SHIELDED METAL ARC WELDING

NC 1
QUARTER 1 MODULE 3
WEEK 3
WELD DEFECTS CAUSES AND REMEDIES
NAME________________                                                 SECTION________________________
TEACHER: ___________________                                     DATE OF SUBMISSION_____________ 
 Module 3                                                                        
LESSON: Perform (1F) Flat position weld on carbon steel plate

OBJECTIVES: Upon completion of this lesson, the students will be able to:
1. Recognize the Parts of weld defects causes and remedies. 
2. Analyze the difference between parts of welding defects and good quality weld.
3. Discuss are the types of acceptable weld profiles

Weld Defects Causes and Remedies

Discussion
The profile of a completed weld may have a considerable effect on the performance of that weld in
service. It is the welding inspector’s function to identify these discontinuities through visual inspection
and often to evaluate their acceptance, or rejection, through the use of the applicable welding code or
standard acceptance criteria.

DEFECT  PROBABLE CAUSE  REMEDY 

1. Burn Through  >>>>>

 - excessive heat input  - reduce heat input 

2. Convexity/ Concavity >>>>>

- too fast travel speed  - observe proper parameters and techniques 

- too high current  - grind off or weld on 
- poor electrode manipulation 

- wrong electrode 
- weld and part sizes
- use proper electrode 
unbalanced 
- adjust weld size to part size 
- faulty welds 
- make sound welds with good root fusion 
- faulty preparation 
3. Cracks >>>>>>>>> - heat parts before welding 
- rigid Joint 
- weld from center towards edges 

- weld slowly enough 

- select electrode properly 
- speed too fast 
4. Incomplete Penetration >>>>> - electrode too large 
- use sufficient current 
- leave proper free space at the bottom of
- current too low 
weld 
- faulty preparation 

 
5. Misalignment >>>>>>>>
- grinding 
- be careful on finished surface 
- uneven thickness of metal 
- carelessness 
6. Overlapping  >>>>>>>

- too slow speed  - hold longer arc 

- current too low  - allow sufficient puddling 
- longer arc 
- large deposits in a single run 

7. Porosity >>>>>>>>>>
- short arc 
- insufficient puddling time  -remove impurities in base metal
- impaired base metal  - use correct current 
- incorrect current  - use weaving motion to eliminate pin holes 
- improper welding technique 

8. Slag Inclusions >>>>>>>>

- low amperage  - increase amperage 

- improper welding technique  - observe proper welding techniques 
- too tight welding area  - grind off tight areas/ reweld 
 - longer arc length 
- severe electrode angle 
9. Spatters >>>>>>>>>>> - high amperage 

- remove by grinding 

10. Undercut >>>>>>>>>>>

- Faulty electrode manipulation  - Use uniform weave 

- Improper electrode  - Avoid using overly large electrodes 
- Current too high  - Use moderate current and weld slowly 

11. Underfill >>>>>>>>> - Improper welding technique  - apply proper welding technique 
- faulty preparation  - may require grinding preparation 

4. A weld defect is any discontinuity in the weld metal, which exceeds the applicable code limit. Please
note that a discontinuity can be termed as a defect only when, if it exceeds the specified code limit,
hence we can say that every defect present in weld metal is a discontinuity but every discontinuity
present in the weld metal may not necessarily be a defect.

I.ACTIVITY 1
Multiple choice.
Directions: Write the letter of the correct answer on the space provided before each number.
_______1. These types of weld discontinuities can often seriously detract from the 
                    overall performance of a    welded component in service. Which of the 
                   following   welding profiles consider according to discontinuities with
                    weld profiles?
a. Spatter                                       c. undercut.
b. Warping                                     d. crack
 _______2. Which of the following ideal measure size of a fillet bed in accordance
                     of acceptable weld?
a. 5/16 in. or 8mm                       c. 1 in.
b. 3 in                                             d. 1/8 or 3mm
_______3. This discontinuity is defined as a groove melted into the base metal adjacent to the weld 
                    toe, or weld root, and left unfilled by weld metal. Which of the following welding defects.
a. Overlap                                       c. crack
b. Undercut                                    d. Excessive convexity
________4. This condition describes a weld profile that is usually concave in shape, and 
                      due to its concavity, provides an inadequate throat thickness. Which of 
                      the following welding defects.
a. Brittle weld                                c. distortion 
b. Crack                                           d. insufficient throat
_______5.  This discontinuity is defined as the protrusion of weld metal beyond the weld 
                     toe or weld root. Which of the following welding defects?
                      a.    Overlap                                       c. crack  
                      b.    Undercut                                    d. Excessive convexity
II. Activity 2

Photo weld of Welding Defects.

Direction: Identify what kind of welding defects the photo presented. Write your answer in 
               the rectangular box provided.

1.

2.

3.

4.

5.

6.
 7.

8.

III. Activity 3

WORD HUNT: Weld Defects Direction: Encircle 12 weld defects listed below. Words may appear
straight, across, backward, up and down, down, and up and diagonally.

S  D  E  Z  E  Y  T  I  V  A  C  N  O  C  R 
A  P  N  N  S  S  G  R  E  A  T  B  U  T  W 
D  E  L  Y  I  U  M  Y  T  R  I  D  U  K  Q 
S  N  L  T  R  N  S  K  C  A  R  C  P  L  H 
R  E  C  I  N  D  F  C  D  A  R  I  U  H  G 
E  T  L  S  S  E  F  S  P  E  L  L  I  G  U 
T  R  E  O  H  R  M  S  D  R  I  N  K  F  O 
T  A  A  R  A  F  R  N  E  M  P  T  Y  V  R 
A  T  N  O  R  I  U  K  G  W  C  C  E  B  H 
P  I  T  P  E  L  S  F  R  I  X  R  L  E  T 
S  O  D  P  O  L  T  I  U  S  L  A  G  S  N 
E  N  P  P  E  S  A  F  E  A  Z  A  L  O  R 
L  F  E  H  U  N  T  T  P  B  E  C  S  A  U 
K  C  C  O  N  V  E  X  I  T  Y  K  G  I  B 
O  E  A  G  H  C  S  V  X  O  N  S  A  T  M 

CONVEXITY  CONCAVITY  POROSITY 

UNDERFILL  UNDERCUT  SPATTERS 
CRACKS  OVERLAP  SLAGS 
MISALIGNMENT  BURN THROUGH  PENETRATION 
ANSWER KEY 
 
  MULTIPLE CHOICE

1. C
2. A
3. B
4. D
5. A

PHOTO INSPECTION: of Welding Defects.

1. Cracks
2. Spatters
3. Underfill
4. Under cut
5. Slag inclusion
6. Over lapping
7. Burn Through
8. Incomplete penetration

WORD HUNT: Weld Defects

NAME________________________                                                                SCORE________________
COURSE______________________                                                                   DATE________________
                                                                                
Post-test:
 I.MATCHING TYPE
Direction: Match the column A with those Column B Write the letter of your choice on a separate sheet
of paper.

Column A Column B

A. UNDERCUT
1.
B. SPATTER

2. C. SLAG INCLUSION

D. MISALIGNMENT
3.
E. POROSITY

4.  
F. BURN THROUGH
5.
G. OVERLAPPING

6. H. CRACKS

I. CONCAVITY
7.

J. UNDERFILL

8.

9.

10.

II. DRAWING:
Direction:  Search the internet and Draw a Flat Position (1F) in long coupon bond.                                     
(Note: Open your past/previous lesson in titled types of flat Position)
 SHIELDED METAL ARC WELDING
NC 1
QUARTER 1 MODULE 4
WEEK 4
WELDING PROCEDURES AND SPECIFICATIONS
NAME____________________                                          SECTION________________________
TEACHER: _________________                                        DATE OF SUBMISSION_____________
 Module 4                                                                      
LESSON:  WELDING PROCEDURE SPECIFICATION (WPS)
               (PERFORM 1F POSITION WELD ON CARBON STEEL PLATE)

OBJECTIVES: Upon completion of this lesson, the students will be able to:
1. Recognize the Welding Procedure Specification (WPS);
2. Identify the types and uses Welding Procedure Specification (WPS);
3. Significance of Welding Procedure Specification (WPS).
What Is it 
What is a WPS?
A Welding Procedure Specification, or WPS, is a document that serves as a guide for the effective
creation of a weld that meets all applicable code requirements and production standards. Think of a
WPS as a recipe for welders. In the same way that a recipe for a cake detail what ingredients and
quantities you’ll need, a WPS contains details that are necessary to create the desired weld. This
includes information such as base metal grade, filler metal classification, amperage range, shielding gas
composition, and pre-heat and inter-pass temperatures. The idea is that if a group of welders adhere to
all the details on a WPS, they should each be able to produce welds with reasonably similar mechanical
properties.

What is a PQR?

To answer this question, we need to take a step back. You see, before a WPS can be drafted, a
preliminary set of procedures and materials must be established. This initial procedure is used to create
a series of welds which are then mechanically tested to ensure they meet all applicable requirements.
The procedures for creating and testing the sample welds, as well as the final results, are documented
on a Procedure Qualification Record, or PQR. If the test results are acceptable, the PQR is approved and
can then serve as the foundation on which one or more WPSs are drafted. In short, a PQR serves as
evidence that a given WPS can be used to produce an acceptable weld.

What's the Importance of a WPS and PQR?

PART B: PRACTICAL (CWI and CWE)
Subject
Procedure and welder Qualifications 28%
Mechanical test and properties 8%
Welding Inspection and flaws 34%
NDE 8%
Utilization of Specification and drawings 8%

How Do I Use a WPS and PQR?

That’s a great question. It’s also one that warrants considerably more time and detail than I can
provide in this venue. As I mentioned earlier, WPSs and PQRs are covered rather extensively
during the live CWI seminars. However, if you’re looking to get a leg up, then you may want to
consider AWS Learning’s “WPS/PQR: Explained” interactive online course. This course was
created in response to continued feedback from students and educators and covers the ins and
outs of welding procedure specifications and procedure qualification records. This includes
everything from what their purpose is, how they are drafted, what kinds of information they
contain, and how to make use of that information.

The course also covers the procedure qualification process, including detailed information on
material properties as well as common non-destructive and destructive tests. The instruction
throughout this course is presented in a series of short modules, allowing you to internalize
information bit by bit, instead of all at once. Each module builds on concepts introduced in the
previous one and includes quizzes and interactive practice questions to help you get a grasp of
the material.

So, Now What?

It’s important to keep in mind that we’re just scratching the surface here. WPSs and PQRs are an
important part of a CWI’s knowledge base, but they’re far from the only thing. With that in mind, if
you’re ready to take the next step and learn more about WPSs and PQRs, be sure to check out the
“WPS/PQR: Explained” page at AWS Learning. While you’re there, you may want to check out some of
our other educational offerings as well. Whether you’re looking to learn about a new topic or brush up
on one you’re already familiar with, AWSL’s suite of online courses is a great place to start.

As always, if you have any questions, or if you have a suggestion for a topic, you’d like us to discuss in an
upcoming blog, give us a call or drop us a line in the comments section below!

PRE-TEST
NAME____________________                                          SECTION________________________
TEACHER: _________________                                         SCORE _____________

SELECT THE BEST ANSWER

A. Directions: Write the letter of the correct answer on the space provided before 
                      Each number.
_________1. What is the percentage of Welding Inspection and flaws in importance of Welding
                           Procedure Specification (WPS) and Procedure Qualification Record (PQR)
a. 30%                               c. 8%
b. 34%                               d. 25%
__________2. It is a document that serves as a guide for the effective creation of a weld that 
                            meets all applicable code requirements and production standards.
a. WPS                               c. AWS
b. PQR                                d. CWI
__________3. It is the test results are acceptable, the PQR is approved and can then serve as the
                            foundation 
                          on which one or more WPSs are drafted.
a. CWI                            c. PQR
b. WPS                            d. all of the above
________4. What is the percentage of Mechanical tests and properties in important of Welding? 
                           Procedure Specification (WPS) and Procedure Qualification Record (PQR)
a. 8%                               c. 34%
b. 25%                              d. 30%

________5. This course was created in response to continued feedback from students and educators 
                      and covers the ins and outs of the welding procedure specifications and procedure 
                      qualification records. Which of the following specification?
a. CWI                              c. WPS
b. NDE                              d. WPS and PQR

TRUE OR FALSE
B. Direction: read each statement below carefully. Write true if the statement is statement     
is correct and false if the statement is wrong.
____________1. A Welding Procedure Specification, or WPS, is a document that serves as a 
                               guide for the effective creation of a weld that meets all applicable code
                               requirements and production standards.
____________2. The Procedure Qualification Record, or PQR includes information such as base 
                               metal grade, filler metal classification, amperage range, shielding gas
                               composition, and pre-heat and inter-pass temperatures.
____________3. The Procedure Qualification Record, or PQR and his initial procedure is used to
                               create a series of welds which are then mechanically tested to ensure they 
                               meet all applicable requirements. 
____________4.  8% is the percentage of Welding Inspection and flaws in importantance 
                         of Welding Procedure Specification (WPS) and Procedure Qualification Record 
                         (PQR)
____________5. The use of WPS and PQR was created in response to continued feedback from 
                               students and educators and covers the ins and outs of welding procedure
                               specifications and procedure qualification records.
 FILL IN THE BLANKS
C. Direction: Fill each blank with the correct answer. Write your answer on the blank provided.
1. It is the course also covers the procedure qualification process, including detailed information on
material properties as well as common nondestructive and destructive tests.is
called________________
2. It is a document that serves as a guide for the effective creation of a weld that meets all applicable
code requirements and production standards. Think of a WPS as a recipe for welders. Is
called_____________
3. It is the test results are acceptable, the PQR is approved and can then serve as the foundation on
which one or more WPSs are drafted is called______________
4. the Importance of a WPS and PQR base of the subject have a 34% total is called_____________
5. This includes information such as base metal grade, filler metal classification, amperage range,
shielding gas composition, and pre-heat and inter pass temperatures is called_____________
Answer Key

True or False
1. true
2. false
3. true
4. true
5. true

Fill the blanks

1. How Do I Use a WPS and PQR?
2. Welding Procedure Specification
3. Procedure Qualification Record
4. Welding Inspection and flaws
5. WPS
 SHIELDED METAL ARC WELDING
NC 1
QUARTER 1 MODULE 5
WEEK 5
WELDING TECHNIQUE AND PROCEDURES
NAME________________                                                 SECTION________________________
TEACHER:                                                                              DATE OF SUBMISSION_____________
 Module 5                    
LESSON: WELDING TECHNIQUE AND PROCEDURE
               (PERFORM WELD CARBON STEEL PLATE FLAT POSITION (1F)

OBJECTIVES: Upon completion of this lesson, the students will be able to:
1. Recognize the Welding Technique and procedure;
2. Identify the types and uses Welding Technique and Procedure;
3. Significance of Welding Technique and Procedure.

What is it? 
Manual metal arc welding (MMA or MMAW), also known as shielded metal arc welding (SMAW), flux
shielded arc welding, or stick welding, is a process where the arc is struck between an electrode flux
coated metal rod and the workpiece. Both the rod and the surface of the workpiece melt to create a
weld. 
Manual metal arc welding was first invented in Russia in 1888. It involved a bare metal rod with no flux
coating to give a protective gas shield. The development of coated electrodes did not occur until the
early 1900s when the Kjellberg process was invented in Sweden and the Quasi-arc method was
introduced in the UK. It is worth noting that coated electrodes were slow to be adopted because of their
high cost. However, it was inevitable that as the demand for sound welds grew, manual metal

1. Arc became synonymous with coated electrodes. When an arc is struck between the metal rod
(electrode) and the workpiece, both the rod and workpiece surface melt to form a weld pool of
molten metal. Simultaneous melting of the flux coating on the rod will form gas and slag which
protects the weld pool from the surrounding atmosphere. The slag will solidify and cool and
must be chipped off the weld bead once the weld run is complete (or before the next weld pass
is deposited).

The process allows only short lengths of weld to be produced before a new electrode needs to be
inserted in the welding electrode holder. Weld penetration is low and the quality of the finished weld
deposit is highly dependent on the skill of the welder.

Types of flux/electrodes
To strike an arc between the electrode and base metal, such as carbon steel, and to produce a good
quality weld, a stick welder must ensure that their welding machines are fitted with suitable electrodes.
Arc stability, depth of penetration, metal deposition rate, and positional capability are greatly influenced
by the chemical composition of the flux coating on the electrode. Electrodes can be divided into three
main groups:

 Cellulosic
 Rutile
 Basic

Cellulosic electrodes
 Contain a high proportion of cellulose in the coating and are characterized by a deeply penetrating arc
and a rapid burn-off rate giving high welding speeds. Weld deposits can be coarse and with fluid slag,
dislodging can be difficult. These electrodes are easy to use in any position and are noted for their use in
the 'stovepipe' welding technique.

Features:

 deep penetration in all positions

 suitability for vertical down welding
 reasonably good mechanical properties
 high level of hydrogen generated - the risk of cracking in the heat affected zone (HAZ)

Rutile electrodes contain a high proportion of titanium oxide (rutile) in the coating. Titanium oxide
promotes easy arc ignition, smooth arc operation, and low spatter. These electrodes are general-
purpose electrodes with good welding properties. They can be used with AC and DC power sources and
in all positions. The electrodes are especially suitable for welding fillet joints in the horizontal/vertical
(H/V) position.
Features:
moderate weld metal mechanical properties, such as tensile strength good bead profile produced
through the viscous slag
positional welding possible with a fluid slag (containing fluoride)
easily removable slag

2. Basic electrodes contain a high proportion of calcium carbonate (limestone) and calcium fluoride
(fluorspar) in the coating. This makes their slag coating more fluid than rutile coatings - this is also fast-
freezing which assists welding in the vertical and overhead position. These electrodes are used for
welding medium, and heavy section fabrications where higher weld quality, good mechanical properties
and resistance to cracking (due to high restraint) are required.

Features:

 low hydrogen weld metal

 requires high welding currents/speeds
 poor bead profile (convex and coarse surface profile)
 slag removal difficult

Metal powder electrodes contain addition of metal powder to the flux coating to increase the maximum
permissible welding current level. Thus, for a given electrode size, the metal deposition rate and
efficiency (percentage of the metal deposited) are increased compared with an electrode containing no
iron powder in the coating. The slag is normally easily removed. Iron powder electrodes are mainly used
in the flat and H/V positions to take advantage of the higher deposition rates. Efficiencies as high as 130
to 140% can be achieved for rutile and basic electrodes without marked deterioration of the arcing
characteristics but the arc tends to be less forceful which reduces bead penetration.

Power source - Electrodes can be operated with AC and DC power supplies. Not all DC electrodes
can be operated on AC power sources, however, AC electrodes may be used on either AC or DC.

Welding current

Welding current level is determined by the size of electrode - the normal operating range and
current are recommended by manufacturers. Typical operating ranges for a selection of
electrode sizes are illustrated in the table. As a rule of thumb when selecting a suitable current
level, an electrode will require about 40A per millimeter (diameter). Therefore, the preferred
current level for a 4mm diameter electrode would be 160A, but the acceptable operating range
is 140 to 180A.
What's new?
Transistor (inverter) - A technology is now enabling very small and comparatively low weight
power sources to be produced. These power sources are finding increasing use for site welding
where they can be readily transported from job to job. As they are electronically controlled,
add-on units are available for TIG and MIG welding which increases the flexibility. Electrodes
are now available in hermetically sealed containers. These vacuum packs obviate the need for
baking the electrodes immediately before use. However, if a container has been opened or
damaged, the electrodes must be retried according to the manufacturer's instructions.

Training
TWI's Training School offers an appreciation course on MMA welding. This includes theory and
practical sessions, with approximately 75% demonstrations and hands-on sessions; appreciation
of the welding processes, and fundamental basic knowledge. Health & safety, setting up
equipment, welding process parameters, process-related defects and how to avoid them,
welding consumables.

ACTIVITIES:

A. Read each item CAREFULLY. Write only the letter of the best answer.
________1. It is technology is now enabling very small and comparatively low weight power sources
                      to be produced. These power sources are finding increasing use for site welding where
                      they can be readily transported from job to job.
a. Transformer welding machine                              c. Rectifier welding machine
b. Inverter welding machine                                      d. Motor generator welding machine
________2. It is a basic electrode that contain a high proportion of calcium carbonate (limestone) 
                    and calcium fluoride (fluorspar) in the coating. This makes their slag coating more fluid
                    than rutile coatings.
a. low hydrogen weld metal                               c. requires high welding currents/speeds
b. slag removal difficult                                       d. all of the above
________3. Cellulosic electrodes contain a high proportion of cellulose in the coating and
                       are characterized by a deeply penetrating arc and a rapid burn-off rate giving
                       high welding speeds.
a. deep penetration in all positions                          c. low hydrogen weld metal
b. requires high welding currents/speeds                d. manipulation.
________4. The power source of Electrodes can be operated with AC and DC power supplies. 
                      Not all DC electrodes can be operated on AC power sources, however AC electrodes 
                      may be used on either AC or DC.
a. Penetration                                                               c. current
b. Angle of electrode                                                   d. speed of travel
_________5. It is a type of flux/electrode to strike an arc between the electrode and base 
                          metal, such as carbon steel, and to produce a good quality weld.
a. Cellulosic                                                               c. Potassium
b. Mercury                                                                d. magnesium 
B. Write TRUE if the statement is correct and FALSE if the statement is wrong.
 ________6. It is a process where the arc is struck between an electrode flux coated metal 
                            rod and the workpiece. Both the rod and the surface of the workpiece melt
                            to create a weld.
________7. Training TWI's Training School offers an appreciation course on MMA welding.
________8. A Transistor (inverter) - the normal operating range and using high current a
                      recommended by manufacturers.
________9. Travel of speed in stick welding can be used with AC and DC power sources and
                      in all positions. The electrodes are especially suitable for welding fillet joints in
                      the horizontal/vertical (H/V) position.
_______ 10. Cellulosic electrodes contain a high proportion of cellulose in the coating and 
                     are characterized by a deeply penetrating arc and a rapid burn-off rate giving
                     high welding speeds.
C. Enumerate the 4 Types of Welding technique using Cellulosic electrodes.
11.__________________________________
12._________________________________
13._________________________________
14._________________________________
D. Enumerate the 4 Characteristics of a higher weld quality by using basic electrodes.
15._________________________________
16._________________________________
17._________________________________
18._________________________________
A. Diagnostic Test B. True or False C. Enumeration
1.B 6.T 11. deep penetration in all positions
2.D 7.T 12.suitability for vertical down welding
3.A 8.F 13.reasonably good mechanical properties
4.C 9.F 14.high level of hydrogen generated – the risk of cracking in the heat-affected zone (HAZ)
5. A 10.T D. Enumeration
15.low hydrogen weld metal
16. requires high welding currents/speeds
17. poor bead profile (convex and coarse surface profile)
18. slag removal difficult

Answer Key
SHIELDED METAL ARC WELDING

NC 1
QUARTER 1 MODULE 5
WEEK 5
DIAGNOSTIC TEST
PRE-TEST/DIAGNOSTIC TEST

NAME________________________                                                                SCORE________________
COURSE______________________                                                                   DATE________________

ACTIVITY 1 – Matching Type

Direction: Identify these Flux shielded arc welding parts in Column A by choosing the letter of your 
                  answer in Column B.

COLUMN A COLUMN B
_________1. Arc
_________2. Parent           
                        Metal
_________3. Slag

_________4. Evolve gas  

                         shield                                     
   
_________5 Consumable 
                        Electrode

_________6. Weld metal

_________7. Flux Covering

_________8. Weld Pool

_________9. Core wire

________10. Gas 
SHIELDED METAL ARC WELDING
 NC 1
QUARTER 1 MODULE 6
WEEK 6
PERSONAL PROTECTIVE EQUIPMENTS
(PPE)AND THEIR USES

NAME________________                                                 SECTION________________________
TEACHER: ___________________                                     DATE OF SUBMISSION_____________ 
Module 6                                                                         
SAFE WELDING PRACTICES

OBJECTIVES:
1. Identify the different parts of Personal Protective Equipment and their uses.
2. The learner independently demonstrates the types of Personal Protective & Equipment (PPE).
 Introduction
Welding is a safe occupation if you follow safety measures. 
Potential hazards. When these measures are over look ignored, however the welders can
encounter such dangers as electric shock, overexposure to fumes and gasses, is radiation. Fire,
and fire explosion:  all of which may result in serious or even fatal injuries.

Learner Outcomes:
 Identify hazards in workplace
 Recognize the need for Personal Protective Clothing and devices
 Handle workplace tools, equipment and materials safely
 Learn and perform first aid use the fire extinguisher properly.

Identifying hazardous areas

What is a workplace hazard?

A workplace hazard is anything at work that can harm a person – physically or mentally.
Hazards – may cause both temporary Ex. Cuts, skin burns, electric shock, and Fire
explosions.
TYPES OF WORKPLACE HAZARDS
Workplace hazards have been classified into just many types.
1. PHYSICAL HAZARDS – A hazard due to transfer of energy between an object and a
worker Ex. Falling from a height, a burn from a hot oven, the loss of a finger, loss of
hearing from a noisy machine.
2. CHEMICAL HAZARDS – Hazards due to contact with chemicals Ex. Cleaners, pesticides,
and fertilizers.
3. BIOLOGICAL HAZARDS – a hazard due to contact with living organisms or their
byproducts, Ex. Molds, bacteria, HIV, grain dust.
4. ERGONOMIC HAZARDS – Are workplace conditions that stress and strain the body. They
can cause by the design of machinery the use of tools, and the way work is done
(repetitive motion, stooping, etc.,)
Common Workplace Injury

What harm possibly comes to you in the work place? In this section, we discuss common workplace
injuries, their sources and give you helpful information about each.
1. FALLS - The most common types of workplace accidents falls to the same surface and falls
below.
2.  factors of the severity of the injury
1. Velocity of an initial impact.
2. Magnitude of deceleration (due to hardness of the surface)
3. Orientation of the body impact.
3. IMPACT – An impact resulting from being struck by and struck against object may cause serious
accidents. The severity of injury from impacting an objects depends on three factors.
 Velocity of impact
 Characteristics of the object (size, hardness, shape, etc.
 Body part impacted.
4. MECHANICAL – there are many hazards created by moving machine parts as there are types of
machines. Mechanical hazards cause caught-in, caught-on, and crush accidents that can cut,
crush, amputate, break bones, strain muscles, and even cause asphyxiation.
5. NOISE – exposure to excessive noise can result in hearing loss that not only affects you but can
impact the people who live and work with you.
6. TOXICS – all materials are potentially toxic to some extent. At work, a material may be
considered toxic a small quantity can cause injury, such ex, tissue damage, cancer, mutations,
it’s important to consider the four (4) possible routes of entry of toxic materials into the human
body:
 Inhalation – Breathing in toxins is the most common and dangerous route.
 Ingestion – Toxic enter through the gastrointestinal tract.
 Absorption – toxic pass-through skin into the bloodstream. 
 Injection – toxic may be injected into the body (needles, etc.) the common
yet most direct route entry.
7. HEAT AND TEMPERATURE – Overexposure to heat and temperature extremes may result in and
range of injuries from burn to frostbite. Temperature indicates the level of heat present. Heat is
produced of chemical reaction, combustion, electrical current, mechanical motion, and
metabolism. Heat transfer by
 Convection – heat transferred by molecules moving through a fluid, gas, or
liquid.
 Radiation – occurs when body temperature is above absolute zero.
 Conduction – heat is transfer through a substance or between substances
without physical movement of the substance itself.
8. FLAMMABILITY/ FIRE – Fire may cause burn injuries. Flammable materials include:
 Fuel                                 solvent
 Cleaning agents             lubricants
 Coating’s                          chemicals
 Refrigerant’s                    insecticides
 Plastic                              hydraulic fluid
 Vegetation                       fabrics
 Wood/ paper                  metals
 Rubber                             
                                        
9. EXPLOSIVES – The result of the explosion may range from minor injury to major catastrophe.
Explosives are used mostly by industry in construction, mining, quarrying, and seismographic
work. Ex. Acetylene, Oxygen, argon, etc.
10. PRESSURE HAZARDS – high- and low-pressure conditions in the workplace can result in injury.
The standard atmospheric pressure is 14.7 pounds per square inch. (psi) examples of pressure
hazards include:
 Ruptured cylinders
 Whipping hoses and lines
 Water hammer
 Using compressed air for cleaning tools
11. Electrical Contact – Exposure to electrical current may cause injury or death
5 principles categories of electrical hazards:
1. Shock – Electrical shock may be caused by bare conductor’s insulation
failures, the buildup of static electricity, and faulty electrical equipment.
 2. Ignition of combustible material – Ignition is usually caused by a spark, arc,
or corona effect (ionized gas allows a current between conductors).
3. Overheating – High current creates high heat that can result in fires,
equipment burnout, and burns to employees.
4. Electrical explosions – fast overheating of circuit breakers, transformers,
and other equipment may result in an explosion.
5. Accidental activation of equipment – unexpected start-up of equipment and
machinery can injure and kill. That’s why lockout/ tag-out procedures are
important.

WELDING TASK IN SAFE WELDING PRACTISES

           The hazards of welding a welder’s life if he or she is not wearing the proper protective clothing
equipment. PPE here is some information on the suitable outfits that a welder must wear PPE.

OBJECTIVE – To identify the different personal protective equipment PPE and their uses.

WELDING SHIELD/ HELMET 

 The welding shed/helmet is used to protect the face and eyes from the molten metal.
 To prevent the impact of the arc that produces by sparking electrodes which result in infrared
rays, ultraviolet rays, and the heat and spatter from the molten metal. 
 To prevent through a filter reduces the intensity of radiation and allows a safe amount of light to
pass for viewing the weld pool.

RECOMMENDED MINIMUM PROTECTIVE FILTER BASED ON THE WELDING CURRENT AND USED            
SHOWN IN THE TABLE BELOW

Approximate Range of welding Filter lens Number

Current
Up to 100 8
100-200 10
200-300 11
300-400 12
Over 400 13

LEATHER JACKET – is made from chrome leather to prevent the entry of slogs and spatter
LEATHER APRON - Made from chrome leather to prevents chest the entry of slogs and spatter

LEATHER GLOVES - Made from chrome leather to prevents Hands from heat particularly spatter 
                                     and electric shock.

CLEAR GOGGLES – To protect our eyes from grinding Projectiles.

Steel Toe Leather boots – Prevent our feet from slags.

PRE-TEST

NAME________________                                                 SECTION____________
TEACHER: ___________________                                   SCORE_____________ 
                                                                         

SAFETY WELDING PRACTICES

MULTIPLE CHOICE: Choose the correct answer and write the letter that corresponds to your choice on
the answer sheet provided.
 
1. Which of the following is the right meaning of PPE?
A. Persons Protective Equipment                c. Personal Protector Equipment
B. Personal Protective Equipment’s           d. Personal Protective Equipment
2. Workplace hazards have been classified into just many types. Which of the following workplace hazard?
a. Physical hazards                                   c. falls
b. Electric shock                                              d. hand burn
3. Which of the following hazard is common workplace injury?
a. Biological hazards                                       c. Physical hazards
b. Explosives                                                     d. chemical hazards
4. The welder wants to grind the steel plate fillet. Which of the following Personal Protective Equipment PPE to be use? 
a. Goggles                                                         c. auto dark helmet
b. Apron                                                            d. leather jacket
5. The welder performs welding steel fillet plate at a current of 120 amperes, what is the recommended filter lens
number?
a. 8                                                                     c. 12
b. 10                                                                   d. 11
6. The welder wants to remove the slags in he is output. Which of the following safety gadget are to be used?
a. Welding gloves                                           c. auto dark helmet
b. Clear glass                                                   d. leather or safety shoes
7. Which of the following is most dangerous from welding task exposure?
a. X- rays                                                          c. Beta – rays
b. Ultraviolet Rays                                        d. Sun rays
8. FLAMMABILITY – Fire may cause burn injuries. Which of the following flammable materials can cause burn and
injuries?
a. Fuel                                                               c. solvent
b. Cleaning agents                                          d. all of the above
9. The welder wants to joint or weld Fillet steel plate. Which of the following Personal Protective Equipment PPE is to be
used?
a. auto dark helmet                                        c. Goggles
b. leather jacket                                              d. leather Apron
 10. A workplace hazard is anything at work that can harm a person. Which of the following types of workplace hazards
can harm?
I – Physical Hazard, Hand burn
II – Biological Hazard, X- rays
III - Sun rays, Beta – rays, electric shock
IV -    Biological Hazard, Chemical Hazard, Physical Hazard 
a. I                                                                      c. III
b. II                                                                     d. IV

Key Answer:

1.d
2.d
3.d
4.a
5.b
6.b
7.b
8.d
9.a
10.c
 SHIELDED METAL ARC WELDING
NC 1
QUARTER 1 MODULE 7 
WEEK 7
ALTERNATING CURRENT AND DIRECT CURRENT IN
WELDING
NAME________________                                                 SECTION________________________
TEACHER: ___________________                                     DATE OF SUBMISSION_____________ 
Module 7                                                                         

LESSON:  ALTERNATING CURRENT (AC) VERSUS DIRECT CURRENT WELDING

Objectives: At the end of the lesson, the students will be able to;
1. Explain the alternating and direct current in welding.
2. Identify the pros and cons of AC and DC in welding.
3. Choose which current is better in welding.

DISCUSSIONS:

AC vs. DC Welding

AC versus DC welding is widely debated because ac and dc current options are used in
all manner of applications. But you tend to find that only one current type is used. In welding,
there is a difference because you can have both AC welding and DC welding options.

The choice of AC versus DC welding causes a number of questions to be raised. These

questions include people asking what the difference is and also professional and hobby welders
across the globe debate on which of the two is the better option for their welding needs.

To help you understand what AC versus DC currents are and what the pros and cons of
each are we have compiled the information below. Hopefully, this will help you make the right
decision in choosing the right current type for your welding needs.

WHAT IS AC WELDING?

• AC welding is where the welder uses an AC current for its supply. An AC current means
an ALTERNATING CURRENT, the term alternating means it’s not linear in its supply.

• Typically AC currents are what you would expect to see from your electrical outlets in
your home or business premises. The AC current when supplied does not move in a straight line,
essentially it changes direction at a 60-hertz frequency.

• Older welding will only carry AC currents because this is what most of the world’s
electrical grids use. An AC current is cheaper and easier to create.
PROS OF AC WELDING
• Welding aluminum because the current supports the requirements of welding at a
higher temperature
• AC welding is the preferred method for tungsten inert gas welding. If you are in an
industrial setting where you are in the shipbuilding industry, for example, then AC welding may
be preferable. This is because AC welding does not suffer from arc blow to the extent of DC
welding.

• AC welding is cheaper to produce and because of this, they are cheaper to buy.

WHAT IS DC WELDING?

• DC welding is where the welder uses a DC current for its supply. A DC current means the
current travels in one direction in a linear setting.

• DC currents are not supplied by electrical grids so DC units need an internal transformer
to change the current from AC to DC for use; this is evident in its use in welders.

PROS OF DC WELDING

• You will gain a smoother weld because of the constant and linear direction of the
current.

• The arc will be more stable and easier to handle using a DC welder and the spatter from
the weld will be less because of this.

• If you are stick welding a DC a welder can use both AC and DC rods while an AC welding
can only use AC rods.

AC vs. DC: The Cons of DC Welding

• There is a greater potential for arc blow using DC welding.

• The DC welder can sometimes be more expensive because of the additional transformer
required to alter the incoming current from AC to DC for use.

AC vs. DC Welding and Choosing a Welding

• In today’s market, a lot of the slightly more expensive welding carries the option of
having both AC and DC currents with a simple switch between the two.

• If you don’t have the ability to switch between the two current types you will most likely
find that the cheaper welders use the AC current as the welder does not need additional
components to change the current. Because of this, you may not have a choice on the current to
use if you have a lower budget.
 • If you have a little extra cash, then you can purchase a DC welder. A DC welder will give
you a smoother weld and a more stable arc but there is an additional cost to this that you may
feel doesn’t warrant the outcome of the weld.

• When it comes to AC vs. DC welding, there are pros and cons for both. But generally,
both professional and hobby welding operators for a DC welder where the choice is available to
them just for the smoother weld. This being said there are still times where an AC welding is
more suitable as mentioned

 ACTIVITY SHEET 1

Direction: Write TRUE if the statement is correct and write FALSE if the statement is incorrect.

____________ 1.  AC welding and DC welding have no difference at all.

____________ 2.  AC welding uses linear current supply.

____________ 3.  DC welding uses currents which travel in one direction.

____________ 4.  DC units need an external transformer to change the current from AC to
                                  DC for use.

____________ 5.  AC current is cheaper and easier to create.

____________ 6.  Older welders carry AC currents because this is what most of the worlds 
                                  electrical grids use.

____________ 7.  DC currents are not supplied by electrical grids.

___________   8.  DC welder can use both AC and DC rods while an AC welder can only use   
                                                 Ac rods.

____________ 9.  The AC welder can sometimes be more expensive because of the 
                                 Additional transformer required. 

___________ 10.  DC welding is ideal for inverter welding.

  ACTIVITY SHEET 2

Direction: Identify if the following statements describe AC or DC welding.

____________ 1.  Preferred method in industrial setting.
____________ 2.  Cheaper to produce and because of this they are cheaper to buy.
____________ 3.  Produces a less smooth weld.
____________ 4.  You will gain a smoother weld because of the constant direction of 
                                  current.
 ____________ 5.  The arc will be more stable and easier to handle.
____________ 6.  You can use this if you have a little extra cash.
____________ 7.  Professional welders choose this kind of welding.
____________ 8.  Cheaper welders choose this kind of welding.
____________ 9.  The current supports the requirements of welding at a higher 
                                  temperature.                                                                    
____________1 0. There is a greater potential for arc blow using this kind of welding.

   KEY ANSWER

ACTIVITY 1
1. False
2. True
3. True
4. False
5. True
6. True
7. True
8. True
9. False
10. False