Arc Master Slides Arc Master
SMAW Fundamentals & Techniques
Shielded Metal Arc Welding Essentials
What is SMAW?
SMAW (Stick Welding) is the most popular welding process in the world.
Uses a consumable flux-covered electrode.
Incredibly versatile and portable.
Perfect for construction and repairs.
Widely used on carbon steel and cast iron.
Power of the Arc
The "Arc" is an electrical discharge between the electrode and the base metal.
10,000°F
Produces extreme heat to instantly melt steel.
Ionized Gas
Creates a plasma path for the current to flow.
The Circuit
Current must complete a full loop to create an arc.
Equipment: Power
Constant Current
Machines maintain stable amperage even if arc length varies.
Current Types:
• AC: Alternating Current
• DCEP: Reverse Polarity
• DCEN: Straight Polarity
Adjust your Amperage (Heat) based on rod size.
Equipment: Leads
Electrode Lead
Connects machine to the stinger.
Work Lead
Completes the circuit (Ground).
Safety First
Check for cracked insulation. Exposed copper is a shock hazard.
Holders & Clamps
Stinger (Holder)
An insulated handle that grips the bare end of the electrode securely.
Work Clamp
Must be clean and tight on the workpiece to ensure a stable arc.
Tight Fit
A loose clamp equals a poor weld.
Electrode Anatomy
Core Wire
Flux Coating
Metal Core
Provides the filler metal and conducts current.
Flux Layer
Protects the puddle and stabilizes the arc.
The Power of Flux
Gas Shield
Creates a gas cloud to keep out Oxygen.
Slag Cover
Protects and shapes the cooling weld.
Arc Stability
Contains chemicals to keep the arc steady.
Decoding Rods
E 60 1 0
Electrode
Stick Process
Strength
60,000 PSI
Position
1 = All Positions
Coating
Flux/Current
Safety: Eyes
The Helmet
Must use a #10 to #14 shade lens.
Blocks harmful UV and IR radiation.
Protects against "Arc Flash" burns.
DON'T LOOK!
One second is all it takes to burn your eyes.
Safety: Clothing
Leathers
Wear a leather jacket to stop heat and sparks.
Boots
Leather steel-toed boots. No sneakers!
Cotton
Use 100% Cotton. Synthetics melt to skin.
Fumes & Smoke
Welding smoke is toxic. You must breathe clean air.
Ventilation
• Use exhaust fans/hoods
• Keep head out of plume
• Use respirators if needed
Danger: Galvanized
Coated metals release poisonous gases when welded.
Fire Prevention
The 35-Foot Rule
Keep all flammable materials far away from sparks.
Fire Watch
Stay 60 minutes after welding to check for smoldering.
BE READY
Striking the Arc
1. Scratch Start
Like striking a match. Drag and lift quickly.
2. Tapping Start
Tap straight down and bounce up fast.
Pro Tip
"If the rod sticks, quickly wiggle the stinger to break it loose."
Arc Length Control
The gap between the electrode tip and the weld puddle.
Too Long
Excessive spatter and weak penetration.
Perfect
Stable arc with a frying bacon sound.
Too Short
Rod sticks and the puddle won't flow.
Rule: Arc length = Diameter of rod metal.
The Five Essentials
Amps
Current
Arc
Length
Angle
Rod tilt
Speed
Travel
Rod
Selection
Rod Angles
Work Angle
Perpendicular to the metal surface (usually 90°).
Travel Angle
Leaning 5°–15° in the direction of travel (Drag).
Technique
"If there is slag,
Read the Puddle
Don't watch the light—watch the liquid metal puddle.
Key Visuals:
Puddle shape
Slag separation
Bead width
If the puddle gets too wide, you're going too slow. If it's too skinny, slow down!
Troubleshooting
Porosity
Cause: Dirty metal or arc too long.
Undercut
Cause: Too much heat or fast speed.
Slag Holes
Cause: Wrong rod angle or low heat.
Spatter
Cause: Arc too long or arc blow.
Ready to Weld
Master the Five Essentials, stay safe, and practice your hand-eye coordination.
01
Safety
02
Setup
03
Practice
Arc Master Worksheet Arc Master Worksheet
SMAW Fundamentals & Equipment Guide
Name:
Date:
Part 1: Defining the Arc
1. What does the acronym SMAW stand for?
2. SMAW is commonly referred to by which "street name"?
3. Describe the "Electric Arc" and the approximate temperature it reaches:
Part 2: The Welding Circuit
Identify the Function:
Electrode Holder (Stinger):
Work Clamp (Ground):
Constant Current (CC) Machine:
Sketch the basic SMAW circuit (Power Source, Leads, Holder, Work Piece, Clamp) in this space:
Part 3: Decoding the Rod
For an E7018 electrode, identify what each part means:
E
70
1
8
The Flux Coating (Short Answer):
List three things the flux coating does during the welding process:
Part 4: Safety Protocol
Helmet Lens Shade:
What shade range is required for arc welding?
Clothing Material:
Which fabric is safe to wear, and which should be avoided?
Fire Safety:
Explain the "35-Foot Rule" and the purpose of a "Fire Watch":
Part 5: Welding Technique
Arc Length Rule:
The arc length should be approximately equal to:
Five Essentials:
List them below:
Reading the Puddle:
Describe what happens to the bead if your travel speed is too fast:
End of Worksheet • Arc Master Lesson Series
Arc Master Teacher Guide Arc Master Guide
Teacher Facilitation & Lab Safety
Lesson Objectives
Equipment
Identify components of the SMAW circuit and explain the function of CC power sources.
Safety
Demonstrate proper PPE selection and explain fire/fume hazard mitigation strategies.
Technique
Define the 'Five Essentials' of welding and decode basic electrode numbering.
Delivery Strategy
15 min
Introduction & Equipment (Slides 1-6)
Discussion Prompt: "Why is stick welding preferred for outdoor repair jobs over other processes like MIG?"
Key Point: Emphasize that SMAW is a constant current (CC) process. Changing arc length changes voltage, but current stays steady.
20 min
Electrodes & Safety (Slides 7-13)
Discussion Prompt: "What happens if you use a #5 lens instead of a #10? Why is polyester clothing dangerous?"
Action: Pass around different electrodes (6010, 7018) for students to feel the flux coating and read the numbers.
25 min
The Five Essentials (Slides 14-20)
Discussion Prompt: "How does the 'fry bacon' sound help you judge your arc length when you can't see clearly?"
Key Point: 'Five Essentials' (Amps, Arc, Angle, Speed, Selection) are the foundation of all manual welding.
Pre-Lab Safety Audit
Teachers should verify these items before allowing students to strike an arc.
Ventilation Check
Exhaust fans are ON and positioned near the weld zone.
Cable Inspection
Leads have no copper showing; insulation is flexible.
PPE Verification
Students have gauntlet gloves, leather jackets, and cotton clothing.
Clear Work Area
No solvents, rags, or sawdust within 35 feet of arcs.
Fire Extinguisher
Type ABC extinguisher is accessible and fully charged.
Helmet Lens Check
Auto-darkening sensors are clean; battery is tested.
Common Student Issues
Symptom Likely Cause Correction Rod Sticks Instantly Amps too low / Slow "Tap" Increase heat; use "Scratch" start. Explosive Arc / Spatter Arc length too long Push rod closer to the puddle. Bead Sits "On Top" Travel too fast / Low heat
Arc Master Answer Key Arc Master Answer Key
SMAW Fundamentals • Teacher Resource
Official Key
Part 1: Defining the Arc
1. SMAW Stand For:
Shielded Metal Arc Welding
2. Street Name:
Stick Welding
3. Description & Temp:
Continuous electrical discharge between electrode and base metal. Reaches approx. 10,000°F (5,500°C).
Part 2: The Welding Circuit
Electrode Holder (Stinger):
Insulated handle used to grip the electrode and conduct current to it.
Work Clamp (Ground):
Connects the work piece to the machine to complete the electrical circuit.
Constant Current (CC) Machine:
Keeps amperage stable even if the arc length varies slightly.
Part 3: Decoding the Rod (E7018)
E
Electrode
70
70,000 PSI
1
All Pos.
8
Low Hydrogen
Flux Coating Functions (Any 3):
Creates a protective gas shield (displaces Oxygen)
Forms a slag blanket (protects/shapes cooling weld)
Stabilizes the electric arc (ionization)
Adds alloying elements/filler metal to the weld
Part 4: Safety Protocol
Helmet Lens Shade:
#10 to #14 shade lens.
Clothing Material:
100% Cotton, Wool, or Leather. Avoid Polyester/Synthetics (they melt).
Fire Safety (35-Foot / Fire Watch):
Keep flammables 35ft away. Watch for 60 mins after welding for smoldering sparks.
Part 5: Welding Technique
Arc Length Rule:
Approximately equal to the diameter of the electrode core wire.
The Five Essentials:
Amperage, Arc Length, Angle of Electrode, Speed of Travel, Selection of Electrode.
Travel Speed (Too Fast):
Bead will be narrow, thin, and likely lack penetration (sits on top).
Teacher Answer Key • Arc Master Series
