low or the amperage too high for a wire and gas combination it can mean that the arc is too cool to keep
the wire and pool molten, causing a stubbing effect on the wire.
Possible cause
1. Amperage to high for the Electrode
2. Arc length to long
Corrective action
1. Decrease amperage or select larger Electrode
2. Reduce arc lenght
Incomplete Fusion - failure of weld metal to fuse completely with base metal or a proceeding weld
metal.
Incomplete fusion is a weld discontinuity in which fusion did not occur between weld metal and fusion
faces or adjoining weld beads. This absence of fusion may occur at any location within the weld joint and
may be present in fillet welds and/or groove welds.
Possible cause
1. Insufficient heat input
2. Improper welding technique
Corrective Action
1. Increase amperage, select larger Electrode and increase amperage. Place stringer bead in proper
location at joint during welding momentarily.
2. Hold arc on groove weld which using wearing technique.
3. Keep arc on leading edge of weld fuddle remove all grease, rust, paint coating and dirt from work
surface before welding.
Lack of penetration - shallow fusion between weld metal and the base metal.
Lack of penetration happens when both sides of the root fail to fuse to the weld; for example, when the
groove of the metal is not filled completely.
Possible cause
1. Improper joint preparation
2. Improper weld technique
3. Insufficient heat input
Correction Action
1. Material too thick
2. Joint preparation and design must provide access to bottom of groove
3. Reduce travel speed
4. Increase amperage
5. Select larger Electrode and increase amperage
Excessive penetration - weld metal melting through base metal and hanging underneath weld
Excessive penetration occurs when excess weld metal protrudes through the weld root. It is usually
caused by a joint gap that is too large, root faces that are too small or heat input that is too high and can
cause erosion and/or corrosion.
Possible cause
1. Exesive heat input
2. Improper weld technique
Corrective action
1. Select lower amperage
2. Using smaller Electrode
3. Adjust travel speed
Burn through - weld metal melting completely through base metal resolting in holes where no metal
remain.
Burn through - is defined as an undesirable open hole when the base metal completely melts, which can
be caused by excessive heat input, improper travel angle, travel speed, and insufficient electrical sickout.
Possible cause
1. Excessive heat input
Corrective action
1. Select lower amperage
2. Use smaller electrode
3. Maintain and or maintain steady travel speed
Waviness of beads - weld metal that doesn't parrallel and doesn't cover form by base metal.
Possible cause
1. Unsteady hand
Corrective action
1. Use two hands, fractice technique
Distortion - contraction of weld metal during welding that force base metal to move.
Possible cause
1. Excessive heat input
Corrective action
1. Use restrains (clams) to hold base metal in position
2. Make tack welds along joint before starting welding operation
3. Select lower amperage, increase travel speed weld in small segments and allow cooling between welds