SMAW
Shielded Metal Arc Welding
OFW/OFC

OXY FUEL WELDING

OXY FUEL CUTTING
Purge

To blow or clean out the lines on the
Oxy/Acetylene setup
Flux





Powdered coating around the electrode
used in SMAW process.
1) Cleans metal/weld while welding
2) Cools Metal/weld/electrode while
welding
3) Stabilizes the arc while welding
4) Keeps out atmospheric gases from the
molten puddle
Electrode

Flux covered conductive rod used as filler
in the SMAW process
Slag

Protective coating over completed weld
made up of burnt flux, impurities that
have rose to the top of weld which aid in
the cooling process.
Crater

Indentation in the weld (below base
metal) usually happens at the end of the
weld
Arc Length





Distance between the tip of the electrode
and the base metal. Also known as Arc
Gap.
Long Arc = large Gap
Short Arc = Small Gap
Shorter the Gap = Cooler the Arc
Longer the Gap = Hotter the Arc
Rod Angle

Angle the electrode is held from the base
metal

1)Base Angle (BA)

2)Direction of Travel Angle (DOTA)
Porosity




Gas Pocket in/on the weld that is a defect
in the weld.
Long arc will cause
Dirty base metal
Broken flux from the rod.
Fusion

Combining or joining of two materials
Penetration

Depth of Fusion
Ductility




Ability of metal to be bent or stretched
without breaking
1) Rolled
2) Bent
3) Stretched
Alloy

What metal is made up of (Elements)

1) Periodic Table
Zinc
 Magnesium
 Iron

Flashback/Backfire

1)
2)
3)
Hissing or Popping sound from tip of
torch caused by gas and flame going
back into the tip.
Tip to close
Dirty Tip
Malfunction of equipment
Amps




The measure of Electrical Flow
1) electrons traveling
2) Water running out of a garden hose
would be compared to Amps
3) Water Flow/Electrical Flow
Volts




Measure of Electrical Pressure
1) Force of electrons
2) Compared to your finger over a running
garden hose to generate more
pressure.
3) water pressure/Electrical pressure
Puddle

Molten metal that follows the electrode,
this solidifies to create the weld.
Arc Flash/Flash Burn





Dangerous lights produced during Arc
Welding that damage your eyes/skin if not
protected with shaded/filtered lens or
protective clothing.
Dangerous lights: Ultraviolet/Infrared
Arc Flash: Burns unprotected eyes
Flash Burn: Burns unprotected skin
SMAW <125 amps shade 10
Flash/Arc Burn
Ultraviolent/Infrared Light
Butt Joint
Corner Joint
Inside
Outside
Edge Joint
T Joint
Lap Joint
Electrode #’s
Tensile Strength
Welding Position
Special Characteristics
60 = 60,000 psi
1 = All Positions
0 = Deep/DC + / Fast Freeze
70 = 70,000 psi
2 = Flat/Horizontal
1 = Deep/AC/DC + / Fast Freeze
80 = 80,000 psi
3 = Flat Only
3 = Shallow /AC/DC+/DC-
90 = 90,000 psi
8 = Medium / AC/DC+/Low Hydro
X 1000 lbs sq inch
Tensile Strength
Special Characteristics
•Current Type
•Flux Characteristics
•Metal Type
Electrode
•Penetration
E 60 1 1
Position
E 60 11
60,000 psi
Special Characteristics
•Deep Penetration
•Cellulose Potassium flux
•Fast Freeze
Electrode
•AC/DC+ (current)
E 60 1 1
All Position
E 60 1 0
60,000 psi
Special Characteristics
•Deep Penetration
•Cellulose sodium flux
•Fast Freeze
Electrode
•DC+ (current)
E 60 1 0
All Position
E 70 1 8
70,000 psi
Special Characteristics
•Medium Penetration
•Iron Powder Low Hydrogen flux
•AC/ DC+ (current)
Electrode
E 70 1 8
All Position
E 60 1 3
60,000 psi
Special Characteristics
•Shallow Penetration
•Titania Potassium flux
•AC / DC+ / DC - (current)
Electrode
E 60 1 3
All Position
Electrode #’s Quiz Slide
E
Electrode
80
80,000 psi tensile
strength
2
Flat/Horizontal
Position
1 Deep Penetration
Fast Freeze
AC/DC +
Tensile Strength
Welding Position
Special Characteristics
60 = 60,000 psi
1 = All Positions
0 = Deep/DC + / Fast Freeze
70 = 70,000 psi
Electrode
80 = 80,000 psi
E
90 = 90,000 psi
60
Low +
Hydrogen
Flux
2 = Flat/Horizontal
1 = Deep/AC/DC
/ Fast Freeze
60,000
psi tensile
Flat Position
strength
Medium Penetration
3 = Flat Only
Only 3 = Shallow /AC/DC+/DC+
8 = Medium AC/DC
/ AC/DC+/Low
Hydro
3
8
B. Welding Procedures (Cont.)

b. A tapping movement is where the electrode
is quickly tapped on the surface of the metal to
prevent it from sticking to the base metal.
4 Things Required for a Good
Weld

Amp Setting : Heat and (proper current type)

Travel Speed

Rod Angle: (Base Angle/Direction of Travel Angle)

Arc Length: Gap Should Equal Diameter of Electrode
B. Welding Procedures (Cont.)

8. There are two methods used in starting the
arc.

A striking movement is similar to striking a match.
Welding Positions

Flat

Horizontal

Vertical: V Up/V Down (v up Gives deeper penetration)

Overhead
Flame Types
Oxygen

Odorless Gas

Colorless Gas

Line Colors Green

Right Handed Threads on Fittings
Types of Combustible Gases




3 types commonly Used for Fuel in
Oxy/Fuel Welding and Cutting
Acetylene
Propane
Mapp Gas
(methylacetylene-propadiene propane)
acetylene
Colorless Gas
 Garlic Odor
 Unstable after 15psi Line Pressure
 Absorbed into Acetone (cork) to allow
higher pressures in Tank
 Red Colored Hoses w/ Left Handed
Threads

Duty Cycle



The amount of time a welding machine
can be operated continuously
70% Duty Cycle= 70% of an hour
70% Duty Cycle = 7 minutes every 10 min
Polarity



DC+
DCEP
Reverse Polarity
DCDCEN
Straight Polarity