CBLM - SMAW NC II - CORE PIPES New

COMPETENCY-BASED
LEARNING MATERIALS
Sector : METALS AND ENGINEERING
Qualification Title : Shielded Metal Arc Welding NC II
Unit of Competency : Weld Carbon Steel Pipes Using SMAW
Module Title : Welding carbon steel pipes Using SMAW
DON BOSCO TVET CENTER - TONDO
CP, GARCIA ST. TONDO, MANILA

HOW TO USE THIS COMPETENCY BASED LEARNING
MATERIAL
Welcome to the module in Weld Carbon Steel Pipes using SMAW.
This module contains training materials and activities for you to complete.
You are required to go through a series of learning activities in order
to complete each learning outcome of the module. In each learning outcome
are Information Sheets, Self-Checks, Operation Sheets a Job Sheet. Follow
these activities on your own. If you have questions, don’t hesitate to ask
your trainer for assistance.
The goal of this course is the development of practical skills. To gain
these skills, you must learn basic components and terminology. For the
most part, you’ll get this information from the Information Sheets.
This module was prepared to help you achieve the required
competency, in “Shielded Metal Arc Welding NC II.”
This will be the source of information for you to acquire knowledge
and skills in this particular competency independently and at your own
pace, with minimum supervision or help from your instructor.
Remember to:
Work through all the information and complete the activities in each
section.
Read information sheets and complete the self-check. Suggested
references are included to supplement the materials provided in this
module.
Most probably your trainer will also be your supervisor or manager.
He/she is there to support you and show you the correct way to do things.
You will be given plenty of opportunity to ask questions and practice
on the job. Make sure you practice your new skills during regular work
shifts. This way you will improve both your speed and memory and also your
confidence.
Use the self-check, Operation Sheets or Job Sheets at the end of each
section to test your own progress.
When you feel confident that you have had sufficient practice, ask
your Trainer to evaluate you. The results of your assessment will be
recorded in your Progress Chart and Accomplishment Chart.
Date Developed: Document No.

Shielded Metal Arc Jan 7, 2015 Issued by:
Welding NC II Page 2 of 199
Developed by:
Welding Carbon Benjie D. Angeles
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LIST OF COMPETENCIES
Core Competencies
1. Weld Carbon Steel Plates Using Welding Carbon Steel Plates MEE721306
SMAW Using SMAW
2. Weld Carbon Steel Pipes Using Welding Carbon Steel Pipes MEE721306
SMAW Using SMAW

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MODULE CONTENT
UNIT OF COMPETENCY: WELD CARBON STEEL PIPES
MODULE TITLE: Welding Carbon Steel Pipes
MODULE DESCRIPTOR :
This module covers the knowledge, skills, and attitude in performing groove welding
on carbon steel pipes in different positions such as 2G, 5G, & 6G it includes
identifying the essentials of welding, the international welding codes and standards,
the acceptable weld profile, weld defects causes and remedies, welding procedures
specifications, welding technique and procedures and safe welding practices.
NOMINAL DURATION : 120 hours
LEARNING OUTCOMES :
Upon completion of this module the students/ trainees will be able to:
LO1. Weld carbon steel pipes in horizontal position (2G)
LO2. Weld carbon steel pipes in fixed pipe vertical position (5G)
LO3. Weld carbon steel pipes in fixed pipe inclined at 45° position (6G)
ASSESSMENT CRITERIA:
࿿࿿࿿R꾘燁࿿࿿࿿࿿࿿࿿࿿࿿࿿S맘㴀࿿࿿࿿࿿࿿࿿࿿࿿࿿Tꮨᖼ࿿࿿࿿࿿࿿࿿࿿࿿࿿U骆下࿿࿿࿿࿿࿿࿿࿿࿿࿿
V깴䍋࿿࿿࿿࿿࿿࿿࿿࿿࿿W伸࿿࿿࿿࿿࿿࿿࿿࿿࿿X⡰䱐࿿࿿࿿࿿࿿࿿࿿࿿࿿Y牚 ᷨ ࿿࿿࿿࿿࿿࿿࿿࿿࿿Z⢊樷
࿿࿿࿿࿿࿿࿿࿿࿿࿿[뜾࿿࿿࿿࿿࿿࿿࿿࿿࿿
ࣸ \둢ದ࿿71 Root penetration not exceeding
allowable tolerances specified by welding codes/ standards on:
0 concavity
1 convexity
2 undercut
3 excess penetration
4 lack of fusion
5 burn-through
6 cracks
࿿࿿࿿R꾘燁࿿࿿࿿࿿࿿࿿࿿࿿࿿S맘㴀࿿࿿࿿࿿࿿࿿࿿࿿࿿Tꮨᖼ࿿࿿࿿࿿࿿࿿࿿࿿࿿U骆下࿿࿿࿿࿿࿿࿿࿿࿿࿿
V깴䍋࿿࿿࿿࿿࿿࿿࿿࿿࿿W伸࿿࿿࿿࿿࿿࿿࿿࿿࿿X⡰䱐࿿࿿࿿࿿࿿࿿࿿࿿࿿Y牚 ᷨ ࿿࿿࿿࿿࿿࿿࿿࿿࿿Z⢊樷
࿿࿿࿿࿿࿿࿿࿿࿿࿿[뜾࿿࿿࿿࿿࿿࿿࿿࿿࿿
ࣸ \둢ದ࿿72 Weld capping/ final pass not
exceeding allowable tolerances specified by welding codes/ standards
on:

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5888 height of reinforcement
5889 underfill
5890 porosities
5891 undercut
5892 cracks
5893 cold laps
5889 Finish weldment visually acceptable in accordance with welding

standards for:
5888 spatters
5889 arc strikes
5890 slag
5891 uniformity of beads

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LEARNING OUTCOME # 1 Weld Carbon Steel Pipes In Horizontal Position
(2G)
CONTENTS:
0 Essentials of welding
1 International welding codes and standards
2 Acceptable weld profiles
3 Weld defects, causes and remedies
4 Welding Procedure Specifications (WPS)
5 Welding techniques and procedures
6 Safe welding practices
PERFORMANCE CRITERIA:
23 Weld root penetration not exceeding allowable tolerances specified by welding

codes/ standards on
23 concavity
24 convexity
25 undercut
26 excess penetration
27 lack of fusion
28 burn-through
29 cracks
24 Weld capping/ final pass not exceeding allowable tolerances specified by

welding codes/ standards on:
23 height of reinforcement
24 underfill
25 porosities
26 undercut
27 cracks
28 cold laps
25 The finish weldment must be visually acceptable in accordance with

welding standards for:
23 spatters
24 arc strikes
25 slag
26 uniformity of beads

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CONDITION:
The student/trainee must be provided with the following:
23 Equipment
23 Welding machine (AC or AC/DC)
24 Welding table or jig
25 Portable grinder
26 Welding booth
27 Portable oven
24 Tools/Accessories
23 Welding mask
24 Steel brush
25 Clear glass
26 Chipping hammer
27 Dark glass
25 Supplies/ Materials
23 Electrodes
24 Carbon steel plates
25 Cutting grinding disk
26 Personal protective equipment

23 Safety shoes
24 Apron
25 Leggings
26 Safety goggles
27 Gloves
27 Training Materials
23 Arc welding manuals
24 Welding procedures specifications (WPS)
25 Welding standards
ASSESSMENT METHOD:
23 Written/oral
24 Interview
25 Direct observation

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LEARNING EXPERIENCES
Learning Outcome #1: Weld Carbon Steel Pipes in

Horizontal Position (2G)
Learning Activities Special Instruction
0 Read Essentials of Welding

(2.1-1)
Compare answers with the answer

key. You are required to get all the
Answer Self Check for (2.1-1) correct answers. If not, read the
information sheets again to answer
all the questions correctly.
0 Read International Welding Codes

and Standards (2.1-2)

0 Read Acceptable Weld Profiles

(2.1-3)

0 Read Weld Defects, Causes and

Remedies (2.1-4)

0 Read Welding Procedure

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Specifications (2.1-5)
10. Answer Self Check for (2.1-5) correct answers. If not, read the
0 Read Safe Welding Practices

(2.1-6)

correct answers. If not, read the information
12. Answer Self Check for (2.1-6)
sheets again to answer
0 Read Welding techniques and

Procedures (2.1-7)
Evaluate your own work using

procedural checklist.
0 Perform Operation Sheet (2.1-7)
Present your work to your trainer for
evaluation and recording.
0 Perform Job Sheet (2.1-7a)
0 Perform Job Sheet (2.1-7b)

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INFORMATION SHEET 2.1-1
ESSENTIALS OF WELDING
Learning Objective:
After reading this INFORMATION SHEET, You should be able to identify the
essentials or parameters to make a good weld.
There are 5 essential variables to be considered in making a quality weld.
Welding is a practical skill that requires continual practice and careful attention to the
variables that the welder controls to improve. The old golden rule “practice makes perfect”
applies to welding in that the more you do, as long as you or someone evaluates your
welds, the better you become.
The term variable as used in this text means something the welder has control of
either before welding or during welding.
Consider the following five essential variables below to avoid weld discontinuities that may
result if control is not maintained.
Remember:
An easy way to remember the variables is by remembering the first letter in each
one spells the word CLASS.
23 CURRENT SETTING.
24 LENGTH OF ARC.
25 ANGLE OF ELECTRODE.
26 SPEED OF TRAVEL.
27 SELECTION OF ELECTRODE.
23 CURRENT SETTING
The welding current or amperage is essential to producing welds with good appearance
and the required strength characteristics. The welder controls the amperage variable by
setting the amperage on the welding machine prior to welding.
The amperage is set from recommended ranges according to the size of the electrode, the
type of electrode, and the type of current AC, DCEN or DCEP you are using.
The correct current setting will determine with the kind of electrode to be used, kinds
and thickness of plates and the welding position
Remember:

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AC means Alternating Current, DC means direct current and can be set for Direct
Current Electrode Negative (Straight Polarity) or Direct Current Electrode
Positive (Reverse Polarity).
Some electrodes are designed to work best on a given Current and Polarity, for
example an E- 6010 should be used with DCEP (direct current electrode positive).
Some electrodes are designed to work best on DCEN while others allow a selection of
Current to be used.
The chart below shows typical amperage ranges
CURRENT RANGES
SIZE E6013 / E6011 E7018
3/32 60 – 90 70 - 100
1/8 90 – 120 120 – 160
5/32 110 - 170 130 - 170
Amperage may be referred to as the heat by some welders.
An excellent place to find amperage ranges, recommended current and polarity and
information on electrode applications are the Electrode Selection Guidebooks
available at any welding supply store.
The amperage range is fine tuned by the welder to the correct amperage before
welding on an actual workpiece or test piece by running practice welds on a piece
of scrap metal in the position of welding as follows;
23 Run a practice weld at the lower recommended range setting.

24 Run a second practice weld at the higher recommended setting.
25 Compare the two welds for evidence of a well formed bead, good fusion, lack
of defects, and a smooth transition into the base metal.
26 If necessary reduce the amperage from lower to highest amperage until
a satisfactory weld bead is produced.
27 It is important to try different setting to avoid wasting time with a setting that is
to low or to high and will need to be changed later.
The illustration below gives an idea of the evaluation process;

In example A the E-6010 weld made with the correct amperage appears properly
formed with the appropriate width and consistency.
In example B the weld made with amperage setting too low appears thin and stringy.
In example C the weld made with amperage setting too high appears wide and flat
with excessive spatter and evidence of undercut.

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Remember:
A. Amperage correct
B. Amperage too low
C. Amperage too high
A B C
The conditions may change for example; if you are welding multiple passes in the
vertical position and using a weave technique you may need to increase the
amperage when weaving over a prior weld bead. You may want to use higher setting
for welding flat and horizontal than for welding in other positions.
A setting used on one machine may need to be adjusted when using another machine,
if the machines are not calibrated the same. One welder (operator) may prefer to use a
slightly higher setting and travel faster than you, so set the amperage for your
technique. The correct amperage is one that provides a good weld and is not based on
a specific number on the machine.
23 LENGTH OF ARC
The correct arc length is one of essential factor in obtaining a good weld. An arc length
should be equal to the diameter of the welding rod being used.
When electricity is made to jump across a gap it is said to arc across the gap. In
Shielded Metal Arc Welding (Stick) it is this arcing effect that creates the intense
heat required for melting the electrode and the base metal together.
The Arc is the term used to describe the distance from the tip of the electrode to the
base metal and can be varied from lightly touching the metal at an angle sufficient to
maintain an arc to a distance far enough from the base metal to extinguish the arc.
If the electrode is held in contact with the work using the slight angle to maintain the arc
it is referred to as the drag technique. This technique is often used to weld in the flat and
horizontal positions, especially with larger or iron powder electrodes. If contact with the
base metal is made too quickly however; the electrode will stick or freeze to the metal.
Another method to employ is to allow a slight gap between the electrode tip and the
base metal.

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The length of the arc gap affects the
appearance of the weld Good penetration
Fine spatter
One way of checking if the arc length is
proper is to listen to the sound of the arc.
Neat, even
5888 Proper arc length will produce a weld run
crackling or hissing sound.
ARC LENGTH CORRECT
5889 Too short arc length may short out
while welding. The beads also will Poor penetration
become high with poor penetration and Coarse spatter
overlap.
5890 Too long arc length will cause a
great deal of filler metal spattering – small
solidified metal drops o the base metal Rough,
Uneven weld run
surface. It cause also that the bead will be
too low with poor penetration and under
ARC LENGTH TOO LONG
cut.
Electrode
The welding machines used in Shielded Metal stuck to
Arc Welding are known as Constant Current work
machines which mean that the current stays
relatively constant through changes in the Narrow,
voltage. The machine increases the voltage Uneven weld
as the arc length is increased to maintain
current flow at the amperage level set on the
ARC LENGTH TOO SHORT
machine. If the voltage is increased too much
the arc may become unstable and result in a
poor quality weld. EFFECT OF ARC LENGTH
The correct arc length may vary according to

the type of electrode and the position of welding.
When production welding flat or horizontal the drag method is often used for ease in
welding and faster travel speeds. When a slight gap is maintained the force of the arc
provides a weld bead with a slightly flatter appearance with less chance of slag
inclusions and better joint penetration.
Remember:
Make sure you are maintaining a proper arc length before adjusting the amperage on the
welding machine. If the arc length is too long and the voltage increases it may seem as
though the amperage is too high or the sticking caused by too low an arc length with
some electrodes may seem as though the amperage is too low.
0 ANGLE OF ELECTRODE
The variation of electrode angle is depending upon the position of welding to be

performed. Therefore the correct electrode angle should be considered by the one who
is performing the welding.
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In the Shielded Metal Arc Welding (STICK) process there are two electrode angles that
the welder must control. The first angle is the one formed between the electrode and the
base metal, called the work angle. The second angle is the angle the electrode is held
at relative to the direction of travel, called the travel angle.
The travel angle for the flat, horizontal and overhead can be either pulled or pushed
and the travel angle for the vertical can be either upward or downward.
STRAIGHT EDGES
WELD
LINE
MOLTEN ARC
EVENLY SPACED
BULLET-NOSE CRATER
SHAPED RIPPLES
DIRECTION OF
MOTION
20º
BEAD AND
RIPPLES
20º
MOLTEN ARC
CRATER
TRAVEL ANGLE WORK ANGLE
The work angle should be one that places the weld metal between the members to be
welded in the manner desired. The weld metal will be deposited in a relatively straight
line from the tip of the electrode to the work. The decision to push or pull is largely
one of experience and practicality. It is believe that a flatter somewhat less rounded
weld can be achieved with a slight push angle when welding flat and horizontal. When
welding in the vertical upward position a more extreme angle using the side of the
electrode seems to produce a flatter weld with tighter ripples.

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23 SPEED OF TRAVEL
Move sideways
The correct travel speed will be Feed down at constant rate to maintain
determined by the width of the bead
and the bullet nose shaped constant arc
appearance of the ripples at the rear of
the molten pool in the arc crater.
The rate of travel across the joint is

controlled by the welder during welding
and greatly affects the appearance and
strength characteristics of the weld.
The amount of weld metal deposited
(weld deposition rate) and the travel ESTABLISHING THE RATE OF TRAVEL
speed may vary with the type and size
of electrode being used. The correct
weld speed will result in a well formed Rate of travel too
weld bead that shows good fusion, slow weld build up
penetration and a gradual transition of
weld metal into the corners of the joint.
Since the travel speed is not timed in

stick welding, the welder must be able
to read the molten weld pool as the Rate of travel
too fast weld
electrode is manipulated across the
bead narrow
joint. A weld speed that is too fast and strung out.
results in a thin stringy weld with poor
strength. A weld bead that is too slow RATE OF TRAVEL EFFECT
a speed will result in a heavy weld that
has too much convexity.
24 SELECTION OF ELECTRODE
In choosing the right kind of electrode that is going to use welding, the welder must
consider the kind of materials types of joint preparation, and the welding position.
There are a variety of electrodes available for welding a wide range of metals. The
electrode for a given application must be selected carefully to provide the strength
characteristics required for the weld joint. One of the most useful tools for electrode
selection is the Electrode Handbooks available from welding supply outlets. These
handbooks provide information from electrode classification to application and usability.
In general the electrode weld metal must be matched to the type and composition of the
base metal being welded. Further some electrodes within the available scope are
designed for specific purposes.
Some of the most widely used Electrodes are those used for welding carbon Steel.
The following is a brief description of the most commonly used electrodes for
welding Carbon Steel.
The electrodes are classified by a letter and numbering system as follows:

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E (X)60 1 3
Electrode Tensile Strength in Welding Position  Flux type
Thousand pounds per  Type of Current

Square inch 1 – All Positions  Electrode
2 - Flat & Horizontal Characteristics
3 – Flat only
4 – Vertical Down
The tensile strength is defined as the ability of the weld metal to withstand forces
acting to pull it apart.
The last digit indicates the type of flux or electrode covering and in turn determines
the type of current, penetration and appearance of the weld.
The following are some commonly used electrodes and their characteristics.
ELECTRODE COATING POSITION CURRENT PENETRATION APPEARANCE TENSILE

STRENGHT
High All
E6010 Cellulose DCEP Deep Rippled Flat 62.000 PSI
Position
Sodium
High All DCEP
E6011 Cellulose Deep Rippled Flat 62.000 PSI
Position AC
Potassium
High All DCEN Smooth
E6012 Titania Medium 67.000 PSI
Position AC Convex
Sodium
High All DCEP Smooth, Flat to
E6013 Titania DCEN Shallow 67.000 PSI
Position Convex
Potassium AC
Iron
E7018 Powder All DCEP Shallow to Smooth, Flat to 72.000 PSI
Low Position AC Medium Convex
Hydrogen
Iron Flat,
Powder DCEP Shallow to Smooth
E7028 Horizontal 72.000 PSI
Low AC Medium Convex
Fillets
Hydrogen
Remember:
The E-6010 and E-6011 Electrodes are similar with only a slight change in the
electrode covering to enable the E-6011 to be used with AC current.
These electrodes have a deep penetrating and forceful arc with quickly solidifying weld
metal. They may be used in all positions including Vertical Downward. Because of the arc

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characteristics they may be used on dirty or rusty metals and for root passes in open root
grooves and pipe. These electrodes have a certain amount of moisture content to enable
the forceful arc and should not be stored in ovens.
The E-6012 and E-6013 electrodes are also similar with some variations in the electrode
covering. These electrodes have shallow to medium penetration making them useful for
welding thinner sections, sheet metal and for welding gaps due to poor joint fit up. Trapping
slag may be a problem when using E-6013 at lower amperages or on dirty metal surfaces.
Both the E-7018 and E-7028 electrodes are Iron powder Low hydrogen electrodes. The E-
7028 is used for flat and horizontal position only and may be used with a drag technique
to produce a smooth weld with good appearance. The addition of Iron powder to these
electrodes covering adds to the available weld metal resulting in heavier convex welds.
These electrodes are classified as low hydrogen meaning they are low in moisture
content and should be stored in ovens or moisture free environment once the container is
opened. Because these electrodes are low hydrogen they are the choice for welding
higher carbon steels.
A short arc length should be maintained especially when striking the arc to avoid
surface porosity (tiny holes).

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SELF CHECK 2.1-1
DIRECTION: Read the statement of each no. and choose the letter of the
correct letter below of each statement.
1. Which ONE of the following electrodes that can be used for all position?
a. EXX1X b. EXX3X
c. EXX2X d. EXX4X
5888 In electrode E6013, the first two digits number represents of what?
a. Compressive Strength b. Tensile Strength

c. Yield Point d. Mild Steel Electrode
3. What does the last digit of E-7018 represents?
a. Type of Electrode b. Alloy Electrode

c. Type of Current d. Mild Steel
Electrode
23 Its good performance will be determined by the width of the bead and the bullet nose
shaped appearance of the ripples at the rear of the molten pool in the arc crater.
a. Arc Length b. Travel

Speed
c. Electrode Angle d. Current Setting
23 It is essential to producing welds with good appearance and the required strength
characteristics. It is set from recommended ranges according to the size of the
electrode, the type of electrode, and the type of current you are using.
a. Arc Length b. Travel

Speed
c. Electrode Angle d. Current Setting

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5888 Its application must be selected carefully to provide the strength
characteristics required for the weld joint.
a. Selection of Electrode b. Travel Speed

c. Electrode Angle d. Arc Length
7. The variation of its angle is depending upon the position of welding to be performed.
a. Selection of Electrode b. Travel Speed

c. Electrode Angle d. Arc Length
0 What amperage setting is recommended if you are using E6011 or E6013 electrode
with 1/8” diameter?
a. 60– 90 b. 110 - 170

c. 70– 100 d. 90 – 120
0 It will cause a great deal of filler metal spattering – small solidified metal drops of the
base metal surface. It cause also that the bead will be too low with poor penetration
and under cut.
a. Travel Speed too fast b. Wrong Electrode Angle

c. Arc Length too short d. Arc length too long
0 If you are using E7018 electrode, what welding position can be applied with this kind
of electrode?
a. Flat and Horizontal only b. All position

c. All Position, Vertical downward d. Flat only

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ANSWER KEY 2.1-1
0 A
0 B
1 C
2 B
3 A
4 A
5 C
6 D
7 D
8 B

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INTERNATIONAL WELDING CODES AND STANDARDS
Learning Objective:
International Welding Codes and Standards
Welding Codes and Standards, When are they Used, and How are they
Developed
Many aspects of the design and fabrication of welded components are governed by
documents known as codes and standards. Other names used for such documents
include guides, recommended practices, regulations, rules, and specifications. These
documents are often specified by an end user/purchaser as a contractual agreement in
order to control the characteristics of the welded fabrication that may affect its service
requirements. They are also used by the manufacturer to assist in the development and
implementation of their welding quality system.
Many end users of welded components have developed and issued specifications that
have been compiled by them to address their specific requirements. Such specifications
may be limited in application and related only to that customer’s situation and
requirements. National interest in areas such as public safety and reliability has
promoted the development of welding codes and standards that command broader
recognition both on a national and industry-specific basis. Numerous committees have
been developed over the years within national engineering and technical societies that
continue to evaluate the needs of industry and develop new welding codes and
standards. Such committees are comprised of members who are technical experts and
represent all interested parties such as manufacturers, end users, inspection authorities,
and government agencies. The membership of these committees is balanced in order to
prevent any one interest group from controlling the committee. On completion of a new
or revised document by the specific committee, it is usually then reviewed and approved
by a review committee, and if accepted, then published in the name of the applicable
engineering society.
Documents that have significant influence upon public health and safety are sometimes
adopted by legislative bodies or by federal regulating agencies. In those jurisdictions, such
documents become law and are often referred to as Codes or Regulations.
The welding inspector should be aware of what codes or standards are applicable
within their jurisdiction, understand the requirements of the relevant documents and
perform their inspection accordingly.

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Sources of Codes and Standards of Interest to the Welding Industry
The following are some of the more popular sources of welding codes and
standards found in the USA.
0 American Welding Society (AWS)
Probably the largest producer of welding codes and standards in the USA. The
AWS publishes many documents addressing the use and quality control of
welding. These documents include such general subjects as Welding Definitions
and Symbols, Classification of Filler Metals, Qualification and Testing, Welding
Processes, Welding Applications, and Safety.
0 American Society of Mechanical Engineers (ASME)
This society is responsible for the development of the Boiler and Pressure
Vessel Code, which contains eleven sections and covers the design,
construction, and inspection of boilers and pressure vessels. ASME also
produces the Code for Pressure Piping, which consists of seven sections. Each
section prescribes the minimum requirements for the design, materials,
fabrication, erection, testing and inspection of a particular type of piping system.
Both of these documents are American National Standards.
1 American Petroleum Institute (API)
This institute publishes many documents relating to petroleum production, a number

of which include welding requirements. The most well known is possibly API Std
1104 – Standard for Welding Pipelines and Related Facilities.
Welding Code and Standard that are Generally Provides
The specific content and requirements of a welding code or standard can vary in
detail, however, there are a number of elements within these types of
documents which are common and which we will examine.
The Scope and General Requirements:
This is found at the beginning of the document and is important as it will normally
provide a description as to the type and extent of welding fabrication for which
the document was developed and intended to be used. It may also provide
information relating to the limitations for the use of the document. Care should be
taken to use codes and standards that are applicable for your particular
application.
Design:
If the document provides a section for design, it may refer the user to a
secondary source of information, or it may contain minimum requirements for the
design of specific welded connections.

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Qualification:
This section of the document will typically outline the requirements for
qualification testing of welding procedure specifications (WPS) and also those
requirements for qualification of welding personnel. It may provide the essential
variables, these being the change limitations that govern the extent of
qualification. Such variables are typically the welding process, type and
thickness of base metal, filler metal type, electrical parameters, joint design,
welding position, and others.
This section of the document may also provide the qualification testing
requirements. Usually this is divided into welding procedure and welder
performance testing requirements. Typically, it will provide the types and sizes of
test samples to be welded and prepared for testing, the testing methods to be
used, and the minimum acceptance criteria to be used for the evaluation of test
samples.
Fabrication:
This section, when included in the document, will typically provide information
associated with the fabrication methods and/or workmanship standards. It may
contain information and requirements on such items as base materials,
welding consumable classification requirements, shielding gas quality, heat
treatment requirements, preparation and care of base material, and other
welding fabrication requirements.
Inspection:
This section of the document will typically address the welding inspector’s
qualification requirements and responsibilities, acceptance criteria for
discontinuities, and requirements relating to procedures for non-destructive
testing.
Opportunities for the Welding Fabricator to Improve Weld Quality and Reliability
With the move by more manufacturing organizations toward the implementation of

quality management systems, such as ISO 9000, and the requirement of such systems
for process control, we must consider welding as a special process and, consequently,
its formal control. Welding codes and standards are often used by the welding fabricator
to assist with the development of their process control system. If we consider the major
elements of process control, as specified by such standards for quality systems, we will
recognize those same elements as being addressed within the welding code or
standard. The first requirement for process control is documented procedures defining
the manner of production. For welding, this is the welding procedure specification
(WPS). A second requirement is criteria for workmanship, which shall be stipulated in the
clearest practical manner. For welding, this may be the code or standard acceptance
criteria. A third requirement is qualification of personnel. This may be addressed by the
welder performance qualification. Regardless of the manufacturer’s overall quality
system, there may be opportunities available through the selection and use of an
appropriate welding code or standard for welding quality and reliability improvements.

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SELF CHECK 2.1-2
0 Design and fabrication of welded components are governed by documents.
a. Quality Control b. Guidelines and Regulation

c. Rules and Specification d. Codes and Standards
0 The system that often used by welding fabricator to assist with the development
of their process control system
a. Codes and Standards b. Guidelines and Regulation

c. Rules and Specification d. Quality Control
0 One of the sources of codes and standards that publish many documents addressing
the use and quality control of welding.
a. American Society of Mechanical b. American Petroleum Institute

Engineers (ASME) (API)
c. European Norm / European d. American Welding Society
Standard (AWS)
0 The institute that publish many documents relating to Standard for Welding Pipelines
and Related Facilities.

Standard (AWS)
0 The organization that is responsible for the development of the Boiler and Pressure
Vessel Code, which contains eleven sections and covers the design, construction,
and inspection of boilers and pressure vessels.

Standard (AWS)
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5888 It is an element of the document of welding code and standard that typically
outline the requirements for qualification testing of welding procedure specifications
(WPS) and also those requirements for qualification of welding personnel
a. Inspection b. Qualification
c. Scope and General d. Fabrication
Requirement
 It is an element of the document of welding code and standard that address the
welding inspector’s qualification requirements and responsibilities, acceptance criteria
for discontinuities, and requirements relating to procedures for non-destructive
testing.
c. Design d.
Fabrication
o It is an element of the document of welding code and standard that refer the user to a
a. Inspection b. Design
Requirement
o It is found at the beginning of the document and is important as it will normally provide
a description as to the type and extent of welding fabrication for which the document
was developed and intended to be used.
Requirement
1. An element of the document of welding code and standard that provide information
associated with the fabrication methods and/or workmanship standards.
Requirement

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ANSWER KEY 2.1-2
 C
 A
 D
 B
 A
 B
 A
 B
 C
 D

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ACCEPTABLE WELD PROFILE

Learning Objective:
acceptable and unacceptable weld profile.
Standard Welding Practices
The way to learn Welding or improve your skills is through practicing the welding
positions assigned over and over again until the Instructor or Inspector is satisfied you
can consistently perform the assigned welding practice. When one practice is of
acceptable quality, you will be moved on to the next practice.
The Standards for all practices at the school and in Industry are the American
Welding Society’s standards as described in the D1.1 Structural Welding Code for Steel and
their various Inspection publications.
Every Welder and Student should be aware of the Visual Inspection criteria used at the
school and described below:
 There shall be no cracks anywhere in the weld.

 There shall be no undercut anywhere in the weld.
 There shall be no porosity anywhere in the weld
 The weld profile shall conform to the weld profiles shown below:
APPENDIX V
ACCEPTABLE AND UNACCEPTABLE WELD PROFILE
(A) DESIRABLE FILLET WELD PROFILE (B) ACCEPTABLE FILLET WELD PROFILE

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 Convexity, C, of a weld or individual surface bead with dimension W shall not exceed the value of the following table:
(E) UNACCEPTABLE FILLET WELD PROFILE
(C) ACCEPTABLE GROOVE WELD PROFILE IN BUTT JOINT
(D) UNACCEPTABLE GROOVE WELD PROFILE IN BUTT JOINTS

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APPENDIX VI
WELD PROFILE ACCEPTANCE DESCRIPTION
 The faces of the weld may be slightly convex, flat, or slightly concave as
shown in Appendix V (A) and (B), with none of the unacceptable profiles
shown in(C). Except at outside corner joints, the convexity, C, of a weld or
individual surface bead with dimension W shall not exceed the values
noted in the table in Appendix V.
 Groove weld shall preferably be made with slight or minimum reinforcement

except as may be otherwise provided. In the case of butt and corner joints, the
reinforcement shall not exceed 1/8 in [3.2 mm] in height and shall have gradual
transition to the plane of the base metal surface. See Appendix V.
They shall be free of the discontinuities shown for butt joints in (E).
 Surfaces of grove welds required to be flush shall be finished so as not to

reduce the thickness of the thinner base metal or weld metal by more than
1/32 in [0.8mm]or 5% of the thickness, whichever is smaller, nor leave
reinforcement that exceeds 1/32 in [0.8 mm].However, all reinforcement must
be removed where the weld forms part of a faying or contact surface. Any
reinforcement must be blend smoothly into the plate surfaces with transition
areas free from weld undercut. Chipping may be used provided it is followed
by grinding. Where surface finishing is required, its roughness value shall not
exceed 250µin [6.3 µm]. surfaces finished to values of over 125 µin [3.2 µm]
through 250 µin [6.3 µm] shall be finished so that the grinding mark are
parallel to the direction of primary stress. Surfaces finished t values of 125
µin [3.2 µm] or less may be finished in any direction.
 Ends of groove welds required to be flush shall be finished so as not to

reduce the width beyond the detailed width or the actual width furnished,
whichever is greater, by more than 1/8 in [3.2mm]or so as not to leave
reinforcement at each end that exceeds1/8 in [3.2mm]. Ends of welds in
butt joints shall be faired to adjacent plate or shape edges at a slope not to
exceed 1 in 10.
 Welds shall be free from overlap.

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APPENDIX VII
VISUAL WELD INSPECTION ACCEPTANCE CRITERIA
Slag shall be removed from all completed welds. All welds and the adjacent base metal shall
be cleaned by brushing or any other suitable means prior to visual inspection. All welds shall
meet the following visual acceptance criteria prior to non – destructive testing. to visually
acceptable, the weld shall meet the following criteria:
 The weld shall have no crack.
 Thorough fusion shall exist between the adjacent layer of weld metal and
between weld metal and base metal.
 All craters shall be filled to the full cross section of the weld.
 Weld profile shall be in accordance with appendices V and VI.
 When the weld is transverse to the primary tensile stress in the part that is
undercut, the undercut shall be no more than 0.010 in. (0.25 mm) deep.
 When the weld is parallel to the primary tensile stress in the part that is undercut, the
undercut shall be no more than 1/32 in. (0.80 mm.) deep.
 The sum of the diameter of the visible porosity shall not exceed 3/8 in. (9.5 mm.) in
any linear inch of weld nor shall the sum exceed ¾ inch (19.0 mm.) in any 12
inches (305 mm.) length of weld.
 Any single continuous fillet weld shall be permitted to under run the nominal
fillet weld size specified by 1/16 inch (1.6 mm.)
 Visual inspection in all metals may begin immediately after the completed welds
have cooled to ambient temperature.
 Arc strikes outside the weld groove are prohibited.

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SELF CHECK 2.1-3
DIRECTION: Identify if the illustration below is desirable, acceptable, or not

acceptable weld profile. Write your answer on the blank provided to
its number.
6. ________________
1. ________________
← ________________
7. ________________
3. ________________
8. ________________
4. ________________
9. ________________
5. ________________
10. _______________
_

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ANSWER KEY 2.1-3
7. Unacceptable
8. Desirable
9. Unacceptable
10. Acceptable
11. Unacceptable
12. Acceptable
13. Unacceptable
14. Acceptable
15. Desirable
16. Acceptable

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WELD DEFECTS, CAUSES, AND REMEDIES
Learning Objective:
weld defects, its causes and remedies.
Common Weld Defects (Causes and Remedies)
1. Poor Weld Appearance
Cause
 Improper Travel Speed

 Irregular weaving
1. Too long arc length
2. Overheating
Remedies
← Weld a correct travel speed

← Use more uniform or only slight weave
← Maintain the correct arc length
← Use correct current
2. Poor Penetration – It is the shallow blending or fusion of the base metal and the weld
metal
Cause
1. Current too low
 Too fast travel speed
 Improper electrode size and type
Remedy Lack of penetration Good penetration
1. Increase current
2. Weld at a slower travel speed
3. Use smaller electrode to adjust to groove size
4. Use deep penetration electrodes

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 Spattering – It is the cooled solid form of molten metal particles that scattered on and
around the weld bead
Causes
 Excessive current
 Too long arc
 Arc blow
 Improper electrode angle
Remedies
← Decrease current
← Maintain short arc
← Use AC current
← Hold electrode more perpendicular to the surface of work piece
2. Porosity – It is small pores or holes that result of gas pocket in weld metal.
Causes
← Insufficient puddling Time

← Impurities in base metal
 Too short arc
 Wrong electrode
Remedies
← Decrease travel speed

← Clean base metal well before welding
← Hold correct arc length
← Use proper electrode (ex. Low hydrogen electrode for high carbon or high
sulphur steels)
3. Undercutting – It is the deep cut at the toes of the base metal.
Causes
 Current too high Undercut
3. Faulty electrode manipulation

 Improper electrode size
Remedies
 Use moderate current especially
for off-position welding
1. Use accepted technique
for vertical welds.
2. Hold electrode at correct angle from vertical plane in horizontal fillet.
3. Avoid using overly size electrode

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 Weld Cracks
Causes
Weld crack
← Welds too small
← Rigid joints
← Faulty welding
← Wrong electrode
Remedies
1. Make larger welds between heavy plates

2. Re-design to eliminate rigidity
3. Use recommended welding sequence and technique at minimum current
4. Use proper type of electrode
5. Preheat parts to be welded
The effect of current, arc length, and travel speed on covered electrode beads.
A B C D E F G
A – Correct current, arc length and travel speed; B-Amperage too low; C-Amperage too high; D-
Too long arc length; E-Arc length too short; F-Travel speed too slow; G-Travel speed too fast.

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SELF CHECK 2.1-4
DIRECTION: A. Encircle the letter of the correct answer below of each

statement and illustration.
1. It is the cooled solid form of molten metal

particles that scattered on and around the
weld.
a. Porosity b. Undercutting c. Poor penetration d. Spattering
2. It is the deep cut at the toes of the base

metal.
a. Weld crack b. Undercutting c. Poor penetration d. Spattering
3. It is small pores or holes that result of gas
pocket in weld metal.

4. The causes of this kind of defect are welds
too small, rigid joints, faulty welding and

wrong electrode.
a. Spattering b. Undercutting c. Weld Crack d. Underfill
5. It is the shallow blending or fusion of the base
metal and the weld metal

a. Underfill b. Undercutting c. Poor penetration d. Spattering

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2. Identify the effect of current, arc length, and travel speed on
covered electrode beads of illustration below
6. 7.
a. Correct current, arc length,

and travel speed
and travel speed
b. Amperage too low
b. Amperage too high
c. Voltage too low
c. Voltage too low
d. Travel speed too slow
d. Too long arc length
8.
a. Correct current, arc

length, and travel speed
b. Amperage too low
c. Voltage too low
9.
10.
a. Correct current, arc length, a. Correct current, arc length,

and travel speed and travel speed
b. Amperage too low
c. Voltage too low c. Voltage too low
d. Travel speed too slow d. Too long arc length

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ANSWER KEY 2.1-4
1. d
2. b
3. a
4. c
5. c
6. d
7. b
8. a
9. d
10. d

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WELDING PROCEDURE SPECIFICATION (WPS)
Learning Objective:
Welding Procedure Specification (WPS).
Welding Procedures
There are many factors involved in the preparation of any welded joint. The detailed
methods and practices used to prepare a particular weldment are called the welding
procedures. A welding procedure identifies all the welding variables pertinent to a
particular job or project. Generally, these variables include the following:
 Welding process
 Type of base metal
 Joint design
 Welding position
 Type of shielding
 Preheating and post heating requirements
 Welding machine setting
 Testing requirements
Welding procedures used to produce welds that will meet the requirements of commonly
used codes. The American Welding Society (AWS) produces the Structural Welding Code
that is used for design and construction of steel structures. Another code that is used for
the construction of steam boilers and pressure vessels is published by the American
Society of Mechanical Engineers (ASME). These codes provide a standardized guide of
proven welding practices and procedures.
While you are not directly responsible for developing of welding procedures, you could be
assigned to a welding job that requires you to follow them. For example, when a job
assigned to a Naval Construction Force unit, it is accompanied by a set of drawings and
specification. When there is a welding required for the job, the specification normally
requires it to be accomplished according to a specific code requirement. For instance, if your
unit is task to fabricate a welded steel structure, the specification may require that all
welding be accomplished according to AWS D1.1 (Structural Welding Code). The unit is
then responsible for ensuring that the welders assigned to the job are qualified to produce
the welds according to this welding `procedure specification. As shown in illustration below,
a welding procedure specification is simply a document that provides details of the required
variables for a specific welding application.

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The welding procedure specification is normally prepared by the certified welding inspector.
Using the Structural Welding Code, along with the project drawing and specifications, the
welding inspector develops a welding procedure specification that meets the requirements
of the job. The importance of this document is that it assures that each of the variables can
be repeated by qualified welders.
Welding Procedure Specification
Courtesy of American Welding Society
Once a welding procedure specification has been developed and qualified, welders are
then required to perform a Welding Performance Qualification test. After the test is
complete, the weld specimens are tested according to the requirements of the Welding
Procedure
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Specification. You may use either destructive or nondestructive tests. One example of a
destructive test is the guided bend test. An X – ray test is considered nondestructive.
Effects of Welding Variables
The effects of variables are somewhat dependent on the welding process being
employed, but general trends apply to all the processes. It is important to distinguish the
difference between constant current (CC) and constant voltage (CV) electrical welding
systems. Shielded metal arc welding is always done with a CC system. Flux cored welding
and gas metal arc welding generally are performed with CV systems. Submerged arc may
utilize either.
Amperage is measure of the amount of current flowing through the electrode and
the work. It is a primary variable in determining heat input. Generally, an increase in
amperage means higher deposition rates, deeper penetration, and more admixtures.
Arc voltage is directly related to the arc length. As the voltage increases, the arc length
increases, as does the demand for arc shielding. For CV welding, the voltage is
determined primarily by the machine setting, so the arc length is relatively fixed in CV
welding. For SMAW on CC systems, the arc voltage is determined by the arc length,
which is manipulated by the welder. As arc lengths are increased with SMAW, the
voltage will increase, and the amperage will decrease. Arc voltage also controls the
width of the weld bead, with higher voltages generating wider beads. Arc voltage has a
direct effect on the heat input computation.
Travel Speed, measured in inch per minute, is the rate at which the electrode is moved
relative to the joint. All other variables being equal, travel speed has an inverse effect on
the size of the weld beads. As travel speed increases, the weld size will decrease.
Extremely low travel speeds may result in reduced penetration, as the arc impinges on a
thick layer of molten metal and the weld puddle rolls ahead of the arc. Travel speed is a
key variable used in computing heat input; reducing travel speed increases heat input.
Wire feed speed is a measure of the rate at which the electrode is passed through the
welding gun and delivered to the arc. Typically measured in inches per minute (ipm) the
wire feed is directly proportional to deposition rate, and directly related to amperage.
When all other welding conditions are maintained constant (e.g., the same electrode
type, diameter, electrode extension, and arc voltage), an increase in wire feed speed
will directly lead to an increase in amperage. For slower wire feed speeds, the ration of
wire feed speed to amperage is relatively constant and linear.
Electrode extension, also known as “stickout,” or ESO, is the distance from the contact
tip to the end of the electrode. It applies only to the wire fed processes. As the electrode
extension is increased in a constant voltage system, the electrical resistance of the
electrode increases, causing the electrode to be heated. As the amount of heating
increases, the arc energy required to melt to melt the electrode decreases. Longer
electrode extensions may be employed to gain higher deposition rates at given
amperage. When the electrode extension is increased without any change in wire feed
speed, the amperage will decrease. This result in less penetration and less admixture.
With the increase in electrode stickout, it is common to increase the machine voltage
setting to compensate for the greater voltage drop across the electrode.

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Electrode diameter – larger electrode can carry higher welding currents. For fixed
amperage, however, smaller electrodes result in higher deposition rates. This is
because of the effect on current density discussed below.
Polarity is a definition of the direction of current flow. Positive polarity (reverse) is

achieved when the electrode lead is connected to the positive terminal of the direct
current (DC) power supply. The work lead is connected to the negative terminal.
Negative polarity (straight) occurs when the electrode is connected to the negative
terminal and the work lead to the positive terminal. Alternating current (AC) is not a
polarity, but a current type. With AC, the electrode is alternately positive and negative.
Submerge arc is the only process that commonly uses either electrode positive or
electrode negative polarity for the same type of electrode. AC may also be used. For fix
wire feed peed, a submerge arc electrode will require more amperage on positive
polarity than on negative. For a fixed amperage, it is possible to utilize higher wire feed
speeds and deposition rates with negative polarity than with positive. AC exhibits a mix
of both positive and negative polarity characteristics. The magnetic field that surrounds
any DC conductor can cause phenomenon known as arc blow, where the arc is
physically deflected by the field. The strength of the magnetic field is proportional to the
square of the current value, so this is more significant potential problem with higher
currents. AC is less prone to arc blow, and can sometimes be used to overcome this
phenomenon.
Heat input is proportional to the welding amperage, times the arc voltage, divided by
the travel speed. Higher heat inputs relate to larger weld cross sectional areas, and
larger heat affected zones, which may negatively affect mechanical properties in that
region. Higher heat input usually results in slightly decreased yield and tensile strength
in the weld metal, and generally lower notch toughness because of the interaction of
bead size and heat input.
Current density is determined by dividing the welding amperage by the cross sectional
area of the electrode. As the current density increases, there will be an increase in
deposition rates, as well as penetration. The latter will increase the amount of admixture
for a joint. Notice that this may be accomplished by either increasing the amperage or
decreasing the electrode size. Because the electrode diameter is a squared function, a
small decrease in diameter may have a significant effect on deposition rates and plate
penetration.
Preheat and interpass temperature are used to control cracking tendencies, typically in
the base materials. Regarding weld metal properties, for most carbon-manganese-
silicon system, a moderate interpass temperature promotes good notch toughness.
Preheat and interpass temperatures greater than 550°F may negatively affect notch
toughness. When the base metal receives little no preheat, the resultant rapid cooling
may also lead to a deterioration of notch toughness. Therefore careful control of preheat
and interpass temperature is critical.

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SELF CHECK 2.1-5
DIRECTION: Read the statement question and choose the letter of the
correct answer.
4. It is a measure of the rate at which the electrode is passed through the welding
gun and delivered to the ar
.
a. Heat input b. Polarity

c. Current density d. Wire feed speed
1. The larger diameter it is, the higher welding currents it can carry

c. Electrode d. Wire feed speed
 It is determined by dividing the welding amperage by the cross sectional area of

the electrode.

1. It is measure of the amount of current flowing through the electrode and the
work. It is a primary variable in determining heat input.
a. Heat input b. Amperage

3. The higher of its inputs relate to larger weld cross sectional areas, and larger heat
affected zones, which may negatively affect mechanical properties in that region.


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It is defined as the direction of current flow.

c. Current density d. Polarity
It is a key variable used in computing heat input; reducing travel speed increases
heat input.
a. Travel speed b. Amperage

also known as “stickout”
a. Travel speed b. Electrode extension

It is a measure of the rate at which the electrode is passed through the welding
gun and delivered to the arc

It is directly related to the arc length.

c. Arc voltage d. Wire feed speed

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ANSWER KEY 2.1-5
D
C
C
B
A
D
A
B
D
C

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SAFE WELDING PRACTICES
Learning Objective:
Safe Welding Practices.
Welding utilize compressed air and/or electric current to provide an intense heat source that
melts or burn away steel and other metals. Observing safety rules and precautions are
needed in order to avoid any accidents that cause danger in health and injury to the operator
and to others around the working area.
Therefore, the welder must have a sufficient knowledge in safety handling the equipment he
is being used and the proper outfit he should use to protect himself and others from flying
sparks, fumes, radiation, electric shock and other accident.
Welding and cutting can be extremely dangerous. It is important to follow proper safety
practices to reduce the risk of burns, explosions electric shock and other hazards.
Common Hazards in Electric and Gas welding or Cutting
Electric shock can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The
electrode and work circuit is electrically live whenever the output is on.
Fumes and gases can be hazardous.
Welding produces fumes and gases. Breathing this fumes and gases can be
hazardous to your health.
Arc rays can burn eyes and skin.
Arc rays from the welding process produce intense visible and invisible
(ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the
weld.
Welding can cause fire and explosion.
Welding on close containers, such as tanks, drums, or pipes can cause them to
blow up.

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Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and
hot equipment can cause fires and burns. Accidental contact of electrode to
metal objects can cause sparks, explosion, overheating or fire. Check and be
sure the area is safe before doing any welding.
Flying metal can injure eyes.
Welding, chipping, wire brushing, and grinding can cause of sparks and flying
metal. As weld cool, they can throw off slag.
Wear appropriate safety glasses with side shields even under your welding
helmet.
Build-up of gas can injure or kill.
Shut off shielding gas supply when not in use.

Always ventilate confined spaces or use approved air-supplied respirator.
Hot parts can cause severe burns.
Do not touch hot parts with your bare hand

Allow cooling period before working on gun or torch
Noise can damage hearing.
Noise from some processes or equipment can damage hearing. o

Wear approved ear protection if noise level is high.
Cylinders can explode if damage.
Gas cylinders contain gas under high pressure. If damage, a cylinder can
explode.
Since gas cylinders are normally part of the welding process, be sure to treat
them carefully.
Protective equipment Used in Welding and Cutting
Personal safety
When performing welding or oxyfuel cutting, wear clothing that will protect you from flying
sparks and heat. Shirts should be long-sleeved, have pocket flaps, and be worn with the
collar buttoned. Pants should not have cuffs and should fit so they hang straight down the
leg, touching the shoe-tops without creases. Cuffs and creases can catch sparks, which can
cause fires. Never wear polyester or other synthetic fibers. Sparks will melt these materials,
causing serious burns. Materials treated for fire resistance or outer coverings of leather
should be worn instead of synthetic fibers.

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PERSONAL PROTECTIVE CLOTHING
Protective equipment
Shields
USING A HAND-HELD HELMET ALLOWS BOTH HANDS
Helmets and handshields are designed to SHIELD FREE
protect the welder’s eyes and face from:
The use of Welding helmet and hand-held shield.
Infra-red and ultra-violet radiation from

the arc.
Intense light emitted by the arc.
Brilliant light emitted by the molten metal.
The shield either fits on the head leaving both hands free, or may be held in one
hand. The shield extends to cover both sides of the face. This gives protection when
working in the vicinity of other welding operators. Full head protection is given by

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welding hoods which cover the back of the head and neck. These are for use in
Use fumes extraction
Avoiding Welding Fumes
confined spaces and for overhead welding.
Welding Fumes Avoidance
Welding and cutting produces fumes and gases. Breathing

these fumes and gases can be hazardous to your health.
Welding and cutting can be avoided by observing the
following:
Keep your head out of the fumes. Do not breathe

 the fumes. Ensure proper ventilation
If inside, ventilate the area and/or use local forced
ventilation at the arc to remove welding fumes and
gases.
 If ventilation is poor, wear an approved air-supplied
respirator.
 Read and understand the Material Safety Data
Sheets (MDSDSs) and the manufacturer’s
instructions for metals, consumables, coatings,
Avoid direct inhalation of
cleaners, and degreasers. welding fumes
Work in a confined space only if it is well ventilated, or
while wearing an air-supplied respirator. Always
have a trained watchperson nearby. Welding fumes
and gases can displace air and lower oxygen level
causing injury or death. Be sure the breathing air is
safe.
Do not weld in locations near degreasing, cleaning, or
spraying operations. The heat and rays of the arc
can react with vapors to form highly toxic and
irritating gases.
 Do not weld on coated metals, such as galvanized,
lead or cadmium plated steel, unless the coating is
removed from the weld area, the area is well ventilated, and while wearing an
air supplied respirator. The coating and any metals containing these elements
can give off toxic fumes if welded.
How to Avoid Electric Shock When Welding
Electrical Safety
Electric shock from welding and cutting equipment can kill or cause severe
burns by coming in contact with bare skin. Serious injury can also result if a fall
occurs because of the shock. The amount of current that passes through the human
body determines the outcome of an electrical shock. The higher the voltage, the
greater the chance for a fatal shock. Electrical current flows along the path of least
resistance to return to its source. Electrical equipment that is properly grounded will

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provide a path for the current to flow that has less resistance than a human body. If
you come in contact with a live conductor, you become a load.
Always follow these electrical safety precautions:
Never operate arc welding equipment on a wet or damp floor.

The electrode, electrode holder, and work circuit are electrically energized when
the output is on. Never touch the bare metal of an electrode holder and a
grounded surface at the same time.
Never place electrode holders in contact with a grounded metal surface since it
could short-circuit the welding machine.
Each welder and operator of the equipment must be trained to recognize the
dangers associated with each particular type of equipment to avoid injuries,
fatalities, and other electrical accidents.
Avoid welding without protective clothing Never use defective welding cables
Figure 2.2.4 - Avoiding Electric Shock
V – Housekeeping
Many accidents have happened in the

home because of the things just lying
around. This also applies to the shop or
workplace. Imagine in a shop where tools,
scrap parts, casting, etc., are lying around
in the aisles and piles loosely on tables or
racks. Housekeeping is the term used in the
industry to mean the safe storage of tools,
parts, and all the rest of the items used in
manufacturing or fabrication.
A sign of a safe shop is a clean and orderly
shop; a place where everything is put away
or stored so that people walking through it
will not trip or fall, thereby causing a
possible injury.
Don’t leave the working area like this
The slogan “A PLACE FOR EVERY TOOL

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AND EVERY TOOLS IN IT’S PLACE” should be adopted by all shops whether they
be welding shops or otherwise. In this way, and only in this way may the shop be
considered a safe place in which to work.
Keep cable and hoses clear of passage ways
Always see to it that the floor is free from any slippery materials or substances.
Supplies and provisions must be placed
in its proper places.
Used and oily rags must have own
container.
Combustible materials should be
disposed properly.
Maintaintheorganizationof
consumables, tools, portable
equipment or machines. Make sure
that they are in proper places.
Avoid leaving of tools or work on the
table of a machine even if its not
running. Foot injury may cause if
tools or work fall off.
Aisles and exits should be kept clear.
See to it that there are enough cleaning
materials available when doing
housekeeping.
Scrap should be placed in a scrap boxes.

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SELF CHECK 2.1-6
DIRECTION: Identify the following protective equipment pointed by an arrow.

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ANSWER KEY 2.1-6

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WELDING TECHNIQUES AND PROCEDURES
LEARNING OBJECTIVE:
After reading this INFORMATION SHEET, you should be able to perform the
welding techniques and procedures
SHIELDED METAL ARC WELDING (SMAW) PROCEDURE

Typical stick welding set-up
Welding current starts as soon as electrode touches the workpiece.
Workpiece
Make sure workpiece is clean

before welding.
Work Clamp
Attach work clamp as close to

the weld as possible.
Electrode
Before striking an arc insert an

electrode in the electrode
holder. A small diameter electrode requires less current than a large one. Follow
recommendations of the electrode manufacturer when setting weld amperage.
Insulated Electrode Holder

Electrode Holder Position
Arc Length
Arc length is the distance from the electrode to the workpiece. A short arc with
correct amperage will give a sharp crackling sound. Correct arc length is related
to electrode diameter. Examine the weld bead to determine if the arc length is
correct. Arc length for 1/16 and 3/32 in. (1.6mm) arc length for 1/8 and 5/32 in.
electrodes should be about 1/8 in. (3.mm).

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Slag
Use a chipping hammer and wire brush to remove slag

and check weld bead before making another weld pass.
Electrodes and Amperage Selection Chart

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Striking an Arc – Scratch Start Technique
The scratch start technique is preferred

for AC welding
Electrode
Work piece
Arc
Drag electrodes across work piece like

striking a match; immediately lift
electrode slightly after touching work.
If arc goes out, electrode was lifted too
high. If electrode sticks to work piece,
use a quick twist to free it.
Striking an Arc – Tapping Technique
Electrode
Work piece
Arc
Bring electrode straight down to work

piece; ten lift slightly to start arc. If arc
goes out, electrode was lifted too high. If
electrode sticks to work piece, use a
quick twist to free it.

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Positioning Electrode holder
After learning and hold an arc, practice running beads of weld metal on flat
plates using a full electrode.
Hold the electrode nearly perpendicular to the work, although tilting it ahead (in
the direction of travel will be helpful)
To produce the best results, hold a short arc, travel at a uniform speed, and feed
the electrode downward at a constant rate as it melts.

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Electrode Movement during Welding
A stringer bead is satisfactory for most narrow groove weld joints; however, for
wide groove weld joints or bridging across gaps, a weave bead or multiple stringer
beads work better.
Stringer Bead – Steady movement along seam

Weave Bead – Side to side movement along seam
Weave Patterns
Use weave patterns to cover a wide area in one pass of the electrode. Limits
weave width to a maximum of 3 times diameter of electrode.
Conditions That Affect Weld Bead Shape
Weld bead shape is affected by electrode angle, arc length, travel speed
and thickness of base metal.

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Typical Weld Joints

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Welding Positions for Plates and Pipes

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OPERATION SHEET 2.1-7
WELD CARBON STEEL PIPES IN HORIZONTAL POSITION (2G)
Title: Set Up Welding Machine
Performance objectives: Given a welding machine, you should be able to

operate welding machine safely.
Equipment: Welding Machine
Steps / Procedure:
Attach the return cable to the welding table

Make sure the welding machine is off when you turn on the main power
source
Set correct polarity for electrodes
Set suitable welding amperage for electrode (Note: don’t set the welding
amperage while the welding machine is on.)
Insert electrode to the electrode holder
Turn on the machine before striking an arc
Turn off the welding machine after the weld is done
Assessment Method: Procedural checklist

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PROCEDURAL CHECKLIST FOR
Operation Sheet 2.1-7

(Set Up Welding Machine)
Trainee’s Name: ____________________________ Date: __________________
Criteria YES NO
Is the welding machine is turned off before the safety
box is turn on
Is the work cable is attached to the welding table
Is the polarity selected for the electrode is correct
Is the welding amperage used for electrode is suitable
Is the welding machine is turned off when not in use
If all items received a YES response, you can take the performance test
Comments / Suggestion:
Trainer : ______________________________ Date: ___________________

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JOB SHEET 2.1-7a
TITLE: Preparing the pipe for Horizontal Position (2G)
Performance Objective: Given a schedule 60 black iron pipe 4”Ø, you should be able
to apply chamfer and root face on the edge of the pipes and
tack weld the parts securely.
Tools, Materials and Equipment:

Welding Gauge
Angle grinder
Pipe beveling
Flat file
Bench vise
Electrode 6011
Welding machine
Steps / Procedure:
Prepare the edge of the pipe and follow

the details as shown in the illustration.
Make a root face according to the size of

electrode to be used.

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Tack welds the parts securely and make
sure the size of root opening is the
same as with the electrode size to be
used.

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PERFORMANCE CRITERIA CHECKLIST FOR
Job Sheet 2.1-7a

(Preparing the pipe for horizontal position 2G)
Trainee’s Name: ____________________________ Date:

__________________
Criteria YES NO
Is the total groove angle of the chamfer on the edge of the
pipe is 60°?
Is the size of the root face is uniform and the same as with
the electrode size to be used?
Are the root faces parallel to each other?
Is the alignment between the pipes are properly set up?
Is the size of root opening is the same as with the
electrode size to be used?
Are tack welds located at both ends?
Are the sizes of the tack welds not more than half of an
inch?
Are the back sides of the plate’s beveled edges free from
burrs?
Trainer : ______________________________ Date: ___________________

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JOB SHEET 2.1-7b
TITLE: Applying Root Pass, Filling Pass and Capping in Horizontal (2G)
Performance Objective: Given tools, materials and equipment you should be able to
apply root pass, filling pass and capping in horizontal
position 2G.

E – 6011
E – 7018
BI pipe schedule 60 4”Ø
Steel brush
Goggles
Angle grinder
Clear glass
Filter glass
Grinding disk
Welding mask
Leather gloves
Welding machine
Chipping hammer
Arc welding manuals
Adjustable combination plier
Personal protective equipment
Steps / Procedure:
Apply root pass using E – 6011

electrode with 90° work angle and
tilt the electrode at an angle of 15°
in direction of travel and use a
welding technique of whipping back
step motion.
Make First Weld (Root Pass)

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Apply filling pass using E-7018 electrode.
Be sure the work angle for second weld pass is 45° and the travel angle is
15° and use straight bead weld.
Set the work angle for third weld pass in 60° and 15° for travel angle and
use straight bead weld.
Direction of Direction of
Welding Welding
Make Second Weld (filling pass) Make Third Weld (filling pass)
3. Apply capping using E-7018 electrode
Put in the fourth weld pass on the top of the second weld with 90° work
angle and 15° travel angle and use straight bead weld.
Add the fifth weld pass between the top of second and third weld with
90° work angle and 15° travel angle and use straight bead weld.
Place the sixth and final weld pass on the top of third weld with 90°
work angle and 15° travel angle and use straight bead weld.
Make Fourth Weld (Capping) Make Fifth Weld (Capping)

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Make Sixth Weld (Capping) Completed Weld

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Job Sheet 2.1-7b

(Applying Root Pass, Filling Pass, and Capping in Horizontal 2G)

__________________
Criteria YES NO
Is the convexity of the root surface not more than 2.mm?
Is the bead width not more than 6.mm?
Is the offset between plates not more than 1 mm and
angular misalignment not more than 2°?
Is the length of slag inclusions not more than 3 mm?
Are the undercuts not more than 1 mm wide or deep?
Is the crater concavity not more than 1 mm?
Is the porosity not more than 1.5 mm in diameter or not
more than the combined total of 3 mm diameter in any
25 square mm of weld?
Trainer : ______________________________ Date: ___________________

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LEARNING OUTCOME # 2 Weld Carbon Steel Pipes in Fixed Vertical Position
(5G)
CONTENTS:
Essentials of welding
International welding codes and standards
Acceptable weld profiles
Weld defects, causes and remedies
Welding Procedure Specifications (WPS)
Welding techniques and procedures
Safe welding practices
Weld root penetration not exceeding allowable tolerances specified by welding

codes/ standards on
concavity
convexity
undercut
excess penetration
lack of fusion
burn-through
cracks
Weld capping/ final pass not exceeding allowable tolerances specified by welding
codes/ standards on:
height of reinforcement
underfill
porosities
undercut
cracks
cold laps
The finish weldment must be visually acceptable in accordance with welding

standards for:
spatters
arc strikes
slag
uniformity of beads

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CONDITION:
Equipment
Welding machine (AC or AC/DC)
Welding table or jig
Portable grinder
Welding booth
Portable oven
Tools/Accessories
Welding mask
Steel brush
Clear glass
Chipping hammer
Dark glass
Supplies/ Materials
Electrodes
Carbon steel plates
Cutting grinding disk

Safety shoes
Apron
Leggings
Safety goggles
Gloves
Training Materials
Arc welding manuals
Welding procedures specifications (WPS)
Welding standards
ASSESSMENT METHOD:
Written/oral
Interview
Direct observation

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Learning Outcome #2: Weld Carbon Steel Pipes in Vertical

Fixed Position (5G)
Read Essentials of Welding

(2.2-1)

Read International Welding Codes


Read Acceptable Weld Profiles

(2.2-3)

Read Weld Defects, Causes and

Remedies (2.2-4)

Read Welding Procedure

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Read Safe Welding Practices

(2.2-6)

Read Welding techniques and

Procedures (2.2-7)

Perform Operation Sheet (2.2-7)
Perform Job Sheet (2.2-7a)
Perform Job Sheet (2.2-7b)

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Learning Objective:
Remember:
CURRENT SETTING.
LENGTH OF ARC.
ANGLE OF ELECTRODE.
SPEED OF TRAVEL.
SELECTION OF ELECTRODE.
CURRENT SETTING
The welding current or amperage is essential to producing welds with good

appearance and the required strength characteristics. The welder controls the
amperage variable by setting the amperage on the welding machine prior to welding.
Remember:

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Current to be used.
CURRENT RANGES
SIZE E6013 / E6011 E7018
3/32 60 – 90 70 - 100
1/8 90 – 120 120 – 160
5/32 110 - 170 130 - 170
Run a practice weld at the lower recommended range setting.

Run a second practice weld at the higher recommended setting.
Compare the two welds for evidence of a well formed bead, good fusion, lack of
defects, and a smooth transition into the base metal.
If necessary reduce the amperage from lower to highest amperage until a
satisfactory weld bead is produced.
It is important to try different setting to avoid wasting time with a setting that is to
low or to high and will need to be changed later.

In example A the E-6010 weld made with the correct amperage appears properly
formed with the appropriate width and consistency.

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Remember:
D. Amperage correct
E. Amperage too low
F. Amperage too high
A B C
vertical position and using a weave technique you may need to increase the
amperage when weaving over a prior weld bead. You may want to use higher setting
for welding flat and horizontal than for welding in other positions.
LENGTH OF ARC
base metal.

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Fine spatter
Neat, even
Proper arc length will produce a crackling or weld run
hissing sound.
ARC LENGTH CORRECT
Too short arc length may short out while
welding. The beads also will become high Poor penetration
with poor penetration and overlap. Coarse spatter
Too long arc length will cause a great deal of
filler metal spattering – small solidified
metal drops o the base metal surface. It
cause also that the bead will be too low Rough,
Uneven weld run
with poor penetration and under cut.
ARC LENGTH TOO LONG
The welding machines used in Shielded Metal
Arc Welding are known as Constant Current Electrode
machines which mean that the current stays stuck to
relatively constant through changes in the work
voltage. The machine increases the voltage
as the arc length is increased to maintain Narrow,
current flow at the amperage level set on the Uneven weld
poor quality weld.
EFFECT OF ARC LENGTH

welding and faster travel speeds. When a slight gap is maintained the force of the
arc provides a weld bead with a slightly flatter appearance with less chance of slag
Remember:
ANGLE OF ELECTRODE

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STRIGHT EDGES
WELD
LINE
MOLTEN ARC
EVENLY SPACED
BULLET-NOSE CRATER
SHAPED RIPPLES
DIRECTION OF
MOTION
20º
BEAD AND
RIPPLES
20º
MOLTEN ARC
CRATER

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SPEED OF TRAVEL
Move sideways


too fast weld
bead narrow
SELECTION OF ELECTRODE
In general the electrode weld metal must be matched to the type and composition of
the base metal being welded. Further some electrodes within the available scope are

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E (X)60 1 3

3 – Flat only
4 – Vertical Down

STRENGHT
High All
Position
Sodium
High All DCEP
Position AC
Potassium
Position AC Convex
Sodium
Position Convex
Potassium AC
Iron
Hydrogen
Iron Flat,
Fillets
Hydrogen
Remember:

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SELF CHECK 2.2-1
e. EXX1X f. EXX3X
g. EXX2X h. EXX4X
11. In electrode E6013, the first two digits number represents of what?
e. Compressive Strength f. Tensile Strength

g. Yield Point h. Mild Steel Electrode
e. Type of Electrode f. Alloy Electrode
g. Type of Current h. Mild Steel Electrode
Its good performance will be determined by the width of the bead and the bullet nose
e. Arc Length f. Travel Speed

g. Electrode Angle h. Current Setting
It is essential to producing welds with good appearance and the required strength
e. Arc Length f. Travel Speed

g. Electrode Angle h. Current Setting

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Its application must be selected carefully to provide the strength characteristics
required for the weld joint.
e. Selection of Electrode f. Travel Speed

g. Electrode Angle h. Arc Length
e. Selection of Electrode f. Travel Speed

g. Electrode Angle h. Arc Length
What amperage setting is recommended if you are using E6011 or E6013 electrode
e. 60 – 90 f. 110 - 170
g. 70 - 100 h. 90 – 120
It will cause a great deal of filler metal spattering – small solidified metal drops of the base
metal surface. It cause also that the bead will be too low with poor penetration and
under cut.
e. Travel Speed too fast f. Wrong Electrode Angle

g. Arc Length too short h. Arc length too long
If you are using E7018 electrode, what welding position can be applied with this kind of
electrode?
e. Flat and Horizontal only f. All position

g. All Position, Vertical downward h. Flat only

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ANSWER KEY 2.2-1
A
B
C
B
A
A
C
D
D
B

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Learning Objective:
Developed

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American Welding Society (AWS)
American Society of Mechanical Engineers (ASME)
American Petroleum Institute (API)

application.
Design:

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Qualification:
samples.
Fabrication:
Inspection:
testing.


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SELF CHECK 2.2-2
11. Design and fabrication of welded components are governed by documents.
e. Quality Control f. Guidelines and Regulation

g. Rules and Specification h. Codes and Standards
The system that often used by welding fabricator to assist with the development of
their process control system
e. Codes and Standards f. Guidelines and Regulation

g. Rules and Specification h. Quality Control
One of the sources of codes and standards that publish many documents addressing

Standard (AWS)
The institute that publish many documents relating to Standard for Welding Pipelines

Standard (AWS)
The organization that is responsible for the development of the Boiler and Pressure

Standard (AWS)
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It is an element of the document of welding code and standard that typically outline the
requirements for qualification testing of welding procedure specifications (WPS) and
also those requirements for qualification of welding personnel
Requirement
It is an element of the document of welding code and standard that address the welding
inspector’s qualification requirements and responsibilities, acceptance criteria for
discontinuities, and requirements relating to procedures for non-destructive testing.
c. Design d.
Fabrication
It is an element of the document of welding code and standard that refer the user to a
e. Inspection f. Design
g. Scope and General h. Fabrication
Requirement
It is found at the beginning of the document and is important as it will normally provide a
description as to the type and extent of welding fabrication for which the document
Requirement
An element of the document of welding code and standard that provide information
Requirement

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ANSWER KEY 2.2-2
C
A
D
B
A
B
A
B
C
D

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Learning Objective:
There shall be no cracks anywhere in the weld.

There shall be no undercut anywhere in the weld.
There shall be no porosity anywhere in the weld
The weld profile shall conform to the weld profiles shown below:
APPENDIX V
(F) DESIRABLE FILLET WELD PROFILE (G) ACCEPTABLE FILLET WELD PROFILE

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Convexity, C, of a weld or individual surface bead with dimension W shall not exceed the value of the following table:
(J) UNACCEPTABLE FILLET WELD PROFILE
(H) ACCEPTABLE GROOVE WELD PROFILE IN BUTT JOINT
(I) UNACCEPTABLE GROOVE WELD PROFILE IN BUTT JOINTS

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APPENDIX VI
The faces of the weld may be slightly convex, flat, or slightly concave as shown
in Appendix V (A) and (B), with none of the unacceptable profiles shown
in(C). Except at outside corner joints, the convexity, C, of a weld or
Groove weld shall preferably be made with slight or minimum reinforcement except
as may be otherwise provided. In the case of butt and corner joints, the
Surfaces of grove welds required to be flush shall be finished so as not to reduce

the thickness of the thinner base metal or weld metal by more than 1/32 in
[0.8mm]or 5% of the thickness, whichever is smaller, nor leave reinforcement
that exceeds 1/32 in [0.8 mm].However, all reinforcement must be removed
where the weld forms part of a faying or contact surface. Any reinforcement
must be blend smoothly into the plate surfaces with transition areas free from
weld undercut. Chipping may be used provided it is followed by grinding.
Where surface finishing is required, its roughness value shall not exceed
250µin [6.3 µm]. surfaces finished to values of over 125 µin [3.2 µm] through
250 µin [6.3 µm] shall be finished so that the grinding mark are parallel to the
direction of primary stress. Surfaces finished t values of 125 µin [3.2 µm] or
less may be finished in any direction.
Ends of groove welds required to be flush shall be finished so as not to reduce

the width beyond the detailed width or the actual width furnished, whichever
is greater, by more than 1/8 in [3.2mm]or so as not to leave reinforcement
at each end that exceeds1/8 in [3.2mm]. Ends of welds in butt joints shall
be faired to adjacent plate or shape edges at a slope not to exceed 1 in 10.
Welds shall be free from overlap.

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APPENDIX VII
The weld shall have no crack.
Thorough fusion shall exist between the adjacent layer of weld metal and between
weld metal and base metal.
All craters shall be filled to the full cross section of the weld.
Weld profile shall be in accordance with appendices V and VI.
When the weld is transverse to the primary tensile stress in the part that is undercut,
the undercut shall be no more than 0.010 in. (0.25 mm) deep.
When the weld is parallel to the primary tensile stress in the part that is undercut, the
The sum of the diameter of the visible porosity shall not exceed 3/8 in. (9.5 mm.) in any
linear inch of weld nor shall the sum exceed ¾ inch (19.0 mm.) in any 12 inches
(305 mm.) length of weld.
Any single continuous fillet weld shall be permitted to under run the nominal fillet
weld size specified by 1/16 inch (1.6 mm.)
Visual inspection in all metals may begin immediately after the completed welds have
cooled to ambient temperature.
Arc strikes outside the weld groove are prohibited.

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SELF CHECK 2.2-3

its number.
16.________________
11.________________
12.________________
17.________________
13.________________
18.________________
14.________________
19.________________
15.________________
20. _______________
_

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ANSWER KEY 2.2-3
Unacceptable
Desirable
Unacceptable
Acceptable
Unacceptable
Acceptable
Unacceptable
Acceptable
Desirable
Acceptable

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Learning Objective:
Poor Weld Appearance
Cause

Too long arc length
Overheating
Remedies
Weld a correct travel speed

Use more uniform or only slight weave
Maintain the correct arc length
Use correct current
Poor Penetration – It is the shallow blending or fusion of the base metal and the weld metal
Cause
Current too low
Increase current
Weld at a slower travel speed
Use smaller electrode to adjust to groove size
Use deep penetration electrodes

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Spattering – It is the cooled solid form of molten metal particles that scattered on and
Causes
 Too long arc
 Arc blow
Remedies
Decrease current
Maintain short arc
Use AC current
Hold electrode more perpendicular to the surface of work piece
Porosity – It is small pores or holes that result of gas pocket in weld metal.
Causes
Insufficient puddling Time

Impurities in base metal
 Too short arc
 Wrong electrode
Remedies
Decrease travel speed

Clean base metal well before welding
Hold correct arc length
Use proper electrode (ex. Low hydrogen electrode for high carbon or high
sulphur steels)
Undercutting – It is the deep cut at the toes of the base metal.
Causes
Faulty electrode manipulation

Remedies
Use accepted technique for
vertical welds.
Hold electrode at correct angle from vertical plane in horizontal fillet.
Avoid using overly size electrode

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Weld Cracks
Causes
Weld crack
Welds too small
Rigid joints
Faulty welding
Wrong electrode
Remedies
Make larger welds between heavy plates

Re-design to eliminate rigidity
Use recommended welding sequence and technique at minimum current
Use proper type of electrode
Preheat parts to be welded
A B C D E F G

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Steel Pipes
SELF CHECK 2.2-4
DIRECTION: A. Encircle the letter of the correct answer below of each statement
and illustration.

weld.

metal.
b. Weld crack b. Undercutting c. Poor penetration d. Spattering


wrong electrode.


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Steel Pipes
Identify the effect of current, arc length, and travel speed on covered
electrode beads of illustration below
6. 7.

and travel speed
and travel speed
b. Amperage too low
c. Voltage too low
c. Voltage too low
8.

b. Amperage too low
c. Voltage too low
9.
10.

b. Amperage too low

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Steel Pipes
ANSWER KEY 2.2-4
d
b
a
c
c
d
b
a
d
d

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Steel Pipes
Learning Objective:
Welding Procedures
Welding process
Type of base metal
Joint design
Welding position
Type of shielding
Preheating and post heating requirements
Welding machine setting
Testing requirements

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Steel Pipes
Procedure
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Steel Pipes
utilize either.

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Steel Pipes

phenomenon.
penetration.

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Steel Pipes
SELF CHECK 2.2-5
correct answer.
.

The larger diameter it is, the higher welding currents it can carry

It is determined by dividing the welding amperage by the cross sectional area of

the electrode.

It is measure of the amount of current flowing through the electrode and the work. It
is a primary variable in determining heat input.

The higher of its inputs relate to larger weld cross sectional areas, and larger heat


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Steel Pipes

heat input.





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Steel Pipes
ANSWER KEY 2.2-5
D
C
C
B
A
D
A
B
D
C

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Steel Pipes
Learning Objective:
weld.
blow up.

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Revision # 00
Steel Pipes
helmet.



explode.
them carefully.
Personal safety

Developed by:
Revision # 00
Steel Pipes
Shields

the arc.

Developed by:
Revision # 00
Steel Pipes

following:

gases.
respirator.
safe.
irritating gases.
Electrical Safety

Developed by:
Revision # 00
Steel Pipes

V – Housekeeping

possible injury.

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Revision # 00
Steel Pipes
container.
disposed properly.
housekeeping.

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Revision # 00
Steel Pipes
SELF CHECK 2.2-6

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Steel Pipes
ANSWER KEY 2.2-6

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Steel Pipes
LEARNING OBJECTIVE:

Workpiece

before welding.
Work Clamp
Attach work clamp as close to

the weld as possible.
Electrode


Arc Length

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Steel Pipes
Slag


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Steel Pipes

for AC welding
Electrode
Work piece
Arc

Electrode
Work piece
Arc


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Revision # 00
Steel Pipes

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Steel Pipes
beads work better.

Weave Patterns

Developed by:
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Steel Pipes
Developed by:
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Steel Pipes
Typical Weld Joints

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Steel Pipes

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Steel Pipes
WELD CARBON STEEL PIPES IN VERTICAL FIXED POSITION (5G)

Steps / Procedure:

source

Developed by:
Revision # 00
Steel Pipes

Criteria YES NO
box is turn on
Trainer : ______________________________ Date: ___________________

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Steel Pipes
JOB SHEET 2.2-7a
TITLE: Preparing the Pipe for Vertical Position (5G)
Performance Objective: Given tools, equipment and materials, you should be able to
apply chamfer and root face on the edge of the pipes and

Welding Gauge
Angle grinder
Pipe beveling
Flat file
Bench vise
Electrode 6011
Welding machine
Steps / Procedure:



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Steel Pipes
used.
Clamp the pipe horizontally about chest

level. Starting at 6 o’ clock position and
stop at 12 o’ clock position. Using a
new electrode start with the same
procedure.

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Steel Pipes
Job Sheet 2.2-7a

(Preparing the Pipe for Vertical Fixed Position 5G)

__________________
Criteria YES NO
Is the total groove angle of the chamfer on the edge of
the pipe is 60°?
Is the size of the root face is uniform and the same as with
the electrode size to be used?
inch?
Are the back sides of the plate’s beveled edges free from
burrs?
Trainer : ______________________________ Date: ___________________

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Steel Pipes
JOB SHEET 2.2-7b
TITLE: Applying Root Pass, Filling Pass and Capping in Vertical (5G)
apply root pass, filling pass and capping in Vertical
position 5G.

E – 6011
E – 7018
Steel brush
Goggles
Angle grinder
Clear glass
Filter glass
Grinding disk
Welding mask
Leather gloves
Welding machine
Chipping hammer
Arc welding manuals
Steps / Procedure:

welding technique of whipping up
motion.

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Steel Pipes
15° and use weaving motion as welding technique.
Make Second Weld (filling pass)
Be sure the work angle for third weld pass is 90° and the travel angle is
15° and use weaving as welding technique.
Make Fourth Weld (Capping)

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Steel Pipes
Job Sheet 2.2-7b

(Applying Root Pass, Filling Pass and Capping in Vertical 5G)

__________________
Criteria YES NO
Is the convexity of the root surface not more than 2.mm?
Is the width of weaving for filling pass not more than
10.mm?
Is the width of weaving for capping not more than 16
mm?
Trainer : ______________________________ Date: ___________________

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Steel Pipes
LEARNING OUTCOME # 3 Weld Carbon Steel Pipes in Fixed Pipe Inclined at
45° Position (6G)
CONTENTS:
Essentials of welding
International welding codes and standards
Acceptable weld profiles
Weld defects, causes and remedies
Welding Procedure Specifications (WPS)
Welding techniques and procedures
Safe welding practices
Weld root penetration not exceeding allowable tolerances specified by welding

codes/ standards on
concavity
convexity
undercut
excess penetration
lack of fusion
burn-through
cracks
Weld capping/ final pass not exceeding allowable tolerances specified by welding
codes/ standards on:
height of reinforcement
underfill
porosities
undercut
cracks
cold laps
The finish weldment must be visually acceptable in accordance with welding

standards for:
spatters
arc strikes
slag
uniformity of beads

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CONDITION:
Equipment
Welding machine (AC or AC/DC)
Welding table or jig
Portable grinder
Welding booth
Portable oven
Tools/Accessories
Welding mask
Steel brush
Clear glass
Chipping hammer
Dark glass
Supplies/ Materials
Electrodes
Carbon steel plates
Cutting grinding disk

Safety shoes
Apron
Leggings
Safety goggles
Gloves
Training Materials
Arc welding manuals
Welding procedures specifications (WPS)
Welding standards
ASSESSMENT METHOD:
Written/oral
Interview
Direct observation

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Steel Pipes
Learning Outcome #3: Weld Carbon Steel Pipes in Fixed

Pipe Inclined at 45° Position (6G)
Read Essentials of Welding

(2.3-1)

Read International Welding Codes


Read Acceptable Weld Profiles

(2.3-3)

Read Weld Defects, Causes and

Remedies (2.3-4)

Read Welding Procedure

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Steel Pipes
Read Safe Welding Practices

(2.3-6)

Read Welding techniques and

Procedures (2.3-7)

Perform Operation Sheet (2.3-7)
Perform Job Sheet (2.3-7a)
Perform Job Sheet (2.3-7b)

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Steel Pipes
Learning Objective:
Remember:
CURRENT SETTING.
LENGTH OF ARC.
ANGLE OF ELECTRODE.
SPEED OF TRAVEL.
SELECTION OF ELECTRODE.
CURRENT SETTING
The welding current or amperage is essential to producing welds with good

appearance and the required strength characteristics. The welder controls the
amperage variable by setting the amperage on the welding machine prior to welding.
Remember:

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Steel Pipes
Current to be used.
CURRENT RANGES
SIZE E6013 / E6011 E7018
3/32 60 – 90 70 - 100
1/8 90 – 120 120 – 160
5/32 110 - 170 130 - 170
Run a practice weld at the lower recommended range setting.

Run a second practice weld at the higher recommended setting.
Compare the two welds for evidence of a well formed bead, good fusion, lack of
defects, and a smooth transition into the base metal.
If necessary reduce the amperage from lower to highest amperage until a
satisfactory weld bead is produced.
It is important to try different setting to avoid wasting time with a setting that is to
low or to high and will need to be changed later.

In example A the E-6010 weld made with the correct amperage appears properly formed
with the appropriate width and consistency.

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Remember:
G. Amperage correct
H. Amperage too low
I. Amperage too high
A B C
vertical position and using a weave technique you may need to increase the amperage
when weaving over a prior weld bead. You may want to use higher setting for welding
flat and horizontal than for welding in other positions.
LENGTH OF ARC
base metal.

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Steel Pipes
Fine spatter
Neat, even
Proper arc length will produce a crackling or weld run
hissing sound.
ARC LENGTH CORRECT
Too short arc length may short out while
welding. The beads also will become high Poor penetration
with poor penetration and overlap. Coarse spatter
Too long arc length will cause a great deal of
filler metal spattering – small solidified
metal drops o the base metal surface. It
cause also that the bead will be too low Rough,
Uneven weld run
with poor penetration and under cut.
ARC LENGTH TOO LONG
The welding machines used in Shielded Metal
Arc Welding are known as Constant Current Electrode
machines which mean that the current stays stuck to
relatively constant through changes in the work
voltage. The machine increases the voltage
as the arc length is increased to maintain Narrow,
current flow at the amperage level set on the Uneven weld
poor quality weld.
EFFECT OF ARC LENGTH

welding and faster travel speeds. When a slight gap is maintained the force of the
arc provides a weld bead with a slightly flatter appearance with less chance of slag
Remember:
ANGLE OF ELECTRODE

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STRIGHT EDGES
WELD
LINE
MOLTEN ARC
EVENLY SPACED
BULLET-NOSE CRATER
SHAPED RIPPLES
DIRECTION OF
MOTION
20º
BEAD AND
RIPPLES
20º
MOLTEN ARC
CRATER

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Steel Pipes
SPEED OF TRAVEL
Move sideways


too fast weld
bead narrow
SELECTION OF ELECTRODE
In general the electrode weld metal must be matched to the type and composition of
the base metal being welded. Further some electrodes within the available scope are

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Steel Pipes
E (X)60 1 3

3 – Flat only
4 – Vertical Down

STRENGHT
High All
Position
Sodium
High All DCEP
Position AC
Potassium
Position AC Convex
Sodium
Position Convex
Potassium AC
Iron
Hydrogen
Iron Flat,
Fillets
Hydrogen
Remember:

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Steel Pipes

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Steel Pipes
SELF CHECK 2.3-1
i. EXX1X j. EXX3X
k. EXX2X l. EXX4X
20. In electrode E6013, the first two digits number represents of what?
i. Compressive Strength j. Tensile Strength

k. Yield Point l. Mild Steel Electrode
i. Type of Electrode j. Alloy Electrode
k. Type of Current l. Mild Steel Electrode
Its good performance will be determined by the width of the bead and the bullet nose
i. Arc Length j. Travel Speed

k. Electrode Angle l. Current Setting
It is essential to producing welds with good appearance and the required strength
i. Arc Length j. Travel Speed

k. Electrode Angle l. Current Setting

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Steel Pipes
Its application must be selected carefully to provide the strength characteristics
required for the weld joint.
i. Selection of Electrode j. Travel Speed

k. Electrode Angle l. Arc Length
i. Selection of Electrode j. Travel Speed

k. Electrode Angle l. Arc Length
What amperage setting is recommended if you are using E6011 or E6013 electrode
i. 60– 90 j. 110 - 170

k. 70– 100 l. 90 – 120
It will cause a great deal of filler metal spattering – small solidified metal drops of the base
metal surface. It cause also that the bead will be too low with poor penetration and
under cut.
i. Travel Speed too fast j. Wrong Electrode Angle

k. Arc Length too short l. Arc length too long
If you are using E7018 electrode, what welding position can be applied with this kind of
electrode?
i. Flat and Horizontal only j. All position

k. All Position, Vertical downward l. Flat only

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Steel Pipes
ANSWER KEY 2.3-1
A
B
C
B
A
A
C
D
D
B

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Steel Pipes
Learning Objective:
Developed

Developed by:
Revision # 00
Steel Pipes
American Welding Society (AWS)
American Society of Mechanical Engineers (ASME)
American Petroleum Institute (API)

application.
Design:

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Steel Pipes
Qualification:
samples.
Fabrication:
Inspection:
testing.


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Steel Pipes
SELF CHECK 2.3-2
21. Design and fabrication of welded components are governed by documents.
i. Quality Control j. Guidelines and Regulation

k. Rules and Specification l. Codes and Standards
The system that often used by welding fabricator to assist with the development of
their process control system
i. Codes and Standards j. Guidelines and Regulation

k. Rules and Specification l. Quality Control
One of the sources of codes and standards that publish many documents addressing

Standard (AWS)
The institute that publish many documents relating to Standard for Welding Pipelines

Standard (AWS)
The organization that is responsible for the development of the Boiler and Pressure

Standard (AWS)
Developed by:
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Steel Pipes
It is an element of the document of welding code and standard that typically outline the
requirements for qualification testing of welding procedure specifications (WPS) and
also those requirements for qualification of welding personnel
Requirement
It is an element of the document of welding code and standard that address the welding
inspector’s qualification requirements and responsibilities, acceptance criteria for
discontinuities, and requirements relating to procedures for non-destructive testing.
c. Design d.
Fabrication
It is an element of the document of welding code and standard that refer the user to a
i. Inspection j. Design
k. Scope and General l. Fabrication
Requirement
It is found at the beginning of the document and is important as it will normally provide a
description as to the type and extent of welding fabrication for which the document
Requirement
An element of the document of welding code and standard that provide information
Requirement

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Steel Pipes
ANSWER KEY 2.3-2
C
A
D
B
A
B
A
B
C
D

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Steel Pipes

Learning Objective:
There shall be no cracks anywhere in the weld.

There shall be no undercut anywhere in the weld.
There shall be no porosity anywhere in the weld
The weld profile shall conform to the weld profiles shown below:
APPENDIX V
(K) DESIRABLE FILLET WELD PROFILE (L) ACCEPTABLE FILLET WELD PROFILE

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Convexity, C, of a weld or individual surface bead with dimension W shall not exceed the value of the following table:
(O) UNACCEPTABLE FILLET WELD PROFILE
(M) ACCEPTABLE GROOVE WELD PROFILE IN BUTT JOINT
(N) UNACCEPTABLE GROOVE WELD PROFILE IN BUTT JOINTS

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APPENDIX VI
The faces of the weld may be slightly convex, flat, or slightly concave as shown
in Appendix V (A) and (B), with none of the unacceptable profiles shown
in(C). Except at outside corner joints, the convexity, C, of a weld or
Groove weld shall preferably be made with slight or minimum reinforcement except
as may be otherwise provided. In the case of butt and corner joints, the
Surfaces of grove welds required to be flush shall be finished so as not to reduce

the thickness of the thinner base metal or weld metal by more than 1/32 in
[0.8mm]or 5% of the thickness, whichever is smaller, nor leave reinforcement
that exceeds 1/32 in [0.8 mm].However, all reinforcement must be removed
where the weld forms part of a faying or contact surface. Any reinforcement
must be blend smoothly into the plate surfaces with transition areas free from
weld undercut. Chipping may be used provided it is followed by grinding.
Where surface finishing is required, its roughness value shall not exceed
250µin [6.3 µm]. surfaces finished to values of over 125 µin [3.2 µm] through
250 µin [6.3 µm] shall be finished so that the grinding mark are parallel to the
direction of primary stress. Surfaces finished t values of 125 µin [3.2 µm] or
less may be finished in any direction.
Ends of groove welds required to be flush shall be finished so as not to reduce

the width beyond the detailed width or the actual width furnished, whichever
is greater, by more than 1/8 in [3.2mm]or so as not to leave reinforcement
at each end that exceeds1/8 in [3.2mm]. Ends of welds in butt joints shall
be faired to adjacent plate or shape edges at a slope not to exceed 1 in 10.
Welds shall be free from overlap.

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Steel Pipes
APPENDIX VII
The weld shall have no crack.
Thorough fusion shall exist between the adjacent layer of weld metal and between
weld metal and base metal.
All craters shall be filled to the full cross section of the weld.
Weld profile shall be in accordance with appendices V and VI.
When the weld is transverse to the primary tensile stress in the part that is undercut,
the undercut shall be no more than 0.010 in. (0.25 mm) deep.
When the weld is parallel to the primary tensile stress in the part that is undercut, the
The sum of the diameter of the visible porosity shall not exceed 3/8 in. (9.5 mm.) in any
linear inch of weld nor shall the sum exceed ¾ inch (19.0 mm.) in any 12 inches
(305 mm.) length of weld.
Any single continuous fillet weld shall be permitted to under run the nominal fillet
weld size specified by 1/16 inch (1.6 mm.)
Visual inspection in all metals may begin immediately after the completed welds have
cooled to ambient temperature.
Arc strikes outside the weld groove are prohibited.

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Steel Pipes
SELF CHECK 2.3-3

its number.
26.________________
21.________________
22.________________
27.________________
23.________________
28.________________
24.________________
29.________________
25.________________
30. _______________
_

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Steel Pipes
ANSWER KEY 2.3-3
Unacceptable
Desirable
Unacceptable
Acceptable
Unacceptable
Acceptable
Unacceptable
Acceptable
Desirable
Acceptable

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Revision # 00
Steel Pipes
Learning Objective:
Poor Weld Appearance
Cause

Too long arc length
Overheating
Remedies
Weld a correct travel speed

Use more uniform or only slight weave
Maintain the correct arc length
Use correct current
Poor Penetration – It is the shallow blending or fusion of the base metal and the weld metal
Cause
Current too low
Increase current
Weld at a slower travel speed
Use smaller electrode to adjust to groove size
Use deep penetration electrodes

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Steel Pipes
Spattering – It is the cooled solid form of molten metal particles that scattered on and
Causes
 Too long arc
 Arc blow
Remedies
Decrease current
Maintain short arc
Use AC current
Hold electrode more perpendicular to the surface of work piece
Porosity – It is small pores or holes that result of gas pocket in weld metal.
Causes
Insufficient puddling Time

Impurities in base metal
 Too short arc
 Wrong electrode
Remedies
Decrease travel speed

Clean base metal well before welding
Hold correct arc length
Use proper electrode (ex. Low hydrogen electrode for high carbon or high
sulphur steels)
Undercutting – It is the deep cut at the toes of the base metal.
Causes
Faulty electrode manipulation

Remedies
Use accepted technique for
vertical welds.
Hold electrode at correct angle from vertical plane in horizontal fillet.
Avoid using overly size electrode

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Steel Pipes
Weld Cracks
Causes
Weld crack
Welds too small
Rigid joints
Faulty welding
Wrong electrode
Remedies
Make larger welds between heavy plates

Re-design to eliminate rigidity
Use recommended welding sequence and technique at minimum current
Use proper type of electrode
Preheat parts to be welded
A B C D E F G

Developed by:
Revision # 00
Steel Pipes
SELF CHECK 2.3-4
DIRECTION: A. Encircle the letter of the correct answer below of each statement
and illustration.

weld.

metal.
c. Weld crack b. Undercutting c. Poor penetration d. Spattering


wrong electrode.


Developed by:
Revision # 00
Steel Pipes
Identify the effect of current, arc length, and travel speed on covered
electrode beads of illustration below
6. 7.

and travel speed
and travel speed
b. Amperage too low
c. Voltage too low
c. Voltage too low
8.

b. Amperage too low
c. Voltage too low
9.
10.

b. Amperage too low

Developed by:
Revision # 00
Steel Pipes
ANSWER KEY 2.3-4
d
b
a
c
c
d
b
a
d
d

Developed by:
Revision # 00
Steel Pipes
Learning Objective:
Welding Procedures
Welding process
Type of base metal
Joint design
Welding position
Type of shielding
Preheating and post heating requirements
Welding machine setting
Testing requirements

Developed by:
Revision # 00
Steel Pipes
Procedure
Developed by:
Revision # 00
Steel Pipes
utilize either.

Developed by:
Revision # 00
Steel Pipes

phenomenon.
penetration.

Developed by:
Revision # 00
Steel Pipes
SELF CHECK 2.3-5
correct answer.
.

The larger diameter it is, the higher welding currents it can carry

It is determined by dividing the welding amperage by the cross sectional area of

the electrode.

It is measure of the amount of current flowing through the electrode and the work. It
is a primary variable in determining heat input.

The higher of its inputs relate to larger weld cross sectional areas, and larger heat


Developed by:
Revision # 00
Steel Pipes

heat input.





Developed by:
Revision # 00
Steel Pipes
ANSWER KEY 2.3-5
D
C
C
B
A
D
A
B
D
C

Developed by:
Revision # 00
Steel Pipes
Learning Objective:
weld.
blow up.

Developed by:
Revision # 00
Steel Pipes
helmet.



explode.
them carefully.
Personal safety

Developed by:
Revision # 00
Steel Pipes
Shields

the arc.

Developed by:
Revision # 00
Steel Pipes

following:

gases.
respirator.
safe.
irritating gases.
Electrical Safety

Developed by:
Revision # 00
Steel Pipes

V – Housekeeping

possible injury.

Developed by:
Revision # 00
Steel Pipes
container.
disposed properly.
housekeeping.

Developed by:
Revision # 00
Steel Pipes
SELF CHECK 2.3-6

Developed by:
Revision # 00
Steel Pipes
ANSWER KEY 2.3-6

Developed by:
Revision # 00
Steel Pipes
LEARNING OBJECTIVE:

Workpiece

before welding.
Work Clamp
Attach work clamp as close to the

weld as possible.
Electrode


Arc Length

Developed by:
Revision # 00
Steel Pipes
Slag


Developed by:
Revision # 00
Steel Pipes

for AC welding
Electrode
Work piece
Arc

Electrode
Work piece
Arc


Developed by:
Revision # 00
Steel Pipes

Developed by:
Revision # 00
Steel Pipes
beads work better.

Weave Patterns

Developed by:
Revision # 00
Steel Pipes
Developed by:
Revision # 00
Steel Pipes
Typical Weld Joints

Developed by:
Revision # 00
Steel Pipes

Developed by:
Revision # 00
Steel Pipes
WELD CARBON STEEL PIPES AT 45° INCLINED FIXED POSITION (6G)

Steps / Procedure:

source

Developed by:
Revision # 00
Steel Pipes

Criteria YES NO
box is turn on
Trainer : ______________________________ Date: ___________________

Developed by:
Revision # 00
Steel Pipes
JOB SHEET 2.3-7a
TITLE: Preparing the pipe at 45° inclined fixed Position (6G)
Performance Objective: Given a schedule 60 black iron pipe 4”Ø, you should be able
to apply chamfer and root face on the edge of the pipes and

Welding Gauge
Angle grinder
Pipe beveling
Flat file
Bench vise
Electrode 6011
Welding machine
Steps / Procedure:



Developed by:
Revision # 00
Steel Pipes
used.
Clamp the pipe at 45° inclined position

about chest level. Starting at 6 o’
clock position and stop at 12 o’ clock
position. Using a new electrode start
with the same procedure.

Developed by:
Revision # 00
Steel Pipes
Job Sheet 2.3-7a

(Preparing the pipe at 45° inclined fixed position 6G)

__________________
Criteria YES NO
Is the total groove angle of the chamfer on the edge of
the pipe is 60°?
Is the size of the root face is uniform and the same as
with the electrode size to be used?
inch?
Are the back sides of the plate’s beveled edges free
from burrs?
Trainer : ______________________________ Date: ___________________

Developed by:
Revision # 00
Steel Pipes
JOB SHEET 2.3-7b
TITLE: Applying Root Pass, Filling Pass and Capping at 45° inclined fixed position (6G)
apply root pass, filling pass and capping at 45° inclined
fixed position (6G).

E – 6011
E – 7018
Steel brush
Goggles
Angle grinder
Clear glass
Filter glass
Grinding disk
Welding mask
Leather gloves
Welding machine
Chipping hammer
Arc welding manuals
Steps / Procedure:

welding technique of whipping back
step motion.

Developed by:
Revision # 00
Steel Pipes
15° and use straight bead weld.
Set the work angle for third weld pass in 90° and 15° for travel angle and
use straight bead weld.
Make Second Weld (filling pass) Make Third Weld (filling pass)
Put in the fourth weld pass on the top of the second weld with 90°
Add the fifth weld pass between the top of second and third weld with 90°
Place the sixth and final weld pass on the top of third weld with 90°
Make Fourth Weld (Capping) Make Fifth Weld (Capping)

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Revision # 00
Steel Pipes
Make Sixth Weld (Capping) Completed Weld

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Revision # 00
Steel Pipes
Job Sheet 2.3-7b

(Applying Root Pass, Filling Pass, and Capping at 45°Inclined Fixed Position)

__________________
Criteria YES NO
Is the convexity of the root surface not more than
2.mm?
Is the bead width not more than 6.mm?
Is the offset between plates not more than 1 mm and
angular misalignment not more than 2°?
Trainer : ______________________________ Date: ___________________

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Steel Pipes

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COMPETENCY-BASED

Sector : METALS AND ENGINEERING

Qualification Title : Shielded Metal Arc Welding NC II

Unit of Competency : Weld Carbon Steel Pipes Using SMAW

Module Title : Welding carbon steel pipes Using SMAW

DON BOSCO TVET CENTER - TONDO

CP, GARCIA ST. TONDO, MANILA

Date Developed: Document No.

Date Developed: Document No.

UNIT OF COMPETENCY: WELD CARBON STEEL PIPES

MODULE TITLE: Welding Carbon Steel Pipes

NOMINAL DURATION : 120 hours

LO1. Weld carbon steel pipes in horizontal position (2G)

Date Developed: Document No.

5889 Finish weldment visually acceptable in accordance with welding

Date Developed: Document No.

23 Weld root penetration not exceeding allowable tolerances specified by welding

24 Weld capping/ final pass not exceeding allowable tolerances specified by

25 The finish weldment must be visually acceptable in accordance with

Date Developed: Document No.

26 Personal protective equipment

Date Developed: Document No.

Learning Outcome #1: Weld Carbon Steel Pipes in

Learning Activities Special Instruction

0 Read Essentials of Welding

Compare answers with the answer

0 Read International Welding Codes

Compare answers with the answer

0 Read Acceptable Weld Profiles

Compare answers with the answer

0 Read Weld Defects, Causes and

Compare answers with the answer

0 Read Welding Procedure

Date Developed: Document No.

0 Read Safe Welding Practices

Compare answers with the answer

all the questions correctly.

0 Read Welding techniques and

Evaluate your own work using

Date Developed: Document No.

There are 5 essential variables to be considered in making a quality weld.

Date Developed: Document No.

The chart below shows typical amperage ranges

SIZE E6013 / E6011 E7018

Amperage may be referred to as the heat by some welders.

23 Run a practice weld at the lower recommended range setting.

The illustration below gives an idea of the evaluation process;

Date Developed: Document No.

B. Amperage too low

C. Amperage too high

Date Developed: Document No.

The correct arc length may vary according to

The variation of electrode angle is depending upon the position of welding to be

Date Developed: Document No.

The rate of travel across the joint is

Since the travel speed is not timed in

The electrodes are classified by a letter and numbering system as follows:

Date Developed: Document No.

Thousand pounds per  Type of Current