2 © 2012 Delmar, Cengage Learning Chapter 3 Shielded Metal Arc Welding, Setup, and Operation
Mar 31, 2015
2 © 2012 Delmar, Cengage Learning
Chapter 3
Shielded Metal Arc Welding, Setup, and Operation
2 © 2012 Delmar, Cengage Learning
Objectives
• Describe the process of shielded metal arc welding (SMAW)
• List and define the three units used to measure a welding current
• Tell how adding chemicals to the coverings of the electrodes affects the arc
• Discuss the three different types of current used for welding
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Objectives (cont'd.)
• Explain the types of welding power supplies and which type the shielded metal arc welding process requires
• Define open circuit voltage and operating voltage• Explain arc blow, what causes it, and how to
control it• Tell what the purpose of a welding transformer is
and what kind of change occurs to the voltage and amperage with a step-down transformer
2 © 2012 Delmar, Cengage Learning
Objectives (cont'd.)
• Compare generators and alternators• Tell the purpose of a rectifier• Read a welding machine duty cycle chart and
explain its significance• Demonstrate how to determine the proper welding
cable size• Demonstrate how to service and repair electrode
holders
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Objectives (cont'd.)
• Discuss the problems that can occur as a result of poor work lead clamping
• Describe the factors that should be considered when placing an arc welding machine in a welding area
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Introduction
• Shielded metal arc welding (SMAW) – A flux-covered metal electrode carries current
• SMAW is a widely used welding process– Low cost
– Flexible
– Portable
– Versatile
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Welding Current and Electrical Measurement
• Electric current– Source of heat
– Flow of electrons
• Units used to describe electrical current– Voltage: measurement of electrical pressure
– Amperage: total number of electrons flowing
– Wattage: measurement of electrical energy or power in the arc
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FIGURE 3-2 Electrons traveling along a conductor. © Cengage Learning 2012
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FIGURE 3-3 Ohm’s law. © Cengage Learning 2012
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SMA Welding Arc Temperature and Heat
• Temperature– Degree or level of energy in a material
– Measured in degrees with a thermometer
• Heat – Quantity of energy in a material
– Cannot easily be measured
– Determined by knowing temperature and object mass
• Temperature of a welding arc – Dependent on voltage, arc length, and atmosphere
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Types of Welding Currents
• Three types of current used for arc welding– Alternating Current (AC)
– Direct-current electrode negative (DCEN)
– Direct-current electrode positive (DCEP)
• Some electrodes can used with only one type of current– Others can be used with two or more
• Each current has a different effect on the weld
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Types of Welding Power
• Welding power can be supplied as:– Constant voltage (CV)
• Arc voltage remains constant
– Rising arc voltage (RAV) • Arc voltage increases as amperage increases
– Constant Current (CC) • Total welding current remains the same
• Shielded metal arc welding – Requires a constant current arc voltage
characteristic
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Open Circuit Voltage
• Voltage at the electrode before striking an arc– Usually between 50 V and 80 V
• Higher open circuit voltage– Easier to strike an arc
– Maximum safe open circuit voltage for welders is 80 volts
• High voltage increases chance of electrical shock
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Operating Voltage
• Voltage at the arc during welding– Also called welding or closed circuit voltage
• Will vary with:– Arc length
– Type of electrode
– Type of current
– Polarity
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Arc Blow
• Electrons flow – Create lines of magnetic force that circle around the
path of flow called magnetic flux lines• These lines space themselves evenly along a
current-carrying wire
• Arc blow– Movement of the arc
– Makes arc drift like a string would drift in the wind
– More of a problem when magnetic fields are the most uneven
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Figure 3-13 Magnetic forces concentrate around bends in wires.
© Cengage Learning 2012
2 © 2012 Delmar, Cengage Learning
Types of Power Sources
• Electrical devices used – Electric motors or internal combustion engines
– Step-down transformers
• Welding transformers – Use high-voltage AC to produce low-voltage
welding power
• Step-down transformers – Takes high voltage, low amperage current and
turns it into low voltage, high amperage current
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Figure 3-17 Diagram of a step-down transformer.
© Cengage Learning 2012
2 © 2012 Delmar, Cengage Learning
Types of Power Sources (cont'd.)
• Multiple-coil machine – Allows the selection of different current setting
• Movable coil or core – Has high and low current
– Handwheel moves internal parts
– Closer coils: greater current
• Inverter welding machines– Smaller, but with same amperage range
– Power changed to thousands of cycles per second
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Generator and Alternator Type Welders
• Both produce welding electricity– Alternator: magnetic lines of force rotate inside a
coil or wire• Produces AC only
– Generators: welding current is produced on the armature and is picked up with brushes
• Produces DC
– Portable engine-driven welders • Require more maintenance
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Figure 3-27 Schematic diagram of an alternator.
© Cengage Learning 2012
2 © 2012 Delmar, Cengage Learning
Figure 3-28 Diagram of a generator.
© Cengage Learning 2012
2 © 2012 Delmar, Cengage Learning
Converting AC to DC
• Alternating current can be converted to direct current by using a series of rectifiers– Current flows in one
direction only
• Rectifiers become hot as they change AC to DC– Heat reduces power
efficiency
FIGURE 3-33 Typical dial on an AC-DC transformer rectifier welder. © Cengage Learning 2012
2 © 2012 Delmar, Cengage Learning
Duty Cycle
• Welding machines – Produce internal heat as they produce the welding
current
• Duty cycle– Percentage of time a welding machine can be used
continuously• 60% duty cycle: machine can operate six minutes out
of every ten at maximum rated current
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Figure 3-34 Duty cycle of a typical shielded metal arc welding machine. © Cengage Learning 2012
2 © 2012 Delmar, Cengage Learning
Welding Cables
• Characteristics– Must be flexible, well insulated, and the correct size
– Most are made of standard copper wire
– Only specially manufactured insulation should be used for welding cable
– Electrode cable and work cable must be the correct size
– A whip-end cable must not be over ten feet long
– Splice in a cable should not be within ten feet of the electrode
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Electrode Holders
• Characteristics– Should be of proper amperage rating and in good
repair
– Designed to be used at their maximum amperage rating or less
– Holder overheats and burns at higher amperage values
– Large holders are hard to manipulate
– Never dip a hot electrode holder in water to cool
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Work Clamps
• Characteristics– Must be the correct size for the current
– Must clamp tightly to the material
– Clamp should be carefully touched occasionally to find out if it is getting hot
– A loose clamp may cause arcing• May damage a part
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Equipment Setup
• Arc welding machines – Should be located near the welding site
• Far enough to avoid spark showers
– Machines can be stacked to save space
– Ensure each machine has sufficient air circulation
– Keep away from cleaning tanks and corrosive fumes
– Water leaks must be fixed and puddles cleaned up before a machine is used
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Equipment Setup (cont'd.)
– Power shutoff must be easy to reach in an emergency
– Machine case or frame must be grounded
– Cables should not be placed on the floor
– Work station must be free of combustible materials
– Cable should never be wrapped around the body or tied to scaffolding or ladders
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Summary
• Understanding electricity and magnetism – Aids in understanding welding currents
• Failure to control arc blow – Can result in weld failures
• Check equipment manufacturer's safety guidelines– Proper operation and maintenance
• Keeping work area clean and orderly – Helps prevent accidents