Grade

11

TVL-IA
SHIELDED METAL ARC WELDING
NCI

QUARTER II – Module 2-Week 2

WELD CARBON STEELPLATE USING SMAW

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 Set-up Welding Accessories

OBJECTIVES:
1. Identify welding cables/wires and other accessories based on functions
and uses.
2. Perform setting/connection of cables and other accessories in according
to manufacturer’s manual.

PREPARED BY:

WILMER J. DIRECTO
SHS-TEACHER

PRE-TEST
Multiple Choice
Directions: Read and analyze the statement carefully. Choose the best answer and write the letter only in
your answer sheet.
1. The prefix "E" designates.
a. Electron b. Electrode c. Electrode holder d. Electricity
2. Connects the current from welding machine to electrode which we use to weld the base metal.
a. Electron b. Electrode cable c. Electrode holder d. Electricity
3. Cable has a function for connecting current from machine to base metal, after that base metal and
electrode touch then will welding process is happening.
a. Massa cable b. Electrode cable c.Electrode holder d. Earth clamp
4. Is a clamping device for holding the electrode securely in any position.
a. Massa cable b. Electrode cable c. Electrode holder d. Earth clamp 5. The symbol E-6013; 60 means
a. Welding position b. Power supply c. Tensile strength d. Flux coating
6. The third digit in the symbol E-6013; 1 stands for
a. Tensile strength b. Welding position c. Flux coating d. Power supply
7. The third digit in the symbol E-6027; 2 stands for
a. Horizontal position b. Flat position c. Flat and horizontal d. All position
8. It has a deep, penetrating arc and is often the first choice for repair or maintenance work when DC is
unavailable.
a. E-6011 b. E-6010 c. E- 7018 d. E-6013
9. To connect the machine to the base metal.
a. Massa cable b. Electrode cable c. Electrode holder d. Earth clamp
10. As a filler metal, after the welding process finish then the electrode will
change be weld metal.
a. Electron b. Electrode c. Electrode holder d. Electricity

Introduction
All arc welding processes have a few basic requirements for their operation. They must
have a safe voltage available that is sufficient for the operator to get the arc started and be maintained. They also
require sufficient amperage to provide the heat for melting ofthe parent metal and filler material.
Arc welding processes have been a popular and widely applied method of welding for
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many years. They offer sound and reliable weld, simple operation and low capital cost.
Arc welding process overview
There are a lot of arc welding processes used in the metal fabrication and welding industries. Some of these
are commonly used and others are used in specialist applications. This section introduces some of the most
commonly used arc welding processes; which are:
1. Shielded metal arc welding (SMAW)
2. Gas metal arc welding (GMAW)
3. Flux cored arc welding (FCAW)
4. Submerged arc welding (SAW)
5. Gas tungsten arc welding (GTAW).
The Shielded Metal Arc Welding process has three type of polarity, the first is Alternating Current (AC),
Direct Current Revers Polarity (DCRP), and Direct Current Straight Polarity (DCSP). For machine type,
SMAW has three kinds current that is machine direct current (DC), the machine with alternating current
(AC), machines with a combination of direct current (DC) and alternating current (AC). You can look
proceshe American Welding Society (AWS) numbering system can tell a welder quite a bit about a specific
stick electrode including what application it works best in and how it should be used to maximize
performance. With that in mind, let's take a look at the system and how it works.

Shielded Metal Arc Welding Process (Wikipedia)

SMAW Welding can use for anything weld joint or welding position. Otherside we use this process for
underwater welding, but the tools must be complete again suitable for underwater welding procedure. If we
do not follow the procedure then can cause our accident, for example, electric shock or other accident types.

Advantages and Disadvantages SMAW Welding:

Advantages Shielded Metal Arc Welding:

 Can use to welding for all type joint.

 SMAW can use all welding position.
 We do not need gas for shielding the molten weld metal.
 Do not need much preparation before welding.

Disadvantages Shielded Metal Arc Welding:

 We must clean the slag after welding process is done.

 There are spatters.
 One electrode just can produce weld metal around ten to fifteen centimeters.
 The speed can not fast because we must change the electrode.

Shielded metal arc welding machine parts and procedure:

SMAW machine parts:

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1.Machine
Shielded Metal Arc Welding machine is the main parts of this process, because without machine certainly,
we cannot do welding process.

2.Electrode Cable
The function Electrode cable connects the current from welding machine to electrode which we use
to weld the base metal.

3.Massa Cable
Massa Cable has a function for connecting current from machine to base metal, after that base
metal and electrode touch then will welding process is happening.

4.Welding Power Source

Have to function for supply current from electrical source to welding machine.
5.Current Control
For control current output which uses for the welding process, big or little the current dependent form
type or thickness of material (base metal).
6. Electrode holder, commonly called a stinger, is a clamping device for holding the electrode securely in
any position. The welding cable attaches to the holder through the hollow insulated handle. The design of
the electrode holder permits quick and easy electrode exchange. Two general types of electrode holders
are in use: insulated and noninsulated.The noninsulated holders are not recommended because they are
subject to accidental short circuiting if bumped against the work- piece during welding. For safety reasons,
try to ensure the use of only insulated stingers on the jobsite. Electrode holders are made in different sizes,
and manufacturers have their own system of designation. Each holder is designed for use within a specified
range of electrode diameters and welding current. You require a larger holder when welding with a

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machine having a 300- ampere rating than when welding with a 100-ampere machine. If the holder is too
small, it will overheat.

7.Earth Clamp
To connect the machine to the base metal.

8.Switch
For on or off the welding machine.
9.Electrode
As a filler metal, after the welding process finish then the electrode will change be weld metal. The
electrode has a flux which the function is to protect steel melting when the welding process takes place.

ELECTRODES

In general, all electrodes are classified into five main groups:

1. Mild steel
2. High-carbon steel
3. Special alloy steel
4. Cast iron
5. Nonferrous

The widest range of arc welding is done with electrodes in the mild steel group.
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Electrodes are manufactured for use in specific positions and for many different types
of metal. They also are specially designed to use with ac or dc welding machines.
Some manufacturer's electrodes work identically on either ac or dc, while others are
best suited for flat-position welding. Another type is made primarily for vertical and
overhead welding, and some can be used in any position. As you can see, electrode
selection depends on many variables.
Types of Electrodes
Electrodes are classified as either bare or shielded. The original bare electrodes were
exactly as their name implied-bare. Today, they have a light covering, but even with
this improvement they are rarely used because of their limitations. They are difficult to
weld with, produce brittle welds, and have low strength. Just about all welding is done
with shielded electrodes.

The shielded electrode has a heavy coating of several chemicals, such as cellulose,
titania sodium, low- hydrogen sodium, or iron powder. Each of the chemicals in the
coating serves a particular function in the welding process. In general, their main
purposes are to induce easier arc starting, stabilize the arc, improve weld appearance
and penetration, reduce spatter, and protect

The prefix "E" designates an arc welding electrode. The first two digits of a 4-digit number and the first
three digits of 5-digit number indicate minimum tensile strength. For example, E6010 is a 60,000 psi tensile
strength electrode while E10018 designates a 100,000 psi tensile strength electrode.
E 60 1 10
Electrode Tensile Strength Position Type of Coating and Current
The next to last digit indicates position. The "1" designates an all position electrode, "2" is for flat and
horizontal positions only; while "4" indicates an electrode that can be used for flat, horizontal, vertical
down and overhead. The last 2 digits taken together indicate the type of coating and the correct polarity or
current to use. See chart below:

As a welder, there are certain electrodes that you will most likely see and use time and time again as you
go about your daily operations. A DC machine produces a smoother arc. DC rated electrodes will only run

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on a DC welding machine. Electrodes which are rated for AC welding are more forgiving and can also be
used with a DC machine. Here are some of the most common electrodes and how they are typically used:
E6010
DC only and designed for putting the root bead on the inside of a piece of pipe, this is the most
penetrating arc of all. It is tops to dig through rust, oil, paint or dirt. It is an all-position electrode that
beginning welders usually find extremely difficult, but is loved by pipeline welders worldwide
E6011
This electrode is used for all-position AC welding or for welding on rusty, dirty, less-than-new metal. It
has a deep, penetrating arc and is often the first choice for repair or maintenance work when DC is
unavailable.
E6013
This all-position, AC electrode is used for welding clean, new sheet metal. Its soft arc has minimal
spatter, moderate penetration and an easy-to-clean slag.
E7018
A low-hydrogen, usually DC, all-position electrode used when quality is an issue or for hard-to-weld
metals. It has the capability of producing more uniform weld metal, which has better impact properties at
temperatures below zero.
E7024
Typically used to make a large weld down hand with AC in plate that is at least ¼" thick, but more
commonly used for plate that is ½" and up.
Other Electrodes
Although not nearly as common, an electrode may have additional numbers after it such as
E8018-B2H4R. In this case, the "B2" indicates chemical composition of the weld metal deposit.
The "H4" is the diffusible hydrogen designator, which indicates the maximum diffusible hydrogen level
obtained with the product. And "R" stands for the moisture resistant designator to indicate the electrode's
ability to meet specific low moisture pickup limits under controlled
humidification tests.

Electrode Selection Guide

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Multiple Choice
Directions: Read and analyze the statement carefully. Choose the best answer and write the letter only in
your answer sheet.
1. The prefix "E" designates.
a. Electron b. Electrode c. Electrode holder d. Electricity
2. Connects the current from welding machine to electrode which we use to weld the base metal.
a. Electron b. Electrode cable c. Electrode holder d. Electricity
3. Cable has a function for connecting current from machine to base metal, after that base metal and
electrode touch then will welding process is happening.
a. Massa cable b. Electrode cable c.Electrode holder d. Earth clamp
4. Is a clamping device for holding the electrode securely in any position.
a. Massa cable b. Electrode cable c. Electrode holder d. Earth clamp 5. The symbol E-6013; 60 means
a. Welding position b. Power supply c. Tensile strength d. Flux coating
6. The third digit in the symbol E-6013; 1 stands for
a. Tensile strength b. Welding position c. Flux coating d. Power supply
7. The third digit in the symbol E-6027; 2 stands for
a. Horizontal position b. Flat position c. Flat and horizontal d. All position
8. It has a deep, penetrating arc and is often the first choice for repair or maintenance work when DC is
unavailable.
a. E-6011 b. E-6010 c. E- 7018 d. E-6013
9. To connect the machine to the base metal.
a. Massa cable b. Electrode cable c. Electrode holder d. Earth clamp
10. As a filler metal, after the welding process finish then the electrode will
change be weld metal.
a. Electron b. Electrode c. Electrode holder d. Electricity

REFERENCES:
1.CBLM, TESDA
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2.Welding Technology, Second Edition by Gower A. Kennedy
3. Welding Inspection Technology, Education Department, American welding Society
4.Welding Principles and Application by Larry Jeffus and Harold V. Johnson