This document provides safety precautions and instructions for shielded metal arc welding (SMAW). It discusses hazards of electric shock, fumes, arc rays, fire and explosions, and flying metal. It also covers principles of SMAW, electrode and amperage selection, techniques for striking an arc and electrode movement, factors that affect weld bead shape, and examples of good and poor welds. Symbols used in welding are explained.

1. Manufacturing
Practice 2
J 4121

2. SECTION 1 − SAFETY PRECAUTIONS
1-1. Symbol Usage

3. 1-2. Arc Welding Hazards
ELECTRIC SHOCK can kill.
FUMES AND GASES can be hazardous.
ARC RAYS can burn eyes and skin.

4. WELDING can cause fire or explosion.
FLYING METAL can injure eyes.

5. CYLINDERS can explode if damaged.

6. 1-3. Additional Symbols For Installation,
Operation, And Maintenance

9. SECTION 2 − PRINCIPLES OF SHIELDED METAL ARC
WELDING (SMAW)
• Shielded Metal Arc Welding (SMAW) or Stick welding is a process which
melts and joins metals by heating them with an arc between a coated
metal electrode and the workpiece. The electrode outer coating, called
flux, assists in creating the arc and provides the shielding gas and slag
covering to protect the weld from contamination. The electrode core
provides most of the weld filler metal.

11. SECTION 3 − SHIELDED METAL ARC WELDING (SMAW)
PROCEDURE

13. 3-2. Electrode And Amperage Selection Chart
• Electrode
E6010
E 60 1 "10"
Electrode Tensile strength Position Type of Coating and Current
Digit Type of Coating Welding Current
10 High cellulose sodium DC+
11 High cellulose potassium AC or DC- or DC+
12 High titania sodium AC or DC-
13 High titania potassium AC or DC+
14 iron powder titania AC or DC- or DC+
15 low hydrogen sodium DC+
16 low hydrogen potassium AC or DC+
27 iron powder iron oxide AC or DC- or DC+
18 iron powder low hydrogen AC or DC+
20 High iron oxide AC or DC- or DC+
22 High iron oxide AC or DC-
24 iron powder titania AC or DC- or DC+
28 Low hydrogen potassium iron powder AC or DC+

16. 3-3. Striking An Arc − Scratch Start Technique

17. 3-4. Striking An Arc − Tapping Technique

18. 3-5. Positioning Electrode Holder

20. 3-6. Electrode Movement During Welding

21. 3-7. Conditions That Affect Weld Bead Shape

23. 3-8. Poor Weld Bead Characteristics

24. 3-9. Good Weld Bead Characteristics

25. 3-10. Typical Weld Joints

26. 3-11. Welding Butt Joints

27. 3-14. Welding Butt Joints
30⁰ 30⁰
Single Pass Flat Butt Joint Weld Or
First Pass Of Multi-Layer Deposit

29. 3-18. Weld Test

30. SECTION 4 − WELDING TROUBLESHOOTING

34. SECTION 5 - SYMBOLS
• The structure of the welding symbol