Republic of the Philippines
UNIVERSITY OF SCIENCE AND TECHNOLOGY OF SOUTHERN PHILIPPINES
Alubijid | Cagayan De Oro | Claveria | Jasaan | Oroquita | Panaon
COLLEGE OF TECHNOLOGY
Shielded Metal Arc Welding (SMAW)
WELDING PROCEDURES
Partial requirement for
MDF10 – MECHANICAL WORKSHOP PRACTICES
Presentors:
Bajarla, Jeremi O. Kabingue, Pamela Mae C.
Cabansay, Maresa B. Caingin, Joshua S.
Linao, Jonathan Dave S. Sarosa, Adonis W.
Ormillada, Robert M.
Presented to:
DOUGLAS KENT R. MAÑA
Faculty
November 7, 2019
Table of Contents
Starting Techniques ...................................................... 1
Scratch Start Technique .................................................... 1
Tapping Technique ........................................................... 2
Positioning of Electrode and Type of Weld .................. 3
Horizontal Position Welding ............................................... 4
Flat Position Welding ........................................................ 5
Vertical Position Welding ........................................... 6-7
Overhead Position Welding ........................................ 8-9
Method of Electrode Movement .................................. 10
Weld Bead .......................................................................10
Techniques .....................................................................11
Stringer Beads ....................................................... 11-12
Weave Beads ..............................................................12
Errors of Welding Beads .............................................. 13
Amperage ........................................................................14
Travel Speed....................................................................14
Arc Length .......................................................................14
WELDING PROCEDURES
1. Starting Techniques
Scratch Start Technique:
The scratch start technique is the easiest way to strike an arc.
It is similar to striking a match
The end of the electrode is simply scratched along the base metal to establish an arc.
When the arc has been established, the electrode is raised to established the correct arc length.
Reference:http://images.pcmac.org/SiSFiles/Schools/AL/LimestoneCounty/CareerTechincalCenter/Uploads/Presentat
ions/Chap_9-SMAW_Beads__Fillet_Welds.pptx
1
Tapping Technique:
The tapping technique is the best method is establishing an arc when using a transformer DC
welding machine
It is more difficult and takes more practice to perfect
The scratching technique leaves arc strikes on the base metal, which are not allowed by the
welding codes.
To strike an arc with the tapping technique, move the electrode quickly to the base metal,
lightly tap it, and then raise the electrode to establish the correct arc length.
Reference:http://images.pcmac.org/SiSFiles/Schools/AL/LimestoneCounty/CareerTechincalCenter/Uploads/Presentat
ions/Chap_9-SMAW_Beads__Fillet_Welds.pptx
2
2. Positioning of Electrode and Type of Weld
In all welding positions, consider the effect that gravity will have on the weld pool before
you begin. This is effectively a pool of molten metal so it will behave in a similar way to
other metals, so make sure you position yourself correctly to weld as safely and effectively
as possible.
*Note that not every electrode is right for each position. Check the manufacturer’s directions before proceeding
with any SMAW operation.
Four basic welding positions defined by the American Welding Society
Reference: https://weldguru.com/OLDSITE/welding-positions.html
https://weldinghelmetpros.com/smaw-stick-welding
3
Horizontal Position Welding
Horizontal weld can benefit from having backing plates and beveled edges, and in both
cases, you should hold the electrode at 90° to the metal that you’re working on.
Single Pass Bead Weld
When doing a horizontal weld, the welder needs to take account of distortion caused by
gravity. The issue with the horizontal welding is the distorting effect gravity will have on
the weld pool. If necessary or if it will help, tack weld a backing strip. Beveled edges can
also be of help.
When welding during the SMAW operation keep the electrode at 90 degrees to the weld.
Lean into the weld direction by 15 degrees.
Reference: https://weldguru.com/OLDSITE/SMAWOperation.html
https://weldinghelmetpros.com/smaw-stick-welding
https://www.wcwelding.com/welding-positions.html
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Flat Position Welding
When a butt weld is being made, the centerline of the welding wire should be directly over the
axis of the weld. A drag travel angle of between 5°–15° is correct for the backhand welding
method. Adjusting the travel angle to near zero reduced the penetration. A push travel angle,
which is forehand welding, can be used to further reduce or control the penetration.
Reference: https://www.wcwelding.com/welding-positions.html
http://www.halversoncts.com/99-welding-joints-in-the-flat-welding-position.html
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Vertical Position Welding
Vertical welds can also benefit from having backing plates and beveled edges, and in both
cases, hold the electrode at 90° to the metal that you’re working. The weld direction can move
from top to bottom or bottom to top. It is easier to weld in an upward direction. Use a tack
welded backing plate if needed and for thicker materials bevel the edges. Hold the electrode at
90 degrees to the material being welding.
Vertical Tee Joint Welding Diagram
Reference: https://weldguru.com/OLDSITE/SMAWOperation.html
https://weldinghelmetpros.com/smaw-stick-welding
https://www.wcwelding.com/welding-positions.html
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Be aware of the distorting effect of gravity. Weld the joint on both sides to
maximize strength. Use a weaving motion when traveling along the weld with
the electrode.
Lap Joint Weld Diagram
Reference: https://weldguru.com/OLDSITE/SMAWOperation.html
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Overhead Welding Position
Overhead welds can be slightly trickier in that you have to be careful of spatter and burns.
Once again, backing plates can help. For flat welds you should hold the electrode at 90° to
the base metal, but in any case, you should always try to tilt it slightly to prevent any drips
from falling onto your equipment.
Each Number Indicates the Location of Each Weld Pass. Note use of a backing plate. Slap must be
removed after each weld.
For an overhead weld the arc should be positioned slightly away and out from the crater.
Tack a weld backing plate and use beveled edges if necessary.
Reference: https://weldguru.com/OLDSITE/SMAWOperation.html
https://weldinghelmetpros.com/smaw-stick-welding
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Overhead Groove Joint Diagram
Overhead Tee Joint
Each Number Indicates the Location of Each Weld Pass. Note use of a backing plate. Slap must be
removed after each weld.
Reference: https://weldguru.com/OLDSITE/SMAWOperation.html
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3. Method of Electrode Movement
Stringer and Weaver Beads
A stringer bead is a weld bead that is made with very little or no side-to-side motion of the
electrode
The width of a stringer bead will vary with the electrode type.
A weave bead is a weld bead that is made with a side-to-side motion of the electrode.
The width of the weave bead is usually specified in the drawings, welding code, or welding
procedure specification (WPS).
Typically, the maximum width of a weave bead is 5 times the electrode diameter.
Reference:https://slideplayer.com/slide/1524961/5/images/2/Weld+Bead+A+weld+resulting+from+a+pass+String
er+Bead+Weave+Bead.jpg
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Stringer Beads
Practice running stringer beads in the flat position using 1/8 – 6010 electrodes
After striking the arc, the electrode axis should be a 10 to 15 degree drag angle in the direction
of travel for the weld and 90 degrees to the base metal.
The whipping motion, also called a stepping motion, can be used when depositing the stringer
bead to control the weld puddle.
The whipping motion is performed by moving the electrode up and forward about ¼”.
A short pause at the end of the backward travel deposits the weld metal.
By momentarily lengthening and advancing the arc, the molten weld pool is allowed to cool.
Lengthening the arc lowers the arc temperature and reduces the transfer from the rod core.
Advancing the arc preheats the base metal ahead of the weld and burns off contaminants.
Reference:https://slideplayer.com/slide/1524961/5/images/5/Techniques+Stringer+%28drag%29+%28whip%29+
Weave+Circles+crescent+zig+zag.jpg
http://images.pcmac.org/SiSFiles/Schools/AL/LimestoneCounty/CareerTechincalCenter/Uploads/Presentations/C
hap_9-SMAW_Beads__Fillet_Welds.pptx
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Stringer Bead Diagram
Weave Beads
The weave bead is made by moving the electrode back and forth.
Many different patterns can be used to make a weave bead, including:
circles, crescents, zigzags, box weaves, and double J
To ensure proper tie-in at the toes, slow down or pause slightly at the edges.
The pause at the edges will also flatten out the weld, giving is the proper profile.
Reference:http://images.pcmac.org/SiSFiles/Schools/AL/LimestoneCounty/CareerTechincalCenter/Uploads/Presentat
ions/Chap_9-SMAW_Beads__Fillet_Welds.pptx
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4. Errors of Welding Beads
Reference:https://www.millerwelds.com/resources/article-library/five-steps-to-improving-your-stick-welding-
technique
https://weldinghelmetpros.com/smaw-stick-welding
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Amperage
Here two points to discuss; too high current and too low current. How these high and low
ends of amperage range, affect your weld? Normally with low current settings, the outcome
is:
We get a convex shape weld.
Little penetration in plate.
Narrow weld bead.
Now if you go for with higher end of current range, to produce weld. In that case higher
current may lead to wider weld bead with a lot of spatter. So, the key to avoid this, try with
the moderate current value somewhere between low and high end of amps range.
Travel Speed
Traveling too slowly produces a wide, convex bead with shallow penetration and the
possibility of cold-lapping, where the weld appears to be simply sitting on the surface of the
material.
Excessively fast travel speeds also decrease penetration, create a narrower and/or highly
crowned bead, and possibly underfill or undercut, which is when the area outside of the weld
is concave or recessed. Note toward the end of the bead in the image below how the bead
appears inconsistent as if the puddle were trying to keep up.
Arc Length
One of the most important factors in arc welding, is the contact tip to work distance. We know
as the arc length increase; the voltage boosts up that causes the weld to spread and may
cause spatter. Here we will discuss both cases with too short of the arc length and too long
of the arc length:
So, making weld bead by keeping the electrode close to the joint or plate, the arc length gets
shortened. And convex look weld is obtained as an outcome. Remember in that case the
voltage is dropped because of the tight arc length.
While making the weld by holding the arc at the considerable distance, the voltage rises and
as a result the arc getting longer and wider.
Reference:https://www.weldpedia.com/2014/07/five-common-mistakes-in-stick-welding-and-their-solution.html
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