Shielded Metal Arc Welding Principles: Chapter Objectives
Shielded Metal Arc Welding Principles: Chapter Objectives
Shielded Metal Arc Welding Principles: Chapter Objectives
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Welding Machine AC or DC Electrode
Electrode Coating Power Source and Controls Holder
Core Wire
Shielding Atmosphere Electrode
Arc Pool
Arc Stream Arc
Solidified Slag
Penetration Depth
Base Metal
Work Cable Work
Solidified Weld Metal
Electrode Cable
Fig. 11-1 Schematic representation of the shielded metal arc.
Adapted from AWS Standard Terms and Definitions, AWS3.0:2010, page 12 Fig. 11-2 Elements of a typical electric circuit for shielded metal
arc welding. Adapted from Welding Handbook, 9/e.
Voltage (Volts)
when used with the power source designed for it. Each
type of power source has certain fundamental electri- 60
Constant
current
Generators Transformer-types
Constant
voltage
Generators
Constant Constant
current6 voltage
d.c.
Engine-driven
generator
Adjustable slope Transformer types
and/or inductance
Spray Spray
Globular4 Globular4 Spray
Short circuiting5 Globular4
Short
circuiting5
Pulse
Fig. 11-4 Common types and uses of arc welding machines.1 Source: Republic Steel Co.
Constant Constant
current6 voltage
The a.c. can be used only on single-phase line power. The d.c. is most commonly used on three-phase power, except for most a.c.-d.c. units.
2
Inductance usually added. Some shorting-arc machines have a fixed slope set at a steeper angle with adjustment made by varying the
5
inductance.
Used with voltage-sensing control and variable speed wire-fed unit.
6
100
Machines for Shielded Metal
Maximum OCV
ArcWelding
Engine-Driven Generator Welding
Machines
Generators are classified by the type of engine that
A drives the generator. The common generator welding
machine consists of a hydraulic or internal combustion
VoltageVolts
Controls of the Engine-Driven Generator Dual Tapped-Current Control On generators with fixed current
steps, the coarse adjustment dial selects the current range,
Start and Stop Controls These controls are for the pur- called steps or taps. It is impossible to secure a current value
pose of starting and stopping the engine that drives the between two steps by setting the dial between them. The dial
generator of the welding machine. must be set squarely on the desired step to prevent burning
out the control device and taps.
Polarity Switch Electrode negative and electrode positive
The fine adjustment dial trims the current between the
are used in d.c. welding. When welding with d.c. electrode
steps. Whether the fine adjustment dial is to be set high
negative (DCEN), the electrode is connected to the nega-
or low depends on the type and size of the electrode, the
tive terminal of the power source, and the work is connected
thickness of the metal, whether a soft or digging arc is
to the positive terminal. When welding with d.c. electrode
required, the arc starting, any restricting characteristics,
positive (DCEP), the electrode is connected to the positive
and the position of welding.
terminal of the power source, and the work is connected to
the negative terminal. Dual Control In constant current or constant voltage gen-
The polarity switch (if provided) changes to either elec- erators with dual control, the coarse adjustment switch
trode positive or electrode negative. This controls the di- adjusts current. (Some manufacturers refer to the coarse
rection of current flow. In the electron theory it is said to adjustment dial as the job selector, mode switch, or elec-
flow from negative to positive. trode selector.)
The fine dial adjusts the current (amperage) or the volt-
Volt-Ampere Meters Meters sometimes serve a dual pur- age. The operator adjusts the output slope/inductance-dig for
pose. On some machines they indicate polarity as well as a given current setting by manipulating both the coarse ad-
current values in volts and amperes. Some machines have justment switch and dig/inductance control dial.
individual meters for volts and amperes. Others have sin- A wheel or knob on both the amperage and the voltage
gle meters that indicate both the volt and ampere readings. setting devices gives the welder continuous control of both
A switch or button must be engaged to obtain individual the amperage and voltage ratings. This separate, complete
readings on a combination volt-ampere meter. In order control of both voltage and amperage makes it possible to
to obtain a true indication of the volt and ampere values set up any volt-ampere combination within the output range
being used, the welder must have some other person check
of the particular machine being usedfrom minimum volt-
the meters while he or she is welding. Digital meters such
age at minimum current to maximum voltage at maximum
as these will hold the display for 3 seconds after the arc
current. Thus, a welding arc having various characteristics
is broken.
may be secured.
Current Controls The student will better understand the Remote Control Welding machines may be obtained that
function of the current controls if he or she keeps in mind are equipped with remote-control, current-control units.
that the ampere rating can be compared with the amount The welding machine may be installed in any remote
of water flowing through a pipe. Amperage is the quantity location, and the welder may adjust the current without
of current and determines the amount of heat produced leaving the welding work site. This is timesaving on work
at a weld. Voltage is like pressure behind the water in the where it is necessary for the welder to leave the fabrication
pipe. It is a measure of the force of the current. Voltage to readjust current.
determines the ability to strike an arc and maintain its
consistency. If voltage is too high, the arc is too harsh and Air Filters Wear in arc welding machines is costly since
may produce arc blow. On the other hand, if it is too low, it necessitates not only the cost of replacement parts and
it is very difficult to maintain the arc. labor, but also the loss of production due to nonuse of the
Dual control welding generators provide a wide range machine. Bearing and engine wear is critical and may be
of welding current selection and make it possible to pro- reduced through the use of air filters. The filter is replaced
vide precise heat values. Good arc control is possible or cleaned regularly with high pressure air, a commercial
because the output slope of the welding machine can be solvent, or steam.