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Sustainability assessment of shielded metal arc welding (SMAW) process
Ibrahim Alkahla 1 and Salman Pervaiz 1
Published under licence by IOP Publishing Ltd IOP Conference Series: Materials Science and Engineering , Volume 244 , 2017 International Conference on Materials and Intelligent Manufacturing (ICMIM 2017) 21–23 August 2017, National University of Singapore (NUS), Singapore Citation Ibrahim Alkahla and Salman Pervaiz 2017 IOP Conf. Ser.: Mater. Sci. Eng. 244 012001 DOI 10.1088/1757-899X/244/1/012001
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Shielded metal arc welding (SMAW) process is one of the most commonly employed material joining processes utilized in the various industrial sectors such as marine, ship-building, automotive, aerospace, construction and petrochemicals etc. The increasing pressure on manufacturing sector wants the welding process to be sustainable in nature. The SMAW process incorporates several types of inputs and output streams. The sustainability concerns associated with SMAW process are linked with the various input and output streams such as electrical energy requirement, input material consumptions, slag formation, fumes emission and hazardous working conditions associated with the human health and occupational safety. To enhance the environmental performance of the SMAW welding process, there is a need to characterize the sustainability for the SMAW process under the broad framework of sustainability. Most of the available literature focuses on the technical and economic aspects of the welding process, however the environmental and social aspects are rarely addressed. The study reviews SMAW process with respect to the triple bottom line (economic, environmental and social) sustainability approach. Finally, the study concluded recommendations towards achieving economical and sustainable SMAW welding process.
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A Method for Evaluation of Welding Performance of SMAW Electrodes
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- Brajesh Asati 14 &
- Ravi Shanker Vidyarthy 15
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The Shielded Metal Arc Welding (SMAW) is used extensively in different industry segments for different applications, e.g. structural welding, general welding fabrication, etc. Stick electrode is one of the major components of SMAW process. However, end users extensively using these electrodes have reported variable weld penetration and unwanted spattering recurrently during the SMAW process. Concerns have been raised about weld spatter defined as loss of electrode material. Excessive spatter results in productivity loss as unscheduled work stoppage happens due to weld cleanup, repair and rework requirements. Extent of spatter is a major quality issue and a product differentiator. After an elaborate exercise, negligible differences were observed among the electrodes in terms of welding performance issues, e.g. spatter, weld bead profile. Spatter measurement results show that Electrode A produced fewer spatters than Electrodes B and C at almost all current levels. All-weld chemical composition and all-weld tensile properties were also found to be similar for all three electrodes as electrodes were hailed from the same category.
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A.I.A.S.I.A.S. Institute: Welding of Stainless Steels and Other Joining Methods, pp. 6–11
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Brajesh Asati
Department of Mechanical Engineering, Birla Institute of Technology and Science, Hyderabad Campus, Hyderabad, 500078, Telangana, India
Ravi Shanker Vidyarthy
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Srinivasa Prakash Regalla
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Asati, B., Vidyarthy, R.S. (2021). A Method for Evaluation of Welding Performance of SMAW Electrodes. In: Rao, Y.V.D., Amarnath, C., Regalla, S.P., Javed, A., Singh, K.K. (eds) Advances in Industrial Machines and Mechanisms. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-16-1769-0_54
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Dissertations and Theses @ UNI
The effect of shielded metal arc welding process variables on delta ferrite control in austenitic stainless steel weld metal.
Ralph Eldon Long , University of Northern Iowa
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Shielded metal arc welding; Austenitic stainless steel--Welding;
This study was to determine the effects of shielded metal arc welding on delta ferrite in austenitic stainless steel weld metal. The two objectives of the study were to determine: (a) what variables of the SMAW process affect the delta ferrite content or Ferrite Number of austenitic stainless steel weld metal, and (b) to what extent the Ferrite Number is affected by SMAW variables.
The research design was experimental with data collected from mechanically produced weld metal using a magnetic instrument calibrated in Ferrite Numbers (FN). The electrode alloys tested were 308, 308L, 316L and 347. The sizes of electrodes used were 3/32, 1/8 and 5/32 inch. Variables tested were amperage, voltage, travel speed, cooling rate, travel angle, work angle, coupon size and static output characteristics of welding machines.
The data were analysed by correlation and regression analysis or by difference of means of the FN values of the control and experimental procedures. A visual evaluation of weld quality was made using criteria of a welding code. The data collected from visually acceptable welds was organized as a series of graphs. It was determined that amperage within a usable range did not cause rejectable FNs, voltage increases of a few volts did cause rejectable FNs, travel speed changes of four through nine inches per minute did not cause rejectable FNs, cooling rate changes studied did not cause rejectable FNs, travel angle changes of 40° forward to 20° reverse did not cause FN changes, work angle changes of 90° to 45° did not cause a significant change in FN, coupon size changes studied did not effect FN and the effect of different static output characteristics of a welding machine did have a significant effect on FN. All tests of significant differences were evaluated at the .05 level.
- Any increase in slag blanket depth over the molten metal caused some increase in FN.
- Welding machines with different static output characteristics may have different arc striking abilities and provide other benefits.
- Variables effecting only slight changes in FN may be accumulative and be a factor in an overall control program.
- The factor for calculating nitrogen content of weld metal was found for this group of welds to more nearly be 0.08 than the recommended 0.06 normally used.
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Long, Ralph Eldon, "The effect of shielded metal arc welding process variables on delta ferrite control in austenitic stainless steel weld metal" (1980). Dissertations and Theses @ UNI . 926. https://scholarworks.uni.edu/etd/926
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Environmental and economic analyses of tig, mig, mag and smaw welding processes.
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1. Introduction
2. materials and methods, 2.1. mechanical methodology, 2.1.1. sheet materials, 2.1.2. filler material, 2.1.3. welding equipment, 2.1.4. measurement of variables, 2.2. environmental methodology, 2.2.1. scope and goals, 2.2.2. functional unit, 2.2.3. life cycle inventory, 2.2.4. life cycle assessment, 2.3. economic methodology, 3. results and discussion, 3.1. environmental results, 3.1.1. general comparison, 3.1.2. case two: tig with filler material, 3.2. economic results, 3.3. combined results, 4. conclusions, author contributions, data availability statement, conflicts of interest.
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Type of Welding | Carbon Steel S275 | Stainless Steel AISI-304L | Aluminium AW-5754-H11 |
---|---|---|---|
TIG without filler | Case 1 | Case 6 | Case 10 |
TIG with filler | Case 2 | Case 7 | Case 11 |
MIG | Case 3 | Case 8 | Case 12 |
MAG | Case 4 | Case 9 | - |
SMAW | Case 5 | - | - |
Type of Welding | Carbon Steel S275 | Stainless Steel AISI-304L | Aluminium AW-5754-H11 |
---|---|---|---|
TIG with filler | PROSTAR T-86 | PROSTAR T-308L | PROSTAR T-1050 |
TIG without filler | - | - | - |
MIG | PROSTAR M86 | PROSTAR M-309L | PROSTAR M-1050 |
MAG | PROSTAR M86 | PROSTAR M-309L | - |
SMAW | PROSTAR B-70 | - | - |
Variable Measured in Tests | Interval |
---|---|
Electricity consumption (kWh) | 0.032–0.31 |
Execution time (s) | 42–144 |
Type of Welding | Carbon Steel S275 | Stainless Steel AISI-304L | Aluminium AW-5754-H11 |
---|---|---|---|
TIG with filler | |||
TIG without filler | |||
MIG | |||
MAG | |||
SMAW |
Inventory | Case Study | |||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12 | |
Electric Energy (kWh) | 0.032 | 0.056 | 0.046 | 0.061 | 0.313 | 0.032 | 0.051 | 0.04 | 0.041 | 0.016 | 0.049 | 0.037 |
Argon (g) | 386.97 | 610.44 | 185.10 | 181.13 | - | 171.88 | 330.54 | 174.21 | 127.68 | 227.73 | 331.03 | 146.72 |
CO (g) | - | - | - | 31.96 | - | - | - | - | 22.53 | - | - | - |
Carbon (g) | - | 0.018 | 0.006 | 0.006 | - | - | 0.03 | 0.002 | 0.002 | - | - | - |
Manganese (g) | - | 0.264 | 0.086 | 0.084 | 0.402 | - | 0.181 | 0.107 | 0.109 | - | 0.002 | 0.001 |
Silicon (g) | - | 0.155 | 0.050 | 0.049 | - | - | 0.052 | 0.050 | 0.051 | - | 0.020 | 0.008 |
Sulphur (g) | - | 0.005 | 0.001 | 0.001 | - | - | 0.002 | 0.001 | 0.001 | - | - | - |
Phosphorus (g) | - | 0.005 | 0.001 | 0.001 | - | - | 0.003 | 0.002 | 0.002 | - | - | - |
Copper (g) | - | 0.064 | 0.021 | 0.02 | 0.060 | - | 0.052 | 0.030 | 0.031 | - | 0.004 | 0.002 |
Nickel (g) | - | 0.027 | 0.009 | 0.009 | 0.060 | - | 1.037 | 0.792 | 0.81 | - | - | - |
Chrome (g) | - | 0.027 | 0.009 | 0.009 | 0.040 | - | 2.095 | 1.461 | 1.496 | - | - | - |
Molybdenum (g) | - | 0.027 | 0.009 | 0.009 | 0.040 | - | 0.052 | 0.030 | 0.031 | - | - | - |
Vanadium (g) | - | 0.005 | 0.002 | 0.002 | 0.010 | - | - | - | - | - | - | - |
Aluminium (g) | - | 0.004 | 0.001 | 0.001 | - | - | - | - | - | - | 20.006 | 7.679 |
Titanium (g) | - | 0.027 | 0.009 | 0.009 | - | - | - | - | - | - | 0.002 | 0.001 |
Iron (g) | - | 17.578 | 5.725 | 5.596 | 19.478 | - | 6.894 | 3.614 | 3.698 | - | 0.050 | 0.019 |
Beryllium (g) | - | - | - | - | - | - | - | - | - | - | 0.006 | 0.002 |
Zinc (g) | - | - | - | - | - | - | - | - | - | - | 0.008 | 0.003 |
Magnesium (g) | - | - | - | - | - | - | - | - | - | - | 0.004 | 0.002 |
Impact Categories | Unit |
---|---|
Acidification | kg SO eq |
Eutrophication | kg PO eq |
Global Warming Potential (GWP) | kg CO eq |
Photochemical oxidation | kg NMVOC |
Abiotic depletion, elements | kg Sb eq |
Abiotic depletion, fossil fuels (ADFF) | MJ |
Water scarcity | m eq |
Ozone layer depletion | kg CFC-11eq |
Welding Equipment | Equipment Cost (€) | Ratio (€/seg) |
---|---|---|
Fronius–TransTIG 1750 Puls | 1800 | 1.3889 × 10 |
Fronius–TransPulsSynergic 270i C | 2300 | 1.775 ×·10 |
Fronius–Magic Wave 2600 | 3400 | 2.6234·× 10 |
Case Study | Energy Cost | Filler Material Cost | Shielding Gas Cost | Labour Cost | ||||
---|---|---|---|---|---|---|---|---|
Electricity (kWh) | By FU (cent€) | Length (mm) | By FU (cent€) | Volume (l) | By FU (cent€) | Execution Time (seg) | By FU (cent€) | |
1 | 0.0325 | 0.389 | - | - | 24.00 | 55.20 | 90 | 0.8750 |
2 | 0.0562 | 0.674 | 512 | 2.533 | 37.87 | 26.40 | 142 | 1.3805 |
3 | 0.0457 | 0.548 | 652 | 3.232 | 11.48 | 34.34 | 53 | 0.5153 |
4 | 0.0612 | 0.734 | 667 | 3.160 | 13.21 | 47.15 | 61 | 0.5931 |
5 | 0.3125 | 3.747 | 521 | 11.234 | - | - | 82 | 0.7972 |
6 | 0.0322 | 0.386 | - | - | 10.66 | 24.51 | 64 | 0.6222 |
7 | 0.0508 | 0.610 | 420 | 2.462 | 20.50 | 24.90 | 123 | 11.958 |
8 | 0.0396 | 0.475 | 685 | 3.677 | 10.83 | 24.20 | 50 | 0.4861 |
9 | 0.0405 | 0.486 | 701 | 3.763 | 9.31 | 32.49 | 43 | 0.4181 |
10 | 0.0165 | 0.198 | - | - | 14.13 | 47.21 | 53 | 0.5153 |
11 | 0.0488 | 0.585 | 318 | 1.629 | 20.53 | 20.93 | 77 | 0.7486 |
12 | 0.0369 | 0.442 | 868 | 4.361 | 9.10 | 55.20 | 42 | 0.4083 |
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González-González, C.; Los Santos-Ortega, J.; Fraile-García, E.; Ferreiro-Cabello, J. Environmental and Economic Analyses of TIG, MIG, MAG and SMAW Welding Processes. Metals 2023 , 13 , 1094. https://doi.org/10.3390/met13061094
González-González C, Los Santos-Ortega J, Fraile-García E, Ferreiro-Cabello J. Environmental and Economic Analyses of TIG, MIG, MAG and SMAW Welding Processes. Metals . 2023; 13(6):1094. https://doi.org/10.3390/met13061094
González-González, Carlos, Jorge Los Santos-Ortega, Esteban Fraile-García, and Javier Ferreiro-Cabello. 2023. "Environmental and Economic Analyses of TIG, MIG, MAG and SMAW Welding Processes" Metals 13, no. 6: 1094. https://doi.org/10.3390/met13061094
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Shielded metal arc welding (SMAW) is the most economical and portable and robust welding processes which utilizes the power source, electrode holder and electrode to weld metals.
Abstract. Shielded metal arc welding (SMAW) process is one of the most commonly employed material joining processes utilized in the various industrial sectors such as marine, ship-building, automotive, aerospace, construction and petrochemicals etc. The increasing pressure on manufacturing sector wants the welding process to be sustainable in ...
The Shielded Metal Arc Welding (SMAW) is (or the Stick welding) defined as a welding process, which melts and joins metals with an arc between a welding filler (electrode rod) and the workpieces.
Abstract. Shielded metal arc welding (SMAW) is the most economical and portable and robust welding processes which utilizes the power source, electrode holder and electrode to weld metals. It is utilized successfully in welding ferrous metals. Nowadays due to increased application of non ferrous metals, the joining of the same with this welding ...
Shielded Metal Arc Welding (SMAW) also called 'stick welding', one of the most popular and widely used processes in welding today, because it is inexpensive and simple. With using an electrode ...
For the quantitative evaluation of arc stability, results show that the root mean square and the standard deviation of the arc center fluctuation, respectively, correspond to welders' sensory evaluation at AC and DC discharges. For welding spatter generation, a method of counting white pixels in a binarized image evaluates the number and size ...
The research focused on the influence of welding inter-pass temperature in 304H type austenitic stainless steel weld joints in the as-welded condition. The shielded metal arc welding process was used to weld the joints. The following was evaluated: the theoretical and measured ferrite numbers, solidification mode and delta ferrite
Shieldedmetalarcwelding(SMAW),usesaconsumablemetal electrode coated with flux. During the process, the flux is vaporized and decomposed. Thereby, the flux gas shields the arc. Therefore, SMAW has often been adopted in outdoor en-vironments with strong winds [1-3]. Actually, SMAW can be done using a simple system at low cost. Furthermore, it is
1 Introduction. Shielded Metal Arc Welding (SMAW) is an arc welding process where metals are joined by heat generated from an arc maintained between a flux-coated electrode and the workpiece being welded. The welding current to the arc passes through the core wire and provides metal for the joint being welded.
Abstract. This study was to determine the effects of shielded metal arc welding on delta ferrite in austenitic stainless steel weld metal. The two objectives of the study were to determine: (a) what variables of the SMAW process affect the delta ferrite content or Ferrite Number of austenitic stainless steel weld metal, and (b) to what extent the Ferrite Number is affected by SMAW variables.
the weld. For example, the research by Shen et al., where they characterise the internal microstructure. As well as the mechanical properties of the weld made using Gas Metal Arc Welding (GMAW) technology. Using a filler material of 308 stainless steel [5]. In addition to other related studies [6,7].
Abstract and Figures. Shielded metal arc welding (SMAW) is the most economical and portable and robust welding processes which utilizes the power source, electrode holder and electrode to weld ...
Metal welding processes, and electric arc welding in particular, constitute a key link in a production chain comprising a large number of companies. This fact, in addition to a growing trend in favour of more in-depth environmental analysis and control of industry, and the need to continue affording due consideration to the economic aspect set the stage for this study. Herein, an environmental ...
Shielded metal arc welding (SMAW) is the common welding technology employed in almost all part of industries. The objective of this paper is the experimental and comparative study of two different electrode weldments. The SMAW welding process is carried out on the low carbon steel of grade E250BK conforms to IS2062:2006 equivalents.
The rate at which something occurs or is repeated over a particular period of time or in a given sample. The rate at which a vibration occurs that constitutes a wave, either in a material (as in sound waves), or in an electromagnetic field (as in radio waves and light), usually measured per second. Percentage.
SHIELD METAL ARC WELDING ELECTRODE SHIELD METAL ARC WELDING ELECTRODE MAKING AND FABRICATION MAKING AND FABRICATION. ISBN 978-977-90-5541-1 This is e-book media (not paper print format), The book format is "pdf", english, 129 pages, size A5, file size 13.6 Mb The book is introduction and the basic concept for SMAW electrode making, and ...
Abstract. This study was conducted to develop a quantitative evaluation system for arc characteristics such as arc stability and welding spatter generation related to shielded metal arc welding ...
SMAW stands for shielded metal arc welding and is one of the oldest types of welding. SMAW, also known as stick welding, uses a flux-coated electrode to form the weld and does not require an external shielding gas. SMAW can be used for a variety of applications and on different alloys and metals. SMAW equipment is portable, versatile and has a ...
Shielded Metal Arc Welding, otherwise known as manual metal arc welding or flux shielded arc welding, is a process that uses a flux-coated electrode to form the weld. ... GA, LA, MN, and TX. Electrical Lineworker program is a short program and not eligible for Title IV funding due to the definition of an Academic Year. For more information ...
The document discusses a study that aims to describe the lived experiences of Technical Vocational students with strand discrimination. The study gathered data through questionnaires to understand students' perceptions of discrimination between their strand and other strands. The researcher used Interpretative Phenomenological Analysis to understand attitudes, behaviors, and emotions related ...
The Shielded Metal Arc Welding (SMAW) is used in this research with the root pass location of ESAB OK 53.04 E7016 electrode type, and BOHLER E7016H4R is used for the filler and cap [19] [20]. ...
agnide312. report flag outlined. Answer: Shielded metal arc welding, also known as manual metal arc welding, flux shielded arc welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode covered. Explanation: hope it will help you.