What Is Shielded Metal Arc Welding (SMAW)? The Beginner's Guide
Learn how SMAW works, what it's used for, the benefits of SMAW welding and more.
Gas metal arc welding (GMAW), also known as wire welding, is one of the most common types of welding. In the GMAW process, an electric arc is formed between the metal and a wire electrode, applying heat to the metal pieces. This action melts and fuses the parts together to form a permanent bond.
As we covered in our history of welding blog, the GMAW welding process emerged in the late 1940s when a continuously fed electrode wire replaced the tungsten electrode in the gas tungsten arc welding (GTAW) process. It quickly became popular because it was more cost-effective than GTAW. Today, GMAW is used in industries ranging from construction and manufacturing to car racing and vehicle production.
Another term for GMAW is metal inert gas (MIG) welding. In the MIG and GMAW processes, a continuous solid wire electrode travels through the welding gun along with a shielding gas, which protects against contaminants in the air. This welding process can be used on both thick and thin sheets of metal, as well as aluminum and other nonferrous materials.
When it comes to GMAW welding, there are a few different techniques that can be used to transfer weld metal from the arc to the base metal. These transfer modes are:
The coldest form of GMAW welding is short circuit, which uses low voltage. The welding wire touches the metal, electricity goes through the gun and a short circuit is created. The effect is a wet metal puddle that quickly solidifies and fuses the materials together.
In a spray transfer mode, wire gets melted into fine droplets that get sprayed or misted into the weld joint. This is a constant voltage process that uses a high heat input and sends a constant stream of weld metal from the arc to the base material.
The globular transfer method is similar to the short circuit method. An electrode wire arcs and touches the base material. However, there is a higher heat input and the wire is heated for a longer period. This creates a larger weld puddle, which collects at the tip of the gun and drips into the joint.
The pulsed spray transfer is similar to the spray arc method but modified to remove potential disadvantages. The welder will pulse the voltage many times per second, allowing a droplet to form at the end of the wire that gets pushed across the arc into the puddle. It is the most functional and flexible transfer time but can be the most expensive as it requires a high-end MIG welding machine.
GMAW welding has many applications in some of the world’s biggest industries and can be used for:
The versatility of GMAW welding makes it a popular choice among locations ranging from small repair shops and businesses to large industrial facilities.
A number of advantages exist for those using GMAW welding, making it one of the most widely used welding processes:
While there are many pros to GMAW welding, it’s also important to know what some of the cons might be:
Now that you know some of the uses and types of GMAW welding techniques, here are more details about the process.
The GMAW welding process happens when an arc is created between a wire electrode and the work piece, which melts them both to form a pool. The electrode is continuously fed and a shielding gas is used. The process is considered semi-automatic since wire feed and arc length are controlled by power, but travel speed and positioning are controlled manually.
To be successful, welders must master how to properly guide and clean the gun and optimize the voltage, flow rate and wire-feed rate. The travel speed a welder employs will influence the quality and shape of the weld. GMAW welders need to judge how the weld puddle size relates to the joint thickness in order to determine the correct travel speed without getting out of range of the welding procedure limitations.
Shielding gases are required for GMAW welding as they are used to protect the weld pool from contaminants in the air. The most common types of gases used during the process are argon and helium, which are both inert gases. This means they will not undergo chemical reactions.
However, active gases such as carbon monoxide can also be used. This is called metal active gas welding. Some welders combine active and inert gas together.
Inert, active and a combination of the two all protect the weld pool from contamination while providing unique penetration profiles.
Constant voltage power sources are used for the majority of GMAW welding and other semi-automatic processes. The power source provides constant voltage to the arc length during the process. There is a self-correcting arc length feature that helps produce stable welding conditions.
GMAW welding processes operate with reverse polarity when the wire electrode is positive. This is because more heat is generated, which helps reduce the chance of defects from a lack of fusion.
Some of the basic tools used for GMAW welding include:
Safety equipment like auto-darkening helmets, gloves and protective clothing are also used during GMAW welding.
GMAW stands for gas metal arc welding. The term is representative of the process.
During the GMAW welding process, an electric arc forms between the electrode and metal to melt metal pieces together. The process also requires a shielding gas to protect the weld pool from contaminants.
MIG welding stands for metal inert gas welding. “Inert” defines the type of shielding gas used during the process.
GMAW and MIG welding are the same, and the terms are used interchangeably.
The shielding agent is the primary difference between shielded metal arc welding (SMAW) and GMAW welding. As previously mentioned, GMAW requires a shielding gas.
However, SMAW, also known as stick welding, uses a flux-covered electrode connected to a power source to create a weld. As the flux around the metal electrode heats up, it melts and produces a gas shielding agent, removing the need for a separate gas source.
MAG welding stands for metal active gas, so the only difference between MIG and MAG is the type of shielding gas that is used.
In the Welding Technology program at Universal Technical Institute (UTI), students learn GMAW processes, equipment and applications in courses like Gas Metal Arc Welding I and II and Welding Applications.1 Students learn skills that include:
UTI students are also taught welding safety, blueprint basics and mathematics used in fabrication. Brian Masumoto, a welding instructor at UTI Rancho Cucamonga, says the main advantage of UTI’s program is the breadth of instructor experience.
“Our instructors have 70+ years of experience in welding and fabrication,” Masumoto says. “As instructors, we find out what type of welding career the students want to get into and apply what’s in the curriculum to that specific job.”
Students aren’t only taught about GMAW at UTI. They learn about the three other major arc welding processes when they choose to attend one of these campuses nationwide:
Whatever location you choose to attend, you’ll receive the hands-on training and experience you need to pursue an entry-level job in the industry. Click the links above to find out more about each individual campus.
Find out more about the Welding program offered at UTI by requesting more information online or by calling us at 1-800-834-7308.
Universal Technical Institute of Illinois, Inc. is approved by the Division of Private Business and Vocational Schools of the Illinois Board of Higher Education.