International Journal of

Emerging Research in Management &Technology Research Article June

ISSN: 2278-9359 (Volume-4, Issue-6) 2015

Analyzing the Effect of Parameters on SMAW Process

Vijayesh Rathi Hunny
Assistant Prof. (ME Dept.), GIMT, M.Tech Scholar (ME Dept.), GIMT,
Kanipla, India Kanipla, India

Abstract--

S
hielded metal arc welding (SMAW) is an AW process that uses a consumable electrode consisting of a filler
metal rod coated with chemicals that provide flux and shielding. This process provides a purer and cleaner
high volume weldment that has a relatively a higher material deposition rate compared to the traditional
welding welding methods. The effect of controllable process variables on the heat input and the microhardness of
weld metal and heat affected zone (HAZ) are calculated and analysed.The main purpose of present work is to
investigate and correlate the relationship between various parameters and microhardness. It is found that the
microhardness of weld metal and heat affected zone increased when low heat input is employed.

Keywords---SMAW, HAZ, AW, MMA, microhardness.

I. INTRODUCTION
Welding is the most reliable, efficient and practical metal joining process which is widely used in industries such as
nuclear, aerospace, automobile, transportation, and off-shore. In spite of the many advantages, there are some limitations
affecting this process. Welding is often done by melting the work pieces and adding a filler material to form a pool of
molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with
heat, or by itself, to produce the weld. This is in contrast with soldering and brazing, which involve melting a lower-
melting-point material between the work pieces to form a bond between them, without melting the work pieces. [5]

Figure 1:Various parts of welding arc.

1.1. Shielded metal arc welding process (SMAW)

Shielded-Metal Arc Welding (SMAW) is one of the oldest, simplest and most versatile arc welding processes. The arc is
generated by touching the tip of a coated electrode to the work piece and withdrawing it quickly to an appropriate
distance to maintain the arc. The heat generated melts a portion of the electrode tip, its coating and the base metal in the
immediate area. The weld forms out of the alloy of these materials as they solidify in the weld area. Slag formed to
protect the weld against forming oxides, nitrides, and inclusions. Welding can be carried out in all positions, both in shop
and at site. Welded joints of sound quality and adequate mechanical properties can be obtained by using correctly
designed electrodes and proper welding procedures. The process is intermittent, because welding has to be interrupted
from time to time to discard the unused stub and to place afresh electrode into the holder and also to deslag the joint, i.e.
to remove the layer of slag covering the weld. For higher productivity, semi-automatic or fully-automatic welding
processes are preferred.
Shielded metal arc welding (SMAW), also known as manual metal arc welding (MMA or MMAW), flux shielded arc
welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode covered with a
flux to lay the weld

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 Rathi et al., International Journal of Emerging Research in Management &Technology
ISSN: 2278-9359 (Volume-4, Issue-6)

Figure 2:SMAW

Multipass welding is often employed with the submerged arc process. When plate thicknesses exceed the limitation of
two pass techniques, or where inability to provide accurate joint fit-up prevents the use of high current - multiple pass
submerged arc welding should be used. Where possible, a split pass procedure should be used to allow easy flux removal
and to prevent weld cracking. Each weld pass should be slightly convex as shown to assist in slag removal and
preventing weld cracking. Multipass welding procedures also enable a variety of weld joints and plate thicknesses to be
welded with the same procedures and materials. In certain base materials, the multiple pass welding technique must be
used to maintain adequate properties in the base HAZ.For pressure vessel circumferential welds such as head-to-shell and
shell butts, this double bevel plate preparation with semiautomatic or automatic Mig used to handle varying fit-up in the
root area is an excellent combination procedure. Fill passes are then welded with submerged arc to provide consistent
quality low cost welds. The gas metal-arc welding process is the best choice for manual or automatic root or first pass
procedures. The resulting weld metal is free from internal slag and external slag is minimal making the subsequent
submerged arc welds free from defects. For welding plates above two inches thick, multipass procedures must be used.
Welding flux and wire must be selected with multipass procedures in mind. Control of weld chemistry is especially
important to insure crack free deposits.

1.2 Problems associated with SMAW

The most common quality problems associated with SMAW include
1) weld spatter,
2) porosity,
3) poor fusion,
4) shallow penetration, and
5) cracking.

Weld spatter, while not affecting the integrity of the weld, damages its appearance and increases cleaning costs. It can
be caused by excessively high current, a long arc, or arc blow, a condition associated with direct current characterized by
the electric arc being deflected away from the weld pool by magnetic forces.
Porosity, Arc blow can also cause porosity in the weld, as can joint contamination, high welding speed, and a long
welding arc, especially when low-hydrogen electrodes are used. Porosity, often not visible without the use of advanced
non destructive testing methods, is a serious concern because it can potentially weaken the weld.
Poor Diffusion Another defect affecting the strength of the weld is poor fusion, though it is often easily visible. It is
caused by low current, contaminated joint surfaces, or the use of an improper electrode.
Shallow penetration, another detriment to weld strength, can be addressed by decreasing welding speed, increasing the
current or using a smaller electrode.
Cracking, Any of these weld-strength-related defects can make the weld prone to cracking, but other factors are involved
as well. High carbon, alloy or sulphur content in the base material can lead to cracking, especially if low-hydrogen
electrodes and preheating are not employed. Furthermore, the work pieces should not be excessively restrained, as this
introduces residual stresses into the weld and can cause cracking as the weld cools and contracts.

1.3. Application and materials

Shielded metal arc welding is one of the world's most popular welding processes, accounting for over half of all welding
in some countries. Because of its versatility and simplicity, it is particularly dominant in the maintenance and repair
industry, and is heavily used in the construction of steel structures and in industrial fabrication. In recent years its use has
declined as flux-cored arc welding has expanded in the construction industry and gas metal arc welding has become more
popular in industrial environments. However, because of the low equipment cost and wide applicability, the process will
likely remain popular, especially among amateurs and small businesses where specialized welding processes are
uneconomical and unnecessary.

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 Rathi et al., International Journal of Emerging Research in Management &Technology
ISSN: 2278-9359 (Volume-4, Issue-6)
SMAW is often used to weld carbon steel, low and high alloy steel, stainless steel, cast iron, and ductile iron. While less
popular for nonferrous materials, it can be used on nickel and copper and their alloys and, in rare cases, on aluminium.
The thickness of the material being welded is bounded on the low end primarily by the skill of the welder, but rarely does
it drop below 0.05 in (1.5 mm). No upper bound exists: with proper joint preparation and use of multiple passes,
materials of virtually unlimited thicknesses can be joined. Furthermore, depending on the electrode used and the skill of
the welder, SMAW can be used in any position.

II. RELATED STUDY

S. Murugan et al (1998) studied that the temperature distribution occurs during multipass welding of 6,8 and 12mm
thick plates affects the material microstructure, hardness, mechanical properties and the residual stresses that will be
present in the welded material. Experimental work was carried out to find out the temperature distribution during
multipass welding of the above plates. From the multipass welding of plates the maximum temperature was estimated
during different passes of weld and from the knowledge of maximum temperature, the likely changes in microstructure
and degradation in mechanical properties are estimated. Average maximum temperature rise during each pass of welding
is calculated and plotted against the distance from the weld pad centre line.
S. Murugan et al (2001) investigates the temperature distribution and residual stresses due to multipass welding in type
304 stainless steel and low carbon steel weld pads .The literature work reports the effect of weld pad thickness on
residual stress in which the author conclude that the peak tensile residual stresses in 6,8mm stainless steel weld pads are
close to each other whereas in12 mm weld pad the value is slightly less and with the no. of passes ,the peak tensile
residual stress gradually reduce in magnitude on the root side and gradually increase in magnitude on the top side of weld
pads.
G. Magudeeswaran et al (2007) studied the effect of Welding Processes and Consumables on Tensile and Impact
Properties of High Strength Quenched and Tempered Steel Joints. In this investigation, an attempt was made to
determine a suitable consumable to replace expensive austenitic consumables. Two different consumables , namely,
austenitic stainless steel and low hydrogen ferritic steel, were used to fabricate the joints by shielded metal arc welding
(SMAW) and flux cored arc welding (FCAW) processes. The experimental work shows that the joints fabricated by
using low hydrogen ferritic steel consumables showed superior transverse tensile properties, whereas joints fabricated by
using austenitic stainless steel consumables exhibited better impact toughness, irrespective of the welding process used.
The SMAW joints exhibited superior mechanical and impact properties, irrespective of the consumables used, than their
FCAW counterparts.
Subodh Kumar et al (2011) studied the effect of heat input on the microstructure and mechanical properties of gas
tungsten arc welded AISI 304 stainless steel joints in which the dendrite size in the fusion zone is smaller in low heat
input joints than the dendrites in medium and high heat input joints, it is found that maximum tensile strength and
ductility is possessed by the weld joints made using low heat input. Near to the fusion boundary the size of the grains in
the HAZ of the joints is found to be relatively coarser at high heat input and finer at low heat input. The results of the
investigation indicate that the joints made using low heat input exhibited higher ultimate tensile strength (UTS) than
those welded with medium and high heat input by using GTAW process.
Andrés R et al (2011) predicted the Characterization of failure modes for different welding processes of AISI/SAE 304
stainless steels. In the study the weld joints manufactured with a welding electrode type 308L by three different arc
welding processes shielded metal arc welding (SMAW), gas metal arc welding (GMAW) and flux cored arc welding
(FCAW) in a AISI/SAE 304 were studied in order to compare the failure mechanisms associated with their mechanical
and micro structural properties. Chemical compositions were analyzed by optical emission spectroscopy and the ferrite
numbers (FN) of the welds were also identified. Relevant micro structural characteristics of the different processes were
analyzed by microscopy techniques. Finally, fatigue tests were performed to study the variations in the mechanical
properties of each process and to analyze their most probable failure modes by means of a fractographic study, in which
the characteristic morphologies of each one (nucleation, propagation, final fracture) were identified by means of optical
stereoscopy and scanning electron microscopy (SEM). The fatigue tests evidenced that the FCAW process has the best
fatigue-life performance compared to the GMAW and SMAW processes. Furthermore, in the fractographic analysis three
different fracture modes were found at the welding joints that showed correlations with micro structural changes
produced during the welding process. The FCAW process was influenced mainly by the first failure mode, while the
other two had a mixture of the three different failure modes.
Woei-Shyan Lee et al (2004) studied the deformation and failure response of 304L stainless steel SMAW joint under
dynamic shear loading. The dynamic shear deformation behaviour and fracture characteristics of 304L stainless steel
shielded metal arc welding (SMAW) joint are studied experimentally with regard to the relations between mechanical
properties and strain rate. The results indicate that the strain rate has a significant influence on the mechanical properties
and fracture response of the tested SMAW joints. It is found that the flow stress, total shear strain to failure, work
hardening rate and strain rate sensitivity all increase with increasing strain rate, but that the activation volume decreases.
It is found that the strain rate has a significant influence upon the dynamic shear properties and fracture response of 304L
SS weldments. The flow stress, yield stress and total shear strain to failure all increase as the strain rate is increased.
K. M. Deen et al (2010) predicted that to understand and predict the mechanical properties a weldment such as strength
and toughness, it is important to know the microstructures and micro-hardness values of the weld metal and heat-affected
zone regions. During welding thermal cycle heating and cooling rates of weld are much faster than those of steel base
metal. Thus metallurgical transformations across the weld and heat affected zone vary, thereby their microstructures and

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 Rathi et al., International Journal of Emerging Research in Management &Technology
ISSN: 2278-9359 (Volume-4, Issue-6)
morphologies become important. The microstructures that develop during welding thermal cycle are dependent on energy
input, preheat, metal thickness (heat sink affect) and weld bead size. As a result of different chemical compositions and
inclusions weld metal microstructures significantly differs from those of the HAZ and base metal.
Y.C. Lin et al (1995) studied a new technique for reducing the residual stress induced by welding in type 304 stainless
steel .The experimental results showed that the maximum principal residual stress and parallel welding direction stress
can be reduced by 21-32% when the conventional welding(CW) process is replaced by the parallel heat welding process
and the effect of stress relief with lower heat input condition is more efficient then that with high heat input condition
.Thus the increase of equilibrium temperature during welding process is a major mechanism of stress relief with PHW
process.
Ravindra Kumar et al (2008) investigates the oxidation behaviour of base metal, weld metal and HAZ regions of
SMAW weldment in ASTM SA210 GrA1 steel. Shielded metal arc welding (SMAW) was used to weld together ASTM
SA210 GrA1 steel. The oxidation studies were conducted on different regions of shielded metal arc weldment i.e., base
metal, weld metal and heat affected zone (HAZ) specimens after exposure to air at 900 ◦C under cyclic conditions. The
oxidation resistance was found to be maximum in case of HAZ due to the formation of densely inner oxide scale and it
was least in case of base metal.
Zhibo Dong et al (2006) Predicted weld solidification cracks in multipass welds of SUS310 stainless steel. It is found
that the driving force of first weld pass is larger than following weld passes. Furthermore, this paper predicts the weld
solidification cracks of walled plates. The predicted results agree well with actual fabrication. The weld metal
solidification cracks are controlled when the Chinese Daqing Oilfield adopts the welding procedure in this paper.

III. PROPOSED WORK

1.)To study the effect of multipass welding on 16mm thick Plates of J7 201 SS using SMAW process with an aim of
achieving maximum hardness.
2.)To analyze the impact toughness of the base metal, weld metal zone (WM) and heat affected zone (HAZ) of low and
high heat inputs.
3.)To study the effect of bend testing on welded samples.

IV. RESULTS AND DISCUSSION

The objective of this paper is to give the experimental results which are conducted for the present work. After
conducting testing on the work samples, data was collected. Then data was analyzed and compared analytically and
graphically.

4.1 Micro hardness results

The samples were first polished on disc polishing machine and after that the micro hardness was checked. The micro
hardness was checked for base metal, weld zone and heat affected zone of low and high heat input welded specimens. At
every place readings were taken. All the readings are shown in Table 6.4. Average micro hardness of base metal is 256
VHN.

Table I. Micro hardness (VHN) results

Specimen name Base metal Weld zone Heat affected zone
Low heat input 226-231 232-235 265-269
High heat input 226-231 215-218 245-249

Figure 3 and 4 represents the variation of micro hardness values obtained from the different sources such as base metal,
as-welded condition. The hardness values of as-welded specimens are much greater than base metal. High hardness
values were observed in the HAZ region of the both low and high heat input weldments.
300 267
247
250 229 234 217
Base Metal
200
Low Heat Input
150
Low Heat Input
100
High Heat Input
50
High Heat Input
0
1

Figure 3: Comparison of micro hardness of base metal and as welded plates

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 Rathi et al., International Journal of Emerging Research in Management &Technology
ISSN: 2278-9359 (Volume-4, Issue-6)
300
269
250 249
232
215
200
Low Heat
150 Input
100 High Heat
Input
50

0
1 2

Figure 4:Line graph Comparison of micro hardness of base metal and as welded plates

From the above observation it can be easily concluded that at the low heat input welded joints the micro hardness is
coming higher as compared to micro hardness values at high heat input welded joints. The main reason is that the cooling
rate of low heat input welded specimens is very higher than at the high heat input and the micro hardness function is
directly proportional to cooling at that point. Higher the cooling rate will produce higher micro hardness.

4.2 Impact toughness results

Table 2. shows the results of impact toughness observed from the base metal, weld metal zone (WM) and heat affected
zone (HAZ) of low and high heat inputs.

Table II. Impact properties of welded joints With Low and High heat inputs
Specimen Impact value Specimen Impact value Specimen Impact value
name name name
B1 (BM) 276 L1 (WM) 206 H1 (WM) 78
B2 (BM) 290 L2 (WM) 130 H2 (WM) 212
B3 (BM) 199 L3 (WM) 150 H3 (WM) 195
B4 (BM) 198 L11 (HAZ) 177 H11 (HAZ) 200
B5 (BM) 190 L12 (HAZ) 192 H12 (HAZ) 202
B6 (BM) 218 L13 (HAZ) 172 H13 (HAZ) 228

Figure 5: Fracture features of impact tested specimens showing the location of fracture.

250
198.5
200
141.2147
150 126.2
113.4
100

50

0
Base metal Low heat input High heat input

Figure 6:Comparison of impact values for base metal and as welded conditions

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 Rathi et al., International Journal of Emerging Research in Management &Technology
ISSN: 2278-9359 (Volume-4, Issue-6)
4.3 Bend test results
Bend test was conducted on universal testing machine. The load is applied to just start the fracture on the work samples.
It was observed that low heat input welded samples have the higher ductility as compared to high heat input welded
specimens. Fig.7 shows the fractured features of low and high heat input welded samples after the test.

Figure 7: Fracture features of Bend tested specimens showing the location of fracture On Low and High Heat input
Welded Joints.

From above figure it can seen that the cracks were found on high heat input welded specimens where as there is no crack
occurred in low heat input welded specimens. Hence it may be concluded that the multipass welding of low heat input
welding shows the positive results for bend test.

V. CONCLUSION
In the multipass welding process parameters directly affect the number of passes and total heat input. The individual
effect of current, voltage, speed on hardness of weld and HAZ is higher. It is observed that the hardness is higher in the
HAZ than the weld metal. With increasing cooling rate, hardness increases in the weld metal and HAZ at higher cooling
rate. Based upon the present study it is recommended that for the multipass welding of J7 201SS using SMAW process
the low heat input should be preferred because of the reason that it gives good hardness,toughness and ductility to the
material.Bend test also turns positive for low heat input.

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