Advanced Shielded Metal Arc Welding (SMAW)

A comprehensive vocabulary flashcard set covering key terms, historical facts, machine principles, safety specifications, electrode classifications, and joint positions from the Advanced Shielded Metal Arc Welding (SMAW) course.

Welding

The joining together of two pieces of metal by heating to a temperature high enough to cause softening or melting, with or without the application of pressure, and with or without filler metal having a melting point above $800\,^\circ\text{F}$.

Shielded Metal Arc Welding (SMAW)

A manual arc welding process that produces coalescence of materials by heating them with an electric arc established between a flux-covered consumable metal rod (electrode) and the workpiece.

Acetylene Discovery

Discovered by Edmund Davy in the 19th century, a gas later used in oxyacetylene welding, heating, and cutting.

Electric Arc Discovery

First discovered in 1801 by Sir Humphry Davy during electricity experiments, who later in 1809 demonstrated maintaining a high voltage arc.

First Documented Fusion Welding

Performed in 1881 by Auguste de Meritens, who welded lead battery plates together using a carbon electrode.

Bare Metal Electrode Welding

Introduced in 1888 by N.G. Slavianoff, becoming the prevailing electric arc welding method in the United States until about 1920.

Coated Electrode Patent

Patented in 1907 by Swedish engineer Kjellberg, who in 1912 patented an electrode with a heavier asbestos coating bound with sodium silicate.

High Frequency Stabilized AC Machine

An industrial welding machine introduced in 1936 by the Miller Electric Manufacturing Company to advance alternating current welding.

Oxyfuel Gas Welding (OFW)

A group of welding processes that produces coalescence by heating materials with an oxyfuel gas flame, using fuel gases such as acetylene ($\text{C}_2\text{H}_2$).

Gas Tungsten Arc Welding (GTAW)

An arc welding process (also called TIG or heliarc) that produces coalescence using an arc between a nonconsumable tungsten electrode and the workpiece, shielded by gas.

Gas Metal Arc Welding (GMAW)

An arc welding process that uses an arc between a continuous automatically fed solid filler metal electrode and the workpiece, shielded by an externally supplied gas.

Flux Cored Arc Welding (FCAW)

An arc welding process using an arc between a continuous tubular filler metal electrode and the workpiece, where shielding is provided by flux contained within the electrode.

Submerged Arc Welding (SAW)

An arc welding process where the arc and molten metal are shielded by a blanket of granular, fusible material on the workpiece.

Plasma Arc Welding (PAW)

An arc welding process that produces coalescence by heating metals with a constricted arc between an electrode and a workpiece or constricting nozzle.

Primary Voltage

The high-voltage incoming electrical input power supplied to a welding machine, typically $230\,\text{V}$ or $460\,\text{V}$.

Secondary Voltage

The lower operating output voltage produced for welding, typically ranging from $6\,\text{V}$ to $100\,\text{V}$.

Welding Spark Hazard Distance

Sparks and spatter from a welding arc can spray up to $35\,\text{ft}$ from the work area, requiring a fire inspection for $30\,\text{min}$ after welding completes.

Transformer Welding Machine

A quiet and energy-efficient power source that uses a primary coil, secondary coil, and laminated steel core to step down incoming AC utility voltage into welding current.

Inverter Welder

A lightweight, portable power source using solid-state electronics to increase power frequency from $60\,\text{Hz}$ to several thousand cycles per second, allowing smaller transformer cores.

Alternator Welder

A mechanical engine-driven power device where magnetic lines of force rotate inside a stationary coil (stator), producing AC welding power only.

Generator Welder

A mechanical engine-driven power device where a wire coil (armature) rotates inside a magnetic force field, capable of producing AC or DC electricity.

Rectifier

An electrical component or bridge assembly that converts alternating current (AC) to direct current (DC) by allowing current to flow in one direction only.

Voltage (V)

The measurement of electrical pressure controlling the maximum gap electrons can jump across the arc; it is directly associated with welding temperature.

Amperage (A)

The measurement of the total volume of electron flow; it controls the size of the arc and is directly associated with welding heat.

Wattage (W)

The total electrical energy or power in the arc ($\text{Watts} = \text{Volts} \times \text{Amperes}$), associated with heat and temperature production.

Direct Current Electrode Negative (DCEN)

Formerly termed straight polarity (DCSP), a setup where electrons flow from electrode to work, producing high electrode melting with approximately $\frac{1}{3}$ heat on the electrode and $\frac{2}{3}$ on the work.

Direct Current Electrode Positive (DCEP)

Formerly termed reverse polarity (DCRP), a setup where electrons flow from work to electrode, placing $\frac{2}{3}$ of heat on the electrode and $\frac{1}{3}$ on the work.

Alternating Current (AC) Welding

A current where electrons change direction every $\frac{1}{120}\,\text{s}$, distributing welding heat evenly ($\frac{1}{2}$ on work, $\frac{1}{2}$ on electrode).

Work Angle

The angle established between the welding electrode and the surface of the workpiece.

Travel Angle

Also called lead angle, it is the angle between the electrode axis and a plane perpendicular to the weld axis.

Standard Arc Length

The recommended distance maintained between the tip of the electrode and the workpiece surface, equal to $\frac{1}{8}\,\text{in}$.

AWS Prefix 'E'

The letter prefix in the American Welding Society numbering system that designates an arc welding electrode.

AWS Tensile Strength Digits

The first two digits of a 4-digit (or first three of a 5-digit) AWS classification indicating minimum tensile strength in thousands of psi (e.g., E60 = $60{,}000\,\text{psi}$).

E6010 Electrode

A high cellulose sodium, DC+ all-position electrode providing a deeply penetrating arc, optimal for pipe root passes and digging through rust or dirt.

E6011 Electrode

A high cellulose potassium, all-position AC/DC+ electrode with a deep penetrating arc used primarily for repair work on uncleaned or rusty metals.

E6013 Electrode

A high titania potassium, all-position AC electrode producing a soft arc with minimal spatter and easy slag removal on clean, new sheet metal.

E7018 Electrode

A low-hydrogen, all-position electrode used for critical welds and hard-to-weld metals, offering uniform metal deposit and sub-zero impact properties.

E7024 Electrode

An iron powder titania, fast-fill electrode designed for high-speed flat and horizontal fillet welds on plate material $\frac{1}{4}\,\text{in}$ or thicker.

Backing Strip

A piece of metal positioned on the back side of a weld joint to prevent molten metal from dripping through an open root, guaranteeing $100\%$ base metal fusion.

Faying Surface

The specific surface area of a metal workpiece that is melted during the welding process.

Butt Joint

A joint design where the metal edges meet in the same plane so that the thickness of the joint equals the thickness of the metal.

Lap Joint

A joint design where the edges of two metal pieces overlap each other.

Tee Joint

A joint design where the edge of one metal piece is placed on the surface of another at an approximate $90^\circ$ angle.

1G / 1F Welding Position

The flat welding position, performed from the upper side of the joint where the weld face lies horizontally.

2G / 2F Welding Position

The horizontal welding position, where the axis of the weld is horizontal along an approximately vertical surface or plane.

3G / 3F Welding Position

The vertical welding position, where the axis of the weld line is oriented vertically.

4G / 4F Welding Position

The overhead welding position, performed from the underside of the joint.

5G Pipe Position

Horizontal fixed pipe welding position, where the pipe axis is horizontal and the weld is performed vertically around the stationary pipe.

6G Pipe Position

Inclined pipe welding position, where the pipe is fixed at a $45^\circ$ angle and the weld is made around the circumference.

6GR Pipe Position

Inclined pipe welding position fixed at a $45^\circ$ angle with an added restriction ring placed around the pipe below the groove.