SMAW ADVANTAGES AND DISADVANTAGES
SMAW is often used for repairs and maintenance, steel construction, and industrial fabrication. It is a common welding process because of its
simplicity, versatility, and affordability. SMAW equipment is portable, so welders can work directly on job sites and in challenging environments,
including areas that are small or difficult to reach. Unlike other welding processes, welders can perform SMAW outside and on different metals
and alloys, including both ferrous and nonferrous metals.
However, SMAW also has disadvantages. For example, it is not a fast process. The welder must constantly change the electrode, which
causes stops and starts that may lead to discontinuities. In addition, SMAW cannot use higher current levels, which also lessens productivity.
SMAW EQUIPMENT
SMAW requires several different pieces of equipment. The most basic components include a constant current (CC) power
source, an electrode cable and electrode holder, a work cable and work clamp, an electrode, and a workpiece.
A constant current power source allows the current level, or amperage, to remain steady throughout welding, even
when voltage changes. The electrode holder keeps the electrode in place and provides an electrical connection from the power
source to the electrode. The work cable and work clamp connect the power source to the workpiece or worktable so
the circuit can be completed. The electrode consists of flux-covered filler metal. The flux protects the conductor at the center of
the electrode. The electrode allows the welder to strike the arc and forms the welding bead. The electrode also determines the
welding polarity.
ELECTRODE COMPOSITION
Electrodes used for SMAW processes have cores made from metal rods that serve as current conductors and filler metals. Each
rod contains alloys with properties similar to those of the base metals and a chemical mixture, often
including carbon and manganese, that strengthens the joint. SMAW electrodes also have a chemical coating known as flux that
is typically composed of materials such as manganese, calcium, and silicon. Flux creates a protective gas that shields the weld
pool from damaging oxygen, nitrogen, and other atmospheric gases. Flux also removes impurities from the base metals and
helps to stabilize the arc.
During the welding process, calcium and silicon from the flux float to the top of the cooling weld bead and form slag. Slag
protects the weld bead and aids in the cooling process. Welders must remove slag with a chipping hammer, or scaling
hammer, to achieve the desired finish on a weld.
The electrode numbering system identifies electrodes with a letter and either four or five digits that may be followed
by a hyphen and additional characters.
The characters before the hyphen indicate the following electrode characteristics:
• The “E” stands for “electrode.”
• The first two numbers on a four-digit label and the first three numbers on a five-digit label indicate the tensile
strength of the welds the electrode is capable of creating. An electrode can produce welds with a minimum tensile
strength that is equal to or greater than these numbers multiplied by 1,000.
• The third number on a four-digit label and the fourth number on a five-digit label indicate the position in which a welder
can use the electrode. A “1” indicates any position, a “2” indicates flat- or horizontal-position welding only, and a “3”
indicates flat-position only.
• The fourth number on a four-digit label and the fifth number on a five-digit label indicate the type of coating on the
electrode. The coating also affects the amount of penetration the weld will achieve and the recommended current and
polarity to be used. Electrode manufacturers offer charts or handbooks that identify the significance of the fourth and
fifth digits.
Digits or letters after the hyphen supply welders with additional details about the electrode's properties and composition.
• A "1" directly after the hyphen indicates that the electrode has an improved impact rating.
• An “H” followed by a number indicates the amount of hydrogen content in the rod.
• An “R” indicates that the electrode is moisture resistant.
