Fig. 11-27 Insulated quick connectors.
McGraw-Hill Education/DavidMoyer,
photographer
When the work is of such nature that different lengths
of cable leads are necessary, cables may be made up in
specific lengths and equipped with cable connectors so
that they can be quickly and easily attached to make up
any desired length. The connector shown in Fig. 11-27
has a cam-type action that ensures a positive stop and lock
and cannot come loose or accidentally fall apart.
Electrode Holders
Metal Electrode Holders
A metal electrode holder is the device used for holding
the electrode mechanically. It conveys electric current
from the welding cable to the electrode, and it has an in-
sulated handle to protect the welders hand fromheat.
The jaws of the holder should be designed so that
they may grip the electrode firmly at any desired angle.
They should be made of a metal that has high electrical
conductivity and possesses the ability to withstand high
temperatures, Figs. 11-28 and 11-29. On many holders
Fig. 11-28 A 300 amp electrode holder. This type is spring
loaded to grip the electrode. McGraw-Hill Education/DavidMoyer,
photographer
Electrode Holder 1
1. Tip Insulator w/Screws
2. Upper Body Tong, Insulated
3. Spring Cup Insulator
4. Spring Set (with items 3 & 5)
5. Spring Flat Insulator
6. Molded Handle
8
7. Hinge Pin
8. Lower Body Tong
9. Oval-point Screw 1
Fig. 11-29 Exploded view of a spring type electrode holder. Adapted from Lenco dba NLC, Inc.
the jaws can be replaced with new ones when they be-
come so badly burned that they do not grip securely. The
holder should be light in weight, well-balanced, and have
a comfortable grip. Although it should be easy to change
the electrode, the holder must be sturdy enough to with-
stand rough usage. The current-carrying parts must be
large enough to prevent overheating, which causes the
handle to become too hot for the welder to hold. For the
same reason, the size of the holder must be in line with
the size of the welding machine; that is to say, a larger
electrode holder is required for a 400-ampere welding
machine than for a 200-ampere machine. Most holders
are fully insulated and may be laid anywhere on the work
without danger of a short circuit. This is especially con-
venient for work in close quarters.
Figure 11-30 shows an electrode holder of relatively
new design. It holds electrodes burned to a very short
stub. Its twist-type locking device permits electrode-
gripping power in excess of 2,000 pounds. There is never
danger of dislodging the electrode when attempting to
break through slag to start the arc. The electrode position
is always known. There is positive contact between the
holder and electrode, thus reducing both heating up of the
holder and electrode waste. The handle is fully insulated
so that it stays cool even with high duty cycles.
Another holder is the angle-head, screw-clamp, fully
insulated holder, shown in Fig.11-31. It is available in
sizes of 400 and 600 amperes and takes electrodes from
1
16 through 516 inch in diameter. Such holders are effi-
cient and reduce costs since electrode stub loss is at a
2 3
4
5
9
7 6
Shielded Metal Arc Welding Principles Chapter 11293
 High welding current conductance
is ensured through aluminum-copper
alloy head.
One-ton pressure contact
provides peak conductance from Special extruded copper-alloy
the holder to the electrode. body with large cross-sectional
area.

Cable connections4 types

for no. 4 and the popular D
type for no. 6.

Entirely insulated from end to end,

assuring complete safety from
electrical shock.

Lifeguard insulation developed

after many years to resist heat,
shock, impact and outwear
all other types 3 to 1.

Fig. 11-30 Short-stub electrode holder with twist-type locking device. Source: 2010 Bernard Welding Equipment Co.

Other Electric Arc Processes

The electric arc generates the heat necessary for several
major welding processes. Chapter 18 will present the prin-
ciples of gas tungsten arc welding (GTAW), and Chap-
ter21 will present the principles of gas metal arc welding
(GMAW). Arc cutting, which utilizes much of the same
equipment as arc welding, is presented in Chapter 6.

Personal Safety Equipment

Fig. 11-31 This type of electrode holder has an angled head,
and it is shorter and lighter than other holders of comparable
capacity. Jackson Products
minimum and holder maintenance is low. The screw-on
head can be replaced to make a new holder.
The holder is usually attached to the welding cable by
means of solderless connections. It is important that good
contact be maintained to prevent overheating.
Hand and Head Shields
The brilliant light caused by an electric arc contains two kinds
of invisible rays that injure the eyes and skin unless protection
is provided. One of these invisible rays is known as ultraviolet
and the other as infrared. Repeated exposure, either directly
or indirectly, results in painful but not permanent injury to the
eyes. Welders speak of this as hot sand in the eyes. The rays
may also produce a severe case of sunburn and sometimes in-
fection. The rays affect the eyes at any distance within 50 feet;
and the skin, at any distance within 20 feet.

294Chapter 11Shielded Metal Arc Welding Principles

Fig. 11-32 The hand shield usually used by foremen and
inspectors. Fibre-Metal Products Co.

Shields protect the welder not only against harmful Fig. 11-34 Note the vertical position of the large viewing
window. Jackson Products
light rays, but also against the hot globules of metal that
the welding operation gives off, especially in the verti-
cal and overhead positions. The hand shield, Fig.11-32,
has a handle so that the person using it may hold the
shield in front of his or her face. Welding inspectors
and supervisors use this type of shield. It is not suit-
able for the welder since he or she can work with only
one hand while using it. It is impossible to manipulate
the electrode and perform other necessary operations at
the same time with the other hand.
The head shield, Figs. 11-33 and 11-34, also called a
hood or helmet, is worn like a helmet. It is attached to Fig. 11-35 An adjustable free-floating headband with adjustable
an adjustable headband, Fig. 11-35, which allows it to crown. Fibre-Metal Products Co.
be moved up or down as the wearer desires. A helmet
and safety cap combination, Fig.11-36, offers practical,

Fig. 11-33 The standard head shield or hood. Fibre-Metal Fig. 11-36 Chrome leather helmets are ideal for those hard-to-
Products Co. get-into areas. Fibre-Metal Products Co.

Shielded Metal Arc Welding Principles Chapter 11295

dependable protection when there is danger of falling or
flying objects. Both hands are free to grasp the electrode
holder and carry out accompanying operations. Partial
protection is provided for the top of the head, but the op-
erator must also wear a leather or nonflammable cap for
adequate protection. This cap should be smooth and have
no pockets or turned-up edges that will hold hot globules
of metal. Most caps have a small bill that can be posi-
tioned to give additional protection to the ear that is most
exposed to weld splatter and slag especially when weld-
ing out of position.
Both the hand shield and the head shield are constructed
of a heat-resisting, pressed-fiber insulating material. The
shields are fully molded at the top and bottom to protect
the head and neck from metal particles, fumes, and dan-
gerous light rays. They are usually black to reduce reflec- Fig. 11-37 The flip-front welding helmet permits the welder to
tion and have a window frame for holding the protective inspect and brush the weld without lifting the hood.
lens which permits the welder to look at the arc safely.
The size of the protective lens is 2 412 inches or
412 514 inches. It is colored so that it can screen out ultra-
violet rays, infrared rays, and most of the visible rays from
the electric arc. A variety of shades of color may be ob-
tained. The density of the color chosen depends on the bril-
liance of the arc, which varies with the size of the electrode
and the volume of current. The shade for welding with me-
tallic electrodes with current values up to 300 amperes is
shade no. 10. Shade no. 12 is recommended for current val-
ues beyond 300 amperes and for shielded gas arc welding.
Good quality lenses are quaranteed to absorb 99.5
percent or more of the infrared rays and 99.75 percent or
more of the ultraviolet rays present. The lenses have ab-
sorbed 100 percent of these rays as reported in tests con-
ducted by the U.S. Bureau of Standards. The purchase of
cheap filter lenses is to be discouraged.
The side of the protective glass exposed to the weld
pool is protected by a clear polycarbonate plastic cover
lens. This is to protect the more costly filter lens from
molten metal spatter and breakage.
When the clear plastic cover becomes dirty from
smoke and fumes and pitted from weld spatter, it should
be replaced. Welding with clouded glass impairs vision Fig. 11-38 An electronic filter helmet improves productivity and
and causes eye strain. Many welders prefer to protect both reduces neck strain. Jackson Products
sides of the colored lens with a clear plastic cover.
Another type of head shield is shown in Fig. 11-37.
This differs from the others only in that it is equipped The helmet in Fig. 11-38 is an autodarkening elec-
with a flip front. The holder, which contains the pro- tronic filter helmet. It is useful when working in close
tective and clear cover lenses, flips up at a touch of the quarters, doing high production work, or where inad-
finger. A clear plastic cover in the stationary section pro- vertent arc strikes must be avoided. These helmets can
tects the eyes from hot scale when inspecting hot welds have a single shade or variable shades. The filter can
and from flying particles of slag and steel during clean- switch from light to dark in less than 1/10,000 (100 mil-
ing. This type is especially useful when working in close lionths) of a second. They are battery powered and may
quarters where it is difficult to raise the helmet. have a solar battery booster.

296Chapter 11Shielded Metal Arc Welding Principles

Safety Glasses
Whenever you are in the work area, safety glasses should
be worn. The practice of wearing them, Fig. 11-39, be-
hind the hood is an important safety precaution. This
is especially true in shops where there are a number of
welders working close to each other. It is almost impos-
sible under these conditions to prevent severe arc flash
reaching the eyes without safety glasses with side shields.
Safety glasses can absorb more than 99.9 percent of harm-
ful ultraviolet rays that can cause arc burn. The lenses are
usually made of a high impact polycarbonate material and
must meet ANSI Z87.1 standards. Welding with tinted or
dark lenses should be discouraged because it causes eye-
strain due to compounding the shading of the lens. Safety
glasses also protect the welders eyes while he or she is in-
specting the recently completed weld, chipping slag, wire
brushing, and grinding.
Goggles should also be worn by helpers, foremen, in-
spectors, and others who work with welders. The goggles
should be light in weight, well ventilated, and comfort- Fig. 11-40 An apron helps protect the welder from sparks
able. In order to protect the eyes from side glare, they and heat. Northeast Wisconsin Technical College McGraw-Hill
should be provided with tented side shields, and the lenses Education/Mark A. Dierker, photographer
should have a tint.
particles. Leather overalls may be worn with leather jack-
Protective Clothing ets. High-top shoes must always be worn when welding.
Gloves are necessary to protect the hands. Gloves are The feet and legs can be further protected by the use of
made of leather or some other type of fire-resistant ma- leggings and spats. Burns on the feet are quite painful, be-
terial. Leather capes, sleeves, shoulder garments with a come infected easily, and are slow to heal. Rolled sleeves
detachable bib, and aprons protect the clothing and body and turned up trouser cuffs provide lodging places for hot
of the welder from harm, Fig. 11-40. They are really metal and should be avoided.
necessary when the welder is called upon to do vertical The clothing of choice for welders should be 100 percent
and overhead work. If much of the work is to be done cotton or wool. Cotton denim shirt and pants are popular
in a sitting position, the welder should wear overalls or attire for todays welders as shown by a student welder in
a split-type apron, because full aprons form a lap for hot Fig.11-41. The clothing should be thick enough to prevent
injurious ultraviolet rays from penetrating to the skin. Shirts
should be long sleeve and button at the cuff. Shirttails are

Fig. 11-39 Wear your safety glasses even underneath your weld- Fig. 11-41 Thick clothing prevents injurious ultraviolet rays from
ing helmet. Miller Electric Mfg. Co. penetrating to the skin. Miller Electric Mfg. Co.

Shielded Metal Arc Welding Principles Chapter 11297

tucked into the welders pants and shirts should button to
the neck. The pants should be long enough so they cover
the top of the leather boots and they should not have cuffs.
However, at times it becomes necessary to wear further
protective clothing either for welding processes and/or po-
sitions. When this is the case, the welder has many options
to choose from to protect his or her skin from sparks and
hot globules of molten metal thrown out by the arc dur-
ing the welding operation. Figure 11-42 shows a student
welder who is well protected from sparks, rays, and heat.
However, the welder can be the best judge of the protective
clothing needed for the job.

Ear Protection
Because of the noise and possibility of hot weld spatter or
slag entering the ear canal, this area must be protected.
Either full ear muffs that cover the entire ear or simple ear

Leather Cap
Helmet

Fig. 11-43 A well-protected student welder. Note the platen

table, clamps, and the position of the fume extractor for optimum
protection. Miller Electric Mfg. Co.
Shoulder
Garment
plugs can be used. A welders cap with a bill on it can be
Welding used to deflect hot material away from the ear area.
Gloves

Fig. 11-42 A well-protected student welder.Note the gloves,
helmet, skull cap, safety glasses, and fire-resistant jacket.
Northeast Wisconsin Technical College. McGraw-Hill Education/
Mark A. Dierker, photographer
Fume Protection
Always use proper ventilation. When welding keep your
head out of the fume plume. If this is not possible, use a
fume extractor as in Fig.11-43, or a respirator.

CHAPTER 11 REVIEW

Multiple Choice c. Heat-resisting steels

Choose the letter of the correct answer. d. All of these
1. Shielded and metal arc electrodes are available to 3. The SMAW process is used for welding .
match the and of most metals. (Obj. 11-3)
(Obj. 11-1) a. Steel
a. Ductility and fatigue b. Tin
b. Density and plasticity c. Zinc
c. Properties and strength d. All of these
d. Stress and hardness 4. SMAW power sources are known as .
2. Metals most easily welded by the SMAW process (Obj. 11-4)
are . (Obj. 11-2) a. Constant voltage
a. Carbon and low alloyed steels b. Constant potential
b. Stainless steels c. Constant current
d. Constant output

298Chapter 11Shielded Metal Arc Welding Principles

 5. A transformer-rectifier can supply . 10. The clothing a welder wears should be of
(Obj. 11-5) material. (Obj. 11-9)
a. a.c. power a. Cotton
b. DCEP power b. Wool
c. DCEN power c. Nylon
d. All of these d. Both a and b
6. Arc voltage is when . (Obj. 11-6)
Review Questions
a. The voltage is being generated between the elec-
trode and the work Write the answers in your own words.
b. The machine is on but idle; no welding is being 11. Name the four basic types of arc welding machines.
done Which type is used most? (Objs. 11-1 and 11-4)
c. The machine is off 12. What is the difference between an engine-driven
d. The machine is converting to volts generator welding machine and a transformer-
7. The duty cycle is the percentage of any given rectifier welding machine? Give the general use
minutes that a machine can operate at its of each. (Obj. 11-2)
rated current without overheating or breaking down. 13. Do a.c. welding machines have more wearing parts
(Obj. 11-6) than d.c. machines? Explain. (Obj. 11-4)
a. 10 14. Are d.c. welding machines capable of welding faster
b. 20 than a.c. machines? Explain. (Objs. 11-5 and 11-7)
c. 30
15. How is the output of an arc welding machine
d. 40
indicated? (Obj. 11-6)
8. A long welding arc . (Obj. 11-7)
16. List three advantages of a.c. arc welding. (Obj. 11-7)
a. Decreases amperage
b. Increases amperage 17. Explain the use of multiple-operator systems.
c. Increases voltage (Obj. 11-7)
d. Both a and c 18. How is the current delivered to the electrode and the
9. The size of an electrode holder must be in line with work? Explain. (Obj. 11-8)
the size of . (Obj. 11-8) 19. Compare the characteristics of engine-driven gener-
a. A welding machine ator, transformer, and transformer-rectifier welding
b. An electrode machines and inverters. (Obj. 11-9)
c. A cable 20. What device is used to hold the electrode? Give a
d. All of these general description of this device. (Obj. 11-9)

INTERNET ACTIVITIES

Internet Activity A
Use a search engine to find a company that sells videos about welding. If it has pho-
tos of various frames of the video, you can see, in color, what the welding process
looks like. Make a color drawing of the process you saw and describe it.
Internet Activity B
Look on the Internet to see if you can locate helmets. Now look for a helmet that
can be used for closed-in spaces that have little or no ventilation. Report on what
you found.

Shielded Metal Arc Welding Principles Chapter 11299