FIRST QUARTER LESSON 2

PREPARE WELD MATERIALS

Course Description:

This is a specialization course which leads to a SMAW Certificate Level I (NC I). It covers three
(3) core competency that a high school student ought to possess,--namely, layout beads, performing
fillet welding on carbon steel plates & performing groove welding on carbon steel plates.

The preliminary of this introduction which leads to specialization include the following: (1) discussion
on the relevance of the course, (2) explanation of key concepts relative to the course, and (3) exploration
of career opportunities.

Lesson Description:

For a new welder, it is often difficult to concentrate on anything other than the bright sparks and
glow at the end of the electrode. As you develop your skills, visual field will increase, allowing you to see
a much larger welding zone. This skill comes with practice and nothing enhances your welding skills
more than time spent actually welding, cleaning off the weld, inspecting it to identify any necessary
corrections and trying to improve your technique. Finally, all welders need to make sure that their
immediate work area is safe and kept in a clean condition for the benefit of all who work there.

Content Standard:

The learner demonstrates an understanding of the concepts and underlying principles in Shielded
Metal .Arc Welding (SMAW).

Performance Standard:

The learner independently performs Shielded Metal Arc Welding (SMAW) processes based on
market standards.

Learning Competencies/MELCS/Objectives

 Prepare welding consumables;

 Prepare welding protective equipment.

MOTIVATION
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Have you ever tried welding personally?

You might answer yes or no, but whether you already tried it personally or not, this question is
still in the mind of each and everyone of us. What are the things that are very helpful for us to
produce a good or better weld?

What Do You Need To Know?

Read Information Sheet on Essential of Welding and Welding protective equipment.

5 ESSENTIALS OF SHIELDED METAL ARC WELDING

1. ELECTRODE SIZE

Electrodes for shielded metal arc welding range in diameter from 3/32 to 3/16 of an inch. You may also
come across some ¼ inch electrodes. They are commonly found in 9, 14 and 18-inch lengths

Electrode diameter is based on the thickness of the base metal, the welding position and the type of joint
to be welded.

Larger diameter electrodes are used on thicker metals and for flat position welding because they offer
higher deposition rates.

Smaller diameter electrodes are used for horizontal, vertical and overhead welding, because they produce
a smaller weld puddle that is easier to control than the bigger puddle produced by larger diameter
electrodes.

Joint design also affects electrode diameter. On groove welds for example, the electrode has to be small
enough to access the root of the joint. The welder’s skill also has a bearing on electrode diameter because
a more capable welder can control a larger, more fluid weld puddle.

As a general rule, when there is no welding procedure specification, use the largest diameter electrode
possible. Larger diameter electrodes produce welds of the required dimensions in the least amount of time
and at lower cost, because they have higher deposition rates and allow faster travel speeds.
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Commonly used Electrodes and descriptions:

TENSILE STRENGTH: is the resistance of a material to breaking under tension. So, If an object has
high tensile strength, it is essentially means that it can resist a lot of tension break it breaks.

Example : E6011 Electrode

The tenisle strength (the 1st & 2nd digits) is 60,000 pounds per square inch (psi).

BASIC WELDING POSITIONS:

The four basic welding positions are: flat, horizontal, vertical, and overhead. 
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The most common type of weld you will do is a Fillet weld and a Groove weld, and you can accomplish
these welds in all four positions.

But you also do surface welds in all four positions as well, thought you will not do this type of weld very
often.

The Flat Position:

In the flat welding position you will do your weld on the top side of your joint. But the actual face of your
weld will be in a near horizontal position.

The common term for this kind of weld is called, 'flat position' but it is also referred to as the 'downhand'
position. 

The image on the left is a flat position fillet weld, and the image on the right is a flat position groove weld
example.

Out Of Position Welding:

The flat welding position is the easiest position and most desirable position to weld in. In the flat position
the metal is flat and your welding torch or rod is going to move in a horizontal direction.

The other positions are called Out Of Position because they are more difficult and require more skill to do
them well. The out of position welding positions are: Horizontal, Vertical, and Overhead.

The Horizontal Position:

The image on the left (above) is a horizontal position fillet weld, and the image on the right is a horizontal
position groove weld example.

 In the Fillet Weld position you will weld on the top side of the surface that is horizontal (or close to it)
and against a surface that is vertical (or close to it). See the illustration above.
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 In the Groove Weld position the weld axis is in a horizontal plane (approximately), and the face of the
weld is on a vertical plane (approximately).  See Image B above.
Vertical Position:

The illustration image on the left (above) is a vertical position fillet weld, and the image on the right is a
vertical position groove weld example.

In the Vertical position welding the welds axis is almost vertical.

Overhead:

In the overhead welding position you will do the welding beneath the joint. It's pretty self explanatory.

The 4F illustration on the left is an overhead position fillet weld, and the illustration next to it is an
overhead position groove weld example.

2. CURRENT

Current is measured in amperes, or amps. Each type of electrode has recommended amperage ranges for
optimum performance. Amperage ranges are usually specified in the welding procedure or in the
manufacturers’ data sheets.

Current used in Arc Welding include:

 Alternating Current (AC), which changes the positive-negative electron flow twice per cycle and
creates an even current build-up
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 Direct Current (DC), in which electrons flow in one direction - a rectifier is used to convert DC
current into AC current, and direct current is specified by one of two polarity options:

2 types of DC current:

 Direct Current Electrode Negative (DCEN) – straight polarity, in which the electrode
is negative and the workspace is positive.

 Direct Current Electrode Positive (DCEP) – reverse polarity, in which the electrode
is positive, and the work is negative (widely considered to be the option for arc welding
purposes).

If the amperage is set above the suggested operating range, the electrode melts too fast. This increases
deposition and the weld puddle becomes too large to control. It could also cause the electrode coating to
overheat and break down.
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Amperage too high – The weld bead is wide and flat with excessive penetration and spatter, and
undercutting frequently occurs along the toes.

If the amperage is set below the designated range, there is insufficient heat to melt the base metal, and the
weld puddle is too small for proper control. The droplets forming on the end of the electrode may bridge
to the weld puddle periodically extinguishing the arc. The weld bead will be irregular with a crowned
appearance and insufficient penetration.

Amperage too low -The weld bead will be irregular with a crowned appearance and insufficient
penetration

3. ARC LENGTH

Arc length is the distance from the tip of the electrode core wire to the weld puddle. Arc length can be
deceiving, because the core wire is recessed inside a cup that forms at the tip of the electrode. You have
to take this into consideration when gauging arc length.

The correct arc length varies according to the electrode classification, diameter and composition of the
flux coating, as well as the amperage and welding position.

As a general rule, when amperage is set within the specified range, arc length should not exceed the
diameter of the core wire. Increasing the arc length increases the arc voltage, and reduces the amperage
slightly.

If the arc is too long, the metal core melts off in large globules that wobble from side to side and drop
onto the work as spatter, rather than forming useful weld metal. The weld bead is wide with excessive
spatter and undercut. The base metal is not properly melted, so the weld metal is deposited on top of the
plate with incomplete penetration, and slag inclusions will probably occur. Long arcing is often used to
preheat the base metal directly after striking the arc.

Shortening the arc length reduces the arc voltage and increases the amperage slightly. If the arc length
is too short, the arc has a tendency to short out and the electrode freezes to the work.

4. TRAVEL SPEED

Travel speed is the rate at which the electrode moves along the work. The key to correct travel speed is
“reading” the weld puddle, because the weld puddle is a liquid version of the weld bead.

A properly formed weld bead has an oval shape with an oval crater and uniform ripple pattern. Travel
speed is influenced by the type of welding current (DCEN, DCEP or AC), amperage, welding position,
electrode melt rate, material thickness, surface condition of the base metal, type of joint, joint fit up and
electrode manipulation.
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If you travel too fast, the puddle cools too quickly trapping gasses and slag. The ripples are pointed and
narrow with irregular penetration and undercut along the toes.

If you travel too slowly, the weld metal piles up forming a high, wide weld-bead with too much
reinforcement that may result in overlap. So read the puddle, and keep the arc on the leading edge.

5. ELECTRODE ANGLE

In shielded metal arc welding, the work and travel angles are used to control the shape of the weld puddle
and the amount of penetration. The travel angle is the angle between the joint and the electrode along the
axis of the weld.

A push angle exists when the electrode points in the direction of travel. And a drag angle points away the
direction of travel.

When all other essentials are under control, a change in the direction of travel changes the heat input to
the puddle. A drag travel angle increases heat input because the arc is pointing into the puddle. A push
travel angle reduces heat input because the arc is pointing away from the puddle.

The work angle is pointing between the electrode and the work surface along the work plane, which runs
perpendicular to the axis of the weld. An incorrect work angle can cause you to favor one side of the joint
more than another. The result is undercut and lack of fusion.
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ACTIVITY

Name: ________________________________________________ Section: _____________________

TEST I. MATCHING TYPE: Match column A’s descriptions with the correct term in column B. Write
letter of your answer on the space provided before the number.

COLUMN A COLUMN B

_____ 1. The basis for setting the amperage. A. Ampere

_____ 2. The rate at which the electrode moves along the work. B. Arc length

_____ 3. It controls the shape of the weld puddle. C. Electrode

_____ 4. It supplies additonal metal to the weld. D.Electrode angle

_____ 5. The angle between the joint and the electrode along the axis of the E. Flat
weld.
G. Horizontal position
_____ 6. It is distance from the tip of the electrode core wire to the weld puddle.
H. Ohm
_____ 7. The angle between the electrode and the work surface along the plane.
I. Tensile strength
_____ 8. The unit of measure for current.
J. Travel angle
_____ 9. The characteristic of the welded metal to resist tension acting on it.
K. Travel speed
_____ 10. The easiest position and most desirable position to weld in.
L. Type of electrode

M. Work angle

TEST II. ESSAY. Explain your answers in 4 to 6 sentences. (5points each).

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1. Explain the meaning of E6013 electrode.

2. What is the most challenging position in welding? Why?

3. What happens if the amperage is set below the designated range?

4. What happens if the travel speed of the electrode is too fast?

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What Do You Need To Know?

Read Information Sheet on Welding protective equipment.

INTRODUCTION

Like other jobs or careers, welders must wear suitable protective equipment. In general, Personal
Protective Equipment (PPE) must protect against hazards such as burns, sparks, spatter, electric shock,
and radiation. The use of PPE is a good safe practice and may be required by regulatory agencies. For
example, OSHA requires the use of PPE when engineering and administrative controls are not feasible or
effective.

Welding shield / helmet: is used to protect our face and eyes from the arc rays and heat, and spatters
from the molten metal. The arc is viewed through a filter (welding dark lens) which reduces the
intensity of radiation but allows a safe amount of light to pass for viewing the weld pool and end of the
electrode.

It is more convenient to use because it allows both hands free to work.

Hand held shield: It allows only one hand free to work

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Leather Jacket: is made of chrome leather and prevents the entry of sparks between our clothes and
body.

Leather Apron: is made of chrome leather and provides a welder with complete protection from sparks
and hot metal from the chest to mid calf.
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Leather Gloves / Gauntlets: is made of chrome leather and protects our hands from heat, spatter and
radiations.

Spats: is made of chrome leather and protects our feet from spatters.

Welding Safety shoes/Boots: It is made of leather protects your feet from sparks and splashes of molten
metal and from falling small objects.
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Safety Googles: is used to protect the eyes when chipping slag and grinding.

Safety glasses: is used to protect the eyes when chipping slag and grinding.

Face shield: A face shield helps to protect your eyes, facial skin, and the whole face in general from
flying elements and debris during grinding and cutting.

Earmuffs: It reduces the amount of noise reaching the ears which prevents damage from our ears and
hearing.
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Tools

Electrode holder: is used to grip the bare end of the electrode.

Return clamp: is fastened to the work or bench on which the work is placed and completes the welding
circuit.

Clip type Screw type

Steel brush: used to remove remnants of slag from weld after chipping.

The following are used in handling pieces of hot metals/welded metals.

Tongs
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Pliers

C clamp: it is used to hold the work for welding.

Portable grinder: An angle grinder, also known as a side grinder or disc grinder, is a handheld power

tool used for grinding (abrasive cutting) and polishing.

ACTIVITY

Name: _________________________________________________ Section: ___________________

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TEST I. MATCHING TYPE: Match column A’s descriptions with the correct PPE or tools in column
B. Write letter of your answer on the space provided before the number.

COLUMN A COLUMN B

_____ 1. It protects our hands from the heat and spatters during welding. A. Chipping hammer

_____ 2. It is used to remove the remnants of slag after chipping. B. Earmuffs

_____ 3. It helps us handle welded metals. C. Electrode holder

_____ 4. An appropriate tool used in removing slags. D. Leather gloves

_____ 5. It grips the electrode when welding. E. Leather jacket

_____ 6. It protects our feet from spatters. F. Return clamp

_____ 7. It prevents the entry of sparks in our body. G. Safety glasses

_____ 8. It protects our eyes when grinding. H. Spats

_____ 9. It is fastened to the work or bench as to complete the circuit. I. Steel brush

_____ 10. It protects our ears from the noise in the welding shop. J. Tongs

TEST II. ESSAY. Explain your answers in 4 to 6 sentences. (5 points each).

1. Why is it necessary to wear welding helmet with dark lens while welding?

2. Why is it necessary to inspect the equipment before starting any arc welding activity?

3. What would you do to prevent injury in the workplace?

POST TEST

Name: ________________________________________________ Section: _____________________

TEST I. MATCHING TYPE: Match column A’s descriptions with the correct term in column B. Write
letter of your answer on the space provided before the number.
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COLUMN A COLUMN B

_____ 1. It protects our hands from the heat and spatters during welding. A. Arc rays

_____ 2. It is used to remove the remnants of slag after chipping. B. Earmuffs

_____ 3. It causes arc flash and burn skin. C. Electrode

_____ 4. It supplies additional metal to the weld. D. Electrode holder

_____ 5. It grips the electrode when welding. E. Leather gloves

_____ 6. The characteristic of the welded metal to resist tension acting on it. F. Safety glasses

_____ 7. It determines the correct arc length. G. Size of electrode

_____ 8. It protects our eyes when grinding. H. Steel brush

_____ 9. The rate at which the electrode moves along the work. I. Tensile strength

_____ 10. It protects our ears from the noise in the welding shop. J. Travel speed

TEST II. TRUE OR FALSE. Write TRUE if the statement is correct and FALSE if it is incorrect. Write
your answers on the space provided before the number.

_____ 1. Before any welding can be done, the equipment should be inspected thoroughly.

_____ 2. The slag must be chipped off between each welding pass.

_____ 3. The flux coating of the electrode forms gaseous atmosphere which protects the weld pool and
welded metal.

_____ 4. Horizontal is the most difficult welding position.

_____ 5. Electrode size is a measure of the rod diameter.

_____ 6. An E6011 electrode is used best in any welding positions.

_____ 7. Flat welding position is called downhand positions.

_____ 8. DCEN or straight polarity indicates that the electrode is positively charge and the workspace is
negatively charge.

_____ 9. An E7018 electrode has a tensile strength of 60,000 psi.

_____ 10. If your travel speed is too fast, the ripples of the weld are pointed and narrow.

TEST III. ESSAY: Answer the questions thoroughly in 4 to 7 sentences.

1. Explain the weld result shown. (10 points)

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2. Explain the reason/s of the weld result below. (10 points)