SHIELDED METAL-ARC

WELDING
2ND GROUP
By

B. Arief Munandar

D. Riko Chandra K

Ardian Novariandaru
Bayu Gumilang

Hendito Suryo L
Lutfi Hakim

SHIELD METAL ARC WELDING

SHIELDED METAL ARC WELDING

Sheilded Metal Arc Welding (SMAW) is also called
Manual Metal Arc Welding (MMAW) or shielded
electrode welding is a process to joining two pieces of
metal or more, be a fixed metal connection, using an
electric heat source and the added material / filler in
the form of shielded electrode.

IN THE PROCESS OF SHIELDED ELECTRODE

WELDING, THE ELECTRIC ARC OCCURS
BETWEEN ELECTRODE AND BASE METAL WILL
PRODUCE THE HEAT. THE HEAT PRODUCED BY
THE ELECTRIC ARC MELTS THE METAL WHICH
MIXES WITH THE MOLTEN DEPOSITS OF THE
COATED ELECTRODE. THE ELECTRICAL ARC
GENERATED BY WELDING MACHINE. THE
ELECTRODE IS A SHIELDED WIRE WITH
COVERED BY FLUKS. WITH THE MOLTEN
METAL, THEN THE CRATER OF THE BASE
METAL WILL BE FILLED AND MIXED BY THE
ELECTRODE AND THE BASE METAL ITSELF, IT
FORMED IN THE MOLTEN CRATER. THEN THE
COOL CRATER CALL WELDING METAL

Advantages
Can be used in any place

Disadvantages
Welding is limited only to

(water)
along the electrode and
Can be weld by many
should be establish the
different types of
connection.
In the next welding, slag
of material
Quick and very easy
should be cleaned.
Easy to be oxidated cause
to set
Can be used in any position
the molten metal cover is
Electode is easy to get in any just a arc welding from fluks
The electrode diameter
size and diameter
Simple equipment, cheap,
suspended from the
and easy to bring in
thickness of metal and the
anywhere
position of welding
Rectifier

Equipment
Stud
Electrode
Aplication
Welding
Video
Welding
Clip
Technique

SMAW

APLICATION

APLICATION

The shielded metal arc welding process is used

extensively in welding both ferrous and
nonferrous metals.It has many applications in
producing a vast assortment of metal products.A
considerable amount of arc welding will be found
in the ship construction industry;and in welding
girders,beams, and columns for buildings and
bridges.Shielded metal arc welding is universal
in repairing and servicing equipment such as
locomotives,farm
implements,automobiles,machinery,and a host of
other items.

EQUIPMENTS

EXTERNAL CONSTRUCTION OF
D.C. MOTOR GENERATOR
WELDING MACHINE

The Lincoln Electric Co.

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MOTOR GENERATOR DESIRABLE

CHARACTERISTICS
Have forceful penetrating arc
Versatile

Can

be used to weld all metals that are weldable by

arc process

Flexible
With

proper electrode, can be used in all positions

Durable and have long machine life

DCEN (STRAIGHT POLARITY)

Usually it is preferable to have more heat at the

workpiece because the area of the work is greater
and more heat and more heat is required to melt
the metal than the electrode. Thus, if large heavy
deposite are to be made to work should be hotter
than the electrode.

DCEP (REVERSE POLARITY)

With reverse polarity, less heat is produced in the

base metal and more heat at electrode. The result
is that the deposits can be applied rapidly while
the base metal is prevented from overheating.

A.C.-D.C. TRANSFORMERRECTIFIER WELDING MACHINES

Permit welder to select either a.c. or d.c. and electrode
negative or electrode positive
Switch

Permits

welder to use only transformer part of machine for

a.c. welding
Flipping switch then output current directed through
rectifier which converts it to d.c. welding

High frequency arc-starting devices, water/gas

flow controls, balance controls for a.c. operation,
remote control often built into machine

A.C.-D.C. TRANSFORMERRECTIFIER WELDING MACHINES

A 300 amp model
shown in use

Miller Electric Mfg. Co.

A 300 amp a.c.-d.c.

GTAW/SMAW
machine.

The Lincoln Electric Co.

The Lincoln Electric Co.

Portable SMAW/GTAW
welding machine

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METAL ELECTRODE HOLDERS

Device used for holding electrode mechanically
Conveys electric current
from welding cable to electrode
Insulated handle protects hand from heat
Jaws of holder grip electrode at any angle
Made of metal with high electrical conductivity
and ability to withstand high temperatures

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

Lenco dba NLC. Inc.

METAL ELECTRODE HOLDERS

Jaws can be replaced with new ones
Should be light in weight, well-balanced and have
comfortable grip
Size of holder must be in line with size of welding
machine
Fully insulated so stays cool even with high duty
cycles

SPRING TYPE ELECTRODE HOLDER

Lenco dba NLC. Inc.

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SHORT-STUB ELECTRODE HOLDER

One-ton pressure
contact

High welding current conductance

Special extruded copper-alloy body
Cable connections

Entirely insulated

Lifeguard insulation

Bernard Welding Equipment Co.

Holds electrodes burned to very short stub.

Twist-type locking device permits electrodegripping power in excess of 2,000 pounds.

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

ANGLE-HEAD ELECTRODE HOLDER

Shorter and lighter

than other holders
of comparable capacity.
Available in sizes of 400 and 600
amperes
and takes electrodes from 1/16
through
5/16 inch in diameter.
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WORK CLAMPS

Variety of structures to be welded; many types of

clamps may be used
Copper

hook, heavy metal weight, C-clamp

Specialized work clamps

Lenco dba NLC. Inc.

Spring loaded

C-clamp
Lenco dba NLC. Inc.

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This clamp stops twisting and turning of

welding cable where work rotates. Clamp
welded to part, thus permits work clamp to be
attached in seconds. It is generally used in fabricating
tanks, pressure vessels, and on weld positioners.
Rotary
type

HAND AND HEAD SHIELDS

Brilliant light caused by electric arc contains two kinds

of invisible rays which injure eyes and skin
Ultraviolet
Infrared

Rays affect eyes within 50 feet;

and skin any distance within
20 feet
Fibre-Metal Products Co.

Hand shield so person may hold

shield in front of face

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HAND AND HEAD SHIELDS

Also called hood or helmet

Attached

Allows it to be moved up or down as wearer desires

Dependable protection
Both

to adjustable headband

hands free to grasp electrode holder

Partial protection
Must

also wear leather or

nonflammable cap for adequate
protection
Fibre-Metal Products Co.

Fibre-Metal Products Co.

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

HAND AND HEAD SHIELDS

Constructed

of heat-resisting, pressed-fiber
insulating material
Shields fully molded at top and bottom to
protect head and neck
Usually black to reduce reflection with
window frame to hole protective lens

Fibre-Metal Products Co.

Chrome leather helmets ideal for

hard-to-get-into areas.
Flip-front welding helmet permits welder to
inspect and brush weld without lifting the hood.
Wilson Products

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HEAD SHIELD LENS

Sizes: 2 x 4.5 or 4.5 x 5.25
Colored to screen out ultraviolet, infrared rays,
and most of visible rays
Variety of shades of color

Density depends on brilliance of arc

Varies with size of electrode and volume

of current

Side exposed to weld pool protected by clear

polycarbonate plastic cover lens
Protect

costly filter lens from molten metal spatter

and breakage (replaced when pitted and clouded)

AUTO-DARKENING ELECTRONIC
FILTER HELMET
Useful when working close quarters,
doing
high production work, or avoiding
.
inadvertent arc strikes
Single shade or variable shades
Filter can switch from light to dark in
less than 1/10,000 of a second
Battery powered

May

have solar battery booster

Jackson Products Co.

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SAFETY GLASSES
Should
Also

be worn

behind hood to prevent

severe arc flash reaching eyes

Can

RobCrandall/The Image Works

Absorb more than 99.9%

harmful ultraviolet rays
Worn by others who work with
welders
Light in weight, well ventilated,
and comfortable
Lenses have light tint (Not
dark!) and tented side shields

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PROTECTIVE CLOTHING
Gloves

Made

to protect hands

of leather or some other type of fireresistant material

Leather

capes, sleeves, shoulder

garments with detachable bibs,
aprons
Split-type apron if sitting down
No

place to collect hot particles

High-top

shoes

Leggings

and spats

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PROTECTIVE CLOTHING
100%

cotton or wool
Thick enough to prevent
injurious untraviolet rays
from penetrating to skin
Long sleeves
Shirts buttoned to neck
Shirttails tucked
Cuffless pants long enough
to cover top of leather
boots

Miller Electric Mfg. Co.

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

PROTECTIVE CLOTHING

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

WELDING TECHNIQUE

STRIKING AN ARC SCRATCH START

TECHNIQUE

STRIKING AN ARC TAPPING

TECHNIQUE

POSITIONING ELECTRODE
HOLDER

CONSTANT CURRENT OR CONSTANT

VOLTAGE
Welding power sources are designed in many sizes and shapes. They may supply
either AC or DC, or both, and they may have various means of controlling their
voltage and amperage output. The reasons for this is that the power source must be
capable of producing the proper arc characteristics for the welding process being
used. A power source that produces a satisfactory arc when welding with coated
electrodes will be less than satisfactory for welding with solid and flux cored wires.
1.9.1 Constant Current Characteristics - Constant current power sources are used
primarily with coated electrodes. This type of power source has a relatively small
change in amperage and arc power for a corresponding relatively large change in arc
voltage or arc length, thus the name constant current. The characteristics of this
power source are best illustrated by observing a graph that plots the volt- ampere
curve. As can be seen in Figure 20, the curve of a constant current machine drops
down- ward rather sharply and for this reason, this type of machine is often called a
"drooper." 1.9.1.1 In welding with coated electrodes, the output current or amperage
is set by the operator while the voltage is designed into the unit. The operator can
vary the arc voltage somewhat by increasing or decreasing the arc length. A slight
increase in arc length will cause an increase in arc voltage and a slight decrease in
amperage. A slight decrease in arc length will cause a decrease in arc voltage and a
slight increase in amperage. 1.9.2 Constant Voltage Characteristics - Constant
voltage power sources, also known as constant potential, are used in welding with
solid and flux cored electrodes, and as the name implies, the voltage output remains
relatively constant.

On this type of power source, the voltage is set at the machine

and amperage is determined by the speed that the wire is fed to
the welding gun. Increasing the wire feed speed increases the
amperage. Decreasing the wire feed speed decreases the
amperage. 1.9.2.1 Arc length plays an important part in
welding with solid and flux cored electrodes, just as it does in
welding with a coated electrode. However, when using a
constant voltage power source and a wire feeder that delivers
the wire at a constant speed, arc length caused by operator
error, plate irregularities, and puddle movement are
automatically

ARC BLOW
Arc blow is the, usually unwanted, deflection
of the arc during arc welding.
There are two types of arc blow commonly
known in the electric welding industry: magnetic
and thermal.

MAGNETIC ARC BLOW

Magnetic arc blow or "arc wander" is the deflection of

welding filler material within an electric arc deposit by a build
up of magnetic force surrounding the weld pool. Magnetic arc
blow can occur because of:
Workpiece connection
Joint design
Poor fit-up
Improper settings
Atmospheric conditions

Arc blow tends to occur if the material being welded

has residual magnetism at a certain level,
particularly when the weld root is being made, and
the welding current is direct current (DC positive or
negative).
Magnetic arc blow is popularly attributed to a change
in the direction of current as it flows into and
through the workpiece. Magnetic arc blow is known
to begin at field densities as low as 10gauss and
becomes severe at densities of, equal to or greater
than, 40gauss; it is directional and can be classified
as forward or backward moving along the joint, but
can occasionally occur to the sides depending on the
orientation of the poles to the workpiece.
Magnetic arc blow is more common in DC welding
than in AC welding.

THERMAL ARC BLOW

Thermal arc blow is widely attributed to
variations in resistance within the base metal
created by the weld pool as it is moved across the
workpiece. Thermal arc blow can occur because
of:
Improper surface preparation
Improper travel speed
Thermal arc blow is not as severe as magnetic
arc blow, but can still leave undesirable defects in
the weld deposit.

ARC LENGTH
If the arc is too long the metal melts of the
electrode in large globules which wobble from
side to side as the arc wavers. This pruducess a
white spattered, and irregular bead without
suifficient fusion between the original metal and
the deposited metal. An arc that is to short fells
to generate suifficient heat to melt the best metal
properly. Furthermore the electrode will stick
frequently and produce uneven with irregular
ripples.

ELECTRODE

ELECTRODE
Electrodes are manufactured to weld different
metals and they are also designed for DC straight
and reverse polarity or AC welding. Of few
electrodes work equaly well on either DC or AC
some electrodes are best suited for flat position
welding. Others are intended primary for vertical
and overhead welding, and some are used in any
position.
The shield electrode has a heavy coating of
several chemicals such as cellulose, titanium
dioxide, ferromanganese, silicaflour, calcium
carbonate and other

FLUX HAS A FUNCTION THAT IS:

1. Forming a protective environment,

2. Form a slag with specific properties.
3. Allows welding on the head and perpendicular.
4. Stabilize the arc.
5. Adding alloying elements to the main metal.
6. Purify metals metallurgy.
7. Reducing the filler metal splashes.
8. Improving the efficiency of the deposition.
9. Removes oxides and impurities.
10. affect the depth of penetration arc.
11. Affect the form of beads.
12. Slowing the rate of cooling the weld.
13. Adding a layer of weld metal from metal powders in a
protective coating.

TYPE
Mild Steel

Low Hydrogen

Stinless Steel

Low Alloy

AWS CLASS
E6010
E6011

E6012
E6013
E6014

E6020
E6024

E6027

E7014

E7024

E6015
E6016
E6018
E7016
E7018
E7028
E308-15, 16

E309-15, 16

E310-15, 16

E311-15, 16

E312-15, 16
E7011-A1
E7020-A1

E8018-C3

CURRENT TIPE
DCR
DCR, AC

DCS, AC
DCR, DCS, AC
DCR, AC

DCR, DCS, AC
DCR, DCS, AC

DCR, DCS, AC

DCR, DCS, AC

DCR, DCS, AC

DCR
DCR, AC
DCR, AC
DCR, AC
DCR, AC
DCR, AC
DC, AC

DC, AC

DC, AC

DC, AC

DC, AC
DCR, AC
DCR, DCS, AC

F,
F,

F,
F,
F,

F,
F,

F,

F,

F,

F,
F,
F,
F,
F,
F,
F,

F,

F,

F,

F,
F,
F

WELDING POSITION
V, OH, H
V, OH, H
V, OH, H
V, OH, H
V, OH, H
H
H
H
V, OH, H
H
V,
V,
V,
V,
V,
H
V,

OH,
OH,
OH,
OH,
OH,

H
H
H
H
H

OH, H

V, OH, H

V, OH, H

V, OH, H

V, OH, H
V, OH, H

WELD RESULTS
Fast Freeze, deep penetrating,
flat beach, all-purpose welding

Fill-freeze, low penetration,

for poor fit-up, good bead contour,
minimum spatter

Fast-fill, high deposition,

deep groave welds, single pass

Iron powder, high deposition,

deep penetration
Iron powder,law penetration, high speed

Iron powder, high deposition,

single and multiple past
Welding of high sulfur at high carbon
steels that tend to develop porosity and
crack under weld bead

Welding stainless steel 301, 302, 303,

304, 308
Welding 309 alloy at elevated
temperature application and dissimillar
metals
Welding type 310 and 314 stainless steel
where high corrosion and elevated
temperature are required
Welding type 316 stainless steel and
welds of highest quality. Containts less
carbon to minimize carbon transfer in
the weld. Type 316 reduces pitting
corrosion
For welding all grades of stainless steels
For welding carbon moly steel

For low alloy high tensile strength

Code in th table
Electrode clasification
Example EXXXX.
- E = Elektroda
- XX = the two first letter X (XX) is a strength from
welding, example E60XX mean the material tensile
strength is 60.000 psi, E70XX material tensile
strength is 70.000 psi,
- X = the third X is show the exact position of welding
for the number one is show that can be used in any
position, number two is show that just can be used in
specific position
- X =The last X is show the kind of electric current that
appropriate with the electrode shield

ARC STUD WELDING

ARC STUD WELDING

Arc stud welding (SW) is a welding process in

which a metal fastener (weld stud) is joined to a
workpiece. This process is generally referred to as
stud welding. The metal fastener is joined under
pressure once sufficiently heated with an electric
arc.

TYPICAL USES OF THE ARC STUD

WELDING PROCESS

The arc stud welding process lends itself to a

wide range of applications such as automotive,
ship building, appliance,
aero-dynamics, boilers, light or heavy
construction, preassembled fabrication designs
and fit-up parts design. ARC Stud Welding is
generally used to weld larger diameter studs to
thick base metals

EQUIPMENT

STUD WELDING CONTROLS

The control circuit of an arc stud welding system

regulates arc duration through the welding cycle
and provides adjustable controls for various stud
diameters. A control circuit consists of a
contactor, timing device, and current control. The
weld time is a percentage of seconds or
milliseconds, the current is typically depicted as
amperage.Weld time is determined by stud
diameter

ARC STUD WELDING GUNS

There are two basic arc stud welding guns available:

1.

Portable, pistol grip configuration, which is used for hand-held or

manual operation.

2.

Fixed, production gun, which is usually mounted on a positioning

device, and is usually incorporated with an automatic fastener
loading system.

The portable, pistol grip design is offered in three capacities:

1.

Light Duty (Stud diameters 1/8 in. (3.2 mm) to 3/8 in. (9.5 mm)

2.

Standard Duty (Stud diameters 1/8 in. (3.2 mm) to 5/8 in. (15.9
mm)

3.

Heavy Duty (Stud diameters 1/8 in. (3.2 mm) to 1-1/4 in. (31.8 mm

STUD WELDING PROCESS

THE WELDING STUD

Welding grade studs are made of most

commercially used metals, and normally range in
diameters from 1/8 in. (3.2mm) to 1-1/4 in. (31.8
mm) with lengths as required. In addition to
straight threaded or unthreaded studs, it is
possible to obtain a wide variety of shapes and
sizes

ARC SHIELDS (FERRULES)

The ceramic ferrule performs several important functions and is
required to do each weld. Some equipment is available with a
permanent shield attached directly to the stud gun. The ferrule:
Concentrates the arc heat to the immediate weld area.
Protects the molten weld pool from atmospheric contamination.
Confines the molten metal to the weld zone, to form a fillet.
Prevents charring and disruption of surrounding base metal
surfaces.
Reduces the possibility of open arc flash; therefore, the operator
and surrounding personnel need only wear suitable flash type
safety glasses.
Upon completion of the weld, the protective ceramic shield can be
easily removed by chipping it away or lifting it off with a suitable
tool.

DIFFERENT TYPES OF WELD

STUDS AND CERAMIC FERRULES

RECOMMENDED SETTINGS FOR

STUD WELDING OF STEEL

WELD INSPECTION/TROUBLESHOOTING

THE CAPACITOR DISCHARGE (CD)

STUDWELDING PROCESS

CD Studwelding is generally used to weld smaller

diameter studs to thin base metals, especially
where reverse side marking is not
permissible.Since the entire weld cycle is
completed in milliseconds

CD STUD WELD INSPECTION

(VISUAL)

ANY QUESTIONS?

QUESTIONS

Mr. Alam
In

slide 5, what is slag mean about?

Cooled flux that forms on top of the bead. Slag protects cooling metal
and is then chipped off.

Mr. Roya
What

is the function of flux?

1. Forming a protective environment,

2. Form a slag with specific properties.

3. Allows welding on the head and perpendicular.
4. Stabilize the arc.
5. Adding alloying elements to the main metal.
6. Purify metals metallurgy.
7. Reducing the filler metal splashes.
8. Improving the efficiency of the deposition.
9. Removes oxides and impurities.
10. affect the depth of penetration arc.
11. Affect the form of beads.
12. Slowing the rate of cooling the weld.
13. Adding a layer of weld metal from metal
powders in a protective coating

Mr. Aan

THANKS 4 YOUR ATTENTION