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The objective in commercial welding is to get the job done as fast as possible so as to lessen the time costs of skilled workers One way to speed the welding process is to raise the current use a higher amperage since the faster electrical energy can be induced in the weld joint, the faster will be the welding rate With manual stick-electrode welding, however, there is a practical limit to the current The covered electrodes are from 9 to 18 in long, and if the current is raised too high, electrical resistance heating within the unused length of electrode will become so great that the covering overheats and breaks down the covering ingredients react with each other or oxidize and do not function properly at the arc Also, the hot core wire increases the melt-off rate and the arc characteristics change.

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The mechanics of stick-electrode welding are such that electric contact with the electrode cannot be made immediately above the arc a technique that would circumvent much of the resistance heating Not until semiautomatic guns and automatic welding heads (which are fed by continuous electrode wires) were developed was there a way of solving the resistance-heating problem and thus making feasible the use of high currents to speed the welding process In such guns and heads, electric contact with the electrode is made close to the arc The length between the tip of the electrode and the point of electric contact is then inadequate for enough resistance heating to take place to overheat the electrode in advance of the arc, even with currents two or three times those usable with stick-electrode welding.

This solving of the point-of-contact problem and circumventing of the effects of resistance heating in the electrode constituted a breakthrough that substantially lowered welding costs and increased the use of arc welding in industrial metals joining In fact, through the ingenuity of welding equipment manufacturers, the resistance-heating effect has been put to work constructively in a technique known as long-stickout welding Here, the length of electrode between the point of electric contact in the welding gun or head and the arc is adjusted so that resistance heating almost but not quite overheats the protruding electrode Thus when a point on the electrode reaches the arc, the metal at that point is about.

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ready to melt and less arc heat is required to melt it. Because of this, still higher welding speeds are possible.

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2661 Shielded Metal-Arc Welding The shielded metal-arc process commonly called stick-electrode welding or manual welding is the most widely used of the various arc-welding processes It is characterized by application versatility and flexibility and relative simplicity in equipment It is the process used by the small welding shop, by the home mechanic, and by the farmer for repair of equipment; it is also a process having extensive application in industrial fabrication, structural steel erection, weldment manufacture, and other commercial metals joining Arc welding, to persons only casually acquainted with welding, usually means shielded metal-arc welding With this process, an electric arc is struck between the electrically grounded work and a 9- to 18-in length of covered metal rod the electrode The electrode is clamped in an electrode holder, which is joined by a cable to the power source.

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