Equipment Used in Shielded Metal Arc Welding: The Guide

Shielded Metal Arc Welding (SMAW) is a popular welding process in use today, and it is widely employed all over the world. It’s a weld-forming method that uses a flux-coated electrode. The flux created by electricity leaving the electrode forms a gas, which shields the electric arc in the vicinity.  It takes place between the metal getting fused and the electrode, protecting the weld from getting contaminated by ambient gasses.

SMAW is among the earliest and simplest welding techniques. Emerging technology is continually upgrading processes and making them more efficient.

Five Critical Equipment Used in Shielded Metal Arc Welding

 

1. Arc welding machine

An arc welding machine is a vital piece of equipment that you should definitely spend on. A welding machine generates the electric current required for welding. You’ll also need to ensure you have enough time to use your equipment. Furthermore, understanding the duty cycle of the machine, voltage power, and AC/DC settings are critical for completing your welds.

Usually, welding machines are classified into two types-

• Constant current (CC) welding machines
• Continuous voltage (CV) welding machines

Furthermore, each kind of welding necessitates a distinct skill level. However, the type of welding you require has a lot to do with affordability and mobility.

2. Power source

The SMAW power supply has a consistent current output. Even if the arc distance and voltage fluctuate, it assures that the current and heating remain roughly constant. It is required since most SMAW applications are mechanical. Maintaining a sufficient, stable arc distance becomes problematic if a constant voltage power source is employed. The current, however, is not kept steady. Expert welders executing complicated welds can divert the arc length, causing slight current fluctuations.

A welding transformer, a DC motor-generator set, or a DC rectifier can be used as the SMAW power source. The equipment chosen is determined by the amount of initial investment and the variety of materials to be worked.

3. Electrodes

Electrodes are terminals that go into one end of a welding tool. Then, an electric current gets directed into the material from the power source. You may need distinct electrodes for multiple processes depending on the type of welding you perform.

Presently, a variety of welding electrodes are available that are best fit for various conventional welding techniques. If you consider SMAW to make the weld joint, you’ll need a consumable electrode that would melt.

4. Oxy-Acetylene setup

When you first initiate welding, you should ensure having an oxy-acetylene setup. Oxy-acetylene can be used in several welding processes, including pre-heating, tempering, forming, hardening, bending, cutting, etc. 

Using an oxy-acetylene setup would give you the necessary command over the heat. You’ll also become more comfortable handling the shape and size of the beads used to connect your metal components.

Welders can use oxy-acetylene to achieve more accurate welds. This configuration provides the welder with a great deal of control. The use of an oxy-acetylene heat intake enables the welder to be precise when working with this high-temperature flame. Furthermore, this equipment is incredibly economical and will provide you with portability when welding.

5. Electrode holder and cables

An electrode holder allows you to fasten the end of your electrode with copper built right into the holder’s head. The shoes in the head area are then linked together utilizing a spring-loaded process or a twist grip. The clamping apparatus that is holding the electrode releases the stub end instantly.

To ensure the procedure’s efficiency, the electrode must remain clamped into the holder. If the electrode doesn’t remain clamped into your holder, you’ll end up having a suboptimal electrical current, which might cause your arc to become unsteady and fluctuate. 

The current-carrying cables in a welding circuit are highly flexible and often made of thin (0-2 mm diameter) copper or aluminum wires. Also, cable connectors are used to extend the length of welding leads. They must be of sufficient size to transmit the specified current and must fit perfectly to avoid voltage drops.

Five Applications of Shielded Metal Arc Welding

The SMAW technique can be employed for a wide range of metal classes and thicknesses. Typically, it is utilized for heavy-duty industrial iron and steel applications such as cast iron, carbon steel, and nickel alloys. SMAW finds its applications in numerous sectors, including-

• Underwater welding
• Shipbuilding
• Construction
• Farm machinery manufacturing
• Pipelines
• Pressure vessels
• Industrial fabrication

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Conclusion

You should now possess a good notion of the equipment and supplies you’ll need to get started with Shielded Metal Arc Welding. It will assist you in producing high-quality, defect-free welds.

About the Author:

Peter Jacobs

Peter Jacobs is the Senior Director of Marketing at CNC Masters. He is actively involved in manufacturing processes and regularly contributes his insights to various blogs on CNC machining, 3D printing, rapid tooling, injection molding, metal casting, and manufacturing in general.