Smaw Profesionalism

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Management Information System (University of Cagayan Valley)

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Sector:
METALS AND ENGEENIRING
Qualification:
SHIELDED METAL ARC WELDING NC II

Unit of Competency:
PRACTICE CAREER PROFESSIONALISM
Module Title:
PRACTICING CAREER PROFESSIONALISM
Technical Education and Skills Development Authority

ACADEMIA DE STA. CECILIA FOUNDATION, INC.


#2 Brgy. Magliba, San Fabian, Pangasinan
[email protected]
Tel /Fax #: +63(75) 653-0267
Mobile #: +63(935) 6370062/ +63(997) 6857340

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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Welcome to the module in Weld carbon steel plates using SMAW contains training
materials and activities for you to complete.
The unit of competency “Welding carbon steel plates using SMAW “contain
knowledge skill and attitude required for welding. It is one of the specialized modules at
national certificates level (NCII).
You are required to go through a series of learning activities in order to complete each
outcome of the module.in each learning outcome are information sheets, Task sheets, follow
this activities on your own answer the self-check, perform the procedural checklist at the end
of the learners outcome .You have questions ay remove the blank answer sheet at the end of
each module(or get from your one facilitator/trainer)to write your answer for each self-check,
if you have questions don’t hesitate to ask your facilitator for assistance.
Recognition of prior learning (RPL)
You may already have some of the most of the knowledge and skills covered in this
learner’s guide because you have:
Been working for some time
Already completed training in this area
If you can demonstrate to your trainer that you are already competent in a particular
skill or skills, talk to him/her about having them formally recognized so you don’t have to do
the same training again, if you have a qualification or certificate competency from previous
training, show it to your trainer.
If the skill you acquired is required is still current and relevant to the units of
competency they me become part the evidence you may present to RPL. If you are not sure
about the currency of your skills, discuss with your trainer.
At the end of this module is a learner’s diary, use this diary to record important date,
jobs undertaken and other work place events that will assist you in providing further details to
your trainer or assessor. A record of achievement is also provided for your trainer to complete
once you complete the module.
This module was prepared to help you achieved the required competency, in welding
carbon steel plates in OVERHEAD position(4G). This will be the source of information
for your acquired knowledge and skill into this particular trade independently and at your
own pace. With minimum supervision or help from your instructor.
Talk to your trainer and agree on how both will organize training of this unit. Read
through module carefully.it is divided into sections, which cover all the skill and knowledge
you need to successfully complete this module.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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Work through all the information and complete all the activities in each section. Read
the information sheets and job sheets and complete the self-check and perform the procedural
check list. Suggested references are included to supplement the material in the module.
Most probably your trainer will also be your supervisor or manager. She/he is there to
support you and show the correct way to do things.
Your trainer will tell you about the important things you need to consider when you are
completing activities and it is important that you listen and take notes.
You will be given plenty of opportunity to ask questions and practice on the job make
sure that you practice new skill during regular work shift. This way you will improve both
your speed and memory and your confidence
Talk to the more experience workmate and ask for their guidance.
Use self-check questions at the end of each section to test your own progress.
When you are ready ask your trainer to watch you perform the activities outline in this
module
As you work to your activities, ask for written feedback on your progress. Your trainer
keeps feedback/pre assessment reports for this reason when you have successfully completed
each element, as your trainer to mark on the reports that you are ready for assessment.
When you have completed this module (or several module) and feel confident that you
have had sufficient practice, your trainer will arrange an appointment with registered assessor
to assess you. The result of your assessment will be recorded in your competency
achievement record.

LIST OF CORE COMPETENCIES

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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No. Unit of competencies


Module Title Code
PERFORMING
WELD CARBON STEEL GROOVE WELDING
1. PLATES AND PIPES ON CARBON STEEL MEE721306
PLATES
USING SHIELDED
METAL ARC WELD PERFORMING
(SMAW) GROOVE WELDING
ON CARBON STEEL
PIPES

SUMMARY of ASSESTMENT CRITERIA


ASSESSMENT CRITERIA:
1. Root penetration not exceeding allowable tolerances specified by welding codes/
standards on
 concavity

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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 convexity
 undercut
 excess penetration
 lack of fusion
 burn-through
 cracks
2. Weld capping/ final pass not exceeding allowable tolerances specified by welding
codes/ standards on
 height of reinforcement
 under fill
 porosities
 undercut
 cracks
 cold laps
3. Uniformity of bead ripples must be in accordance with welding standards
4. Stringer or layered beads deposited in accordance with welding standards
5. Finish weldment visually acceptable in accordance with welding standards for:
 spatters
 arc strikes
 slag
 uniformity of beads

MODULE CONTENT

UNIT OF COMPETENCY: WELD CARBON STEEL PLATES AND PIPES USING


SHEILDED METAL ARC WELD (SMAW)
MODULE TITLE: PERFORMING GROOVE WELDING ON CARBON STEEL PLATES
MODULE DESCRIPTION: This module covers the knowledge, skills and attitude in
performing groove welding on carbon steel plates in different positions such as 1G, 2G,
3G, & 4G
FINAL DURATION : 194hrs.
LEARNING OUTCOME :
Date Developed: Document No: CBLM-SMAWNCII-BC-03
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Upon completion of this module, the trainee/student must be able to

LO1.1 Weld carbon steel plates in flat position (1G)

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

LO1.3 Weld carbon steel plates in vertical position (3G)

LO1.4 Weld carbon steel plates in overhead position (4G)

LEARNING OUTCOME 1.4 Weld carbon steel plates in overhead position


(4G)
CONTENTS:
This unit covers the knowledge, skills and attitudes required to weld carbon steel plates in overhead
position (4G).

ASSESSMENT CRITERIA:
1. Root penetration not exceeding allowable tolerances specified by welding codes/
standards on
 concavity
 convexity
 undercut
 excess penetration
 lack of fusion
 burn-through
 cracks
2. Weld capping/ final pass not exceeding allowable tolerances specified by welding codes/
standards on
 height of reinforcement
 under fill
 porosities
Date Developed: Document No: CBLM-SMAWNCII-BC-03
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 undercut
 cracks
 cold laps
3. Uniformity of bead ripples must be in accordance with welding standards
4. Stringer or layered beads deposited in accordance with welding standards
5. Finish weldment visually acceptable in accordance with welding standards for:
 spatters
 arc strikes
 slag
 uniformity of beads

CONDITIONS:
Student/trainee must be provided with the following

WORK PLACE TOOLS MATERIAL ASSESSMENT METHOD


LOCATION OF AND SUPPLIES
EQUIPMENT
1. Equipment - Observation
Laboratory - Welding machine - Written Examination
(AC or AC/DC) - Demonstration of Practical Skill
- Welding table or jig - Interview
- Portable grinder
- Welding booth
- Portable oven

2. Tools/Accessories
- Welding mask
- Steel brush
- Clear glass
- Chipping hammer
- Dark glass

3. Supplies/ Materials
- Electrodes
- Carbon steel plates
- Cutting grinding disk

4. Personal protective
equipment
- Safety shoes
- Apron
- Leggings
- Safety goggles
- Gloves

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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5. Training Materials
- Arc welding manuals
- Welding procedures
specifications (WPS)
- Welding standards

LEARNING EXPERIENCE
Learning outcome: 1.4 Weld carbon steel plates in overhead position (4G)

LEARNING ACTIVITIES SPECIAL INSTRUCTION


1. Read Information Sheet #1.4-1 on essentials of ® After reading the learner is encourage to
welding. answer self-check# 1.4-1
 Answer Self-check #1.4-1 ® Compare your answer to the answer key #1.4-1

 Perform task sheet # 1.4-1 on essentials of ® Evaluate the Performance Criteria Checklist
welding. #1.4-1
2. Read Information Sheet #1.4-2 on International ® After reading the learner is encourage to
welding codes and standards answer self-check #1.4-2

® Compare your answer to the answer key #1.4-2


 Answer-self #1.4-2
3. Read Information Sheet #1.4-3 on acceptable weld ® After reading the learner is encourage to
profiles answer self-check #1.4-3

 Answer Self-check #1.4-3 ® Compare your answer to the answer key #1.4-3
4. Read Information Sheet #1.4-4 on weld defects, causes ® After reading the learner is encourage to
and remedies answer self-check #1.4-4
 Answer Self-check #1.4-4 ® Compare your answer to the answer key #1.4-4
5.Read Information Sheet #1.4-5 on welding procedure ® After reading the learner is encourage to
and specifications (WPS) answer self-check #1.4-5

 Answer Self-check #1.4-5 ® Compare your answer to the answer key #1.4-5
6. Read Information Sheet #1.4-6 on welding techniques ® After reading the learner is encourage to
and procedures answer self-check #1.4-5
 Answer Self-check #1.4-6 ® Compare your answer to the answer key #1.4-6
7. Read Information Sheet #1.4-7 on safe welding ® After reading the learner is encourage to
practices answer self-check #1.4-7
 Answer Self-check #1.4-7 ® Compare your answer to the answer key 1.4-7

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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INFORMATION SHEET #1.4-1


Essentials of welding
Learning Objectives:

After reading this information sheet, trainees must be able to;

1. Identify the essential variables of SMAW Welding.


2. Classify the meaning of number and letter of Electrode.
3. Determine the commonly used electrodes.

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 to
control of either before welding or during welding.

The Five Essential Variables in SMAW (Stick) Welding

1. 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 correct amperage required on the welding
machine prior to welding.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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The amperage is set from the recommended ranges according to the


size of the electrode, the type of electrode, and the type of current (Alternating
Current (AC), Direct Current Reverse Polarity (DCRP), and Direct Current
Straight Polarity (DCSP)) to be used

Current Ranges

Size E6010/E6011 E7018

3/32” 60 - 90 70 – 100

1/8” 90 – 120 120 – 160

5/32” 110 - 170 130 – 170

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

Illustration below gives an idea of the evaluation process.

A B C

A – Amperage correct

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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B – Amperage too low

C – Amperage too high

2. Length of Arc
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.

The welding machines used in SMAW are known as Constant Current


Welding Machines which means that the current stays relatively constant
through changes in the voltage. The machine increases the voltage as the arc
length is increased to maintain current flow at the amperage level set on the
machine. If the voltage is increased too much the arc may become unstable
and result in a poor quality weld.

The correct arc length may vary according to the type and size of
electrode and the position of welding.

3. Angle of Electrode

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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In SMAW process two electrode angles that the welder must have to
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 of the electrode is
held at relative to the direction of travel called the travel angle.

4. Speed of Travel

The rate of travel across the joint is controlled by the welder during
welding and greatly affects the appearance and strength characteristics of the
welds

The amount of weld metal deposited (weld deposition rate) and the
travel speed may vary with the type and size of electrode being used. The
correct weld speed will result in a well formed weld bead that shows good
fusion, penetration and a gradual transition of weld metal into the corners of
the joint.

Too fast travel speed will result in stringy weld with poor strength.

Too slow a speed will result in a heavy weld that has too much
convexity

5. Selection of Electrode

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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There are a variety of electrodes available for welding a wide range of


metals. The electrode for a given application must be selected

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:

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.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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Date Developed: Document No: CBLM-SMAWNCII-BC-03


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Self-Check No. 1.4-1


Essential Variables of SMAW (Stick) Welding
Multiple Choice:
Direction: Read the statement or questions carefully, write the correct
letter of your answer on space provided before each number.

___1. Direct Current Reverse Polarity (DCRP) set up means positive terminal of the
welding is connected to the
a. circuit breaker c. ground of the welding machine
b. electrode holder d. item being welded
___2. E 6010 electrode is designed to work best on
a. AC – DC c. DCRP
b. AC only d. DCSP
___3. The correct arc length may vary according to
a. welding position c. type of welding machine
c. type of current d. kind of base metal
___ 4. The correct travel speed will result in a well formed weld bead that shows
a. spatter d. thin stringy weld
b. good fusion d. heavy weld with much convexity
___5. Which electrode is used to weld on flat and horizontal position?
a. E 6010 c. E 7018
b. E 6013 d. E 6027
___6. From the five Essentials of Welding in shielded metal arc weld, it is the process
where the welder must control the correct angle of the electrode.
a. Current setting c. Current setting
Date Developed: Document No: CBLM-SMAWNCII-BC-03
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b. Angle of electrode d. Length of Arc


____7. It is the term used to describe the distance from the tip of the electrode to the
base metal.
a. Length of arc c. Speed of travel
b. Current setting d. Angle of electrode
____8. It is the process where the welder set the recommended amperage prior to the
electrode size, type, and the type of current to be used.
a. Speed of travel c. Current Setting
b. Selection of electrode d. Angle of electrode

____9. It is defined as the ability of the weld metal to withstand forces acting to pull
it apart.
a. Tensile strength c. Ductility
b. Stringy weld d. Variable
_____10. The rate of travel across the joint to attain good welding output.
a. Speed of travel c. Angle of electrode
b. Current Setting d. Selection of electrode

Answer Key 1.4-1

Essential Variables of SMAW


1. b 6. b

2. c 7. a

3. d 8. c

4. a 9. a

5. d 10. a

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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TASK SHEET 1.4-1

Weld Carbon Steel Plates in 4G Position using SMAW


Performance Objectives:
Given the necessary supplies, materials, tools and equipment, the trainee should be able to;
Make multiple pass in carbon steel plates in 4G position using SMAW
Supplies/Materials:
2 pcs Carbon Steel Plates 3/8” T x 7” L x 2” W
3 pcs Electrode E 6011, 3.2 mm Ø
6 pcs Electrode E 7018 3.2mm Ø
1 pc Soapstone

Tools:
1 set PPE
1 pc Chipping Hammer
1 pc Ballpeen Hammer
1 pc Steel Brush
1 pc Spacer Wire
1 pc Plier/ Tong

Equipment
1 unit SMAW machine with complete accessories
1 unit Portable Electric Grinder

Steps/Procedure
Procedures:
A. Check work area to make sure it is free of flammable materials and well ventilated, and note
the location of the nearest fire extinguisher.

B. Attach ground cable to work table or work piece.

C. Select correct polarity for electrode.

D. Turn on SMAW machine.

E. Put on welding helmet and adjust machine to correct amperage by running a test bead on
scrap metal.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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F. Place the plates on work table positioned with a 1/16” gap wire placed between the two
plates.

G.

H. Make sure that the area (work table) is plain to attain a good alignment upon fitting the two
plates.

I. Tack weld the members in place according to the following procedure:


1. Start fitting the two plates by placing them on a platform (work table).
2. Place the spacer between the two plates.
3. After checking the alignment, tack weld one end after the other end.
Note: tack weld must not be at the same size; one end must be twice bigger to the
other tacked end.
J. Feather all tack welds with a grinder, but be careful not to grind all the way through the tack
weld.
K. Place the nipples so that they are in the position indicated in specifications

L. Place E 6011 electrode in the electrode holder and adjust to correct electrode angle.

M. Strike an arc on end of the feathered tacks and quickly adjust to proper arc length
Caution: Strike the arc only in the weld zone and not on the finished sides of the pipe.
N. Make a puddle and immediately form a keyhole

O. Whip the rod slightly forward the keyhole to solidify, then whip the rod back to deposit
more metal n the keyhole.

Note:
Do not deposit filler metals outside the keyhole as you whip the rod back and
forth; always move the rod back to the middle of the keyhole, and keeps electrode arcing
in the middle of the joint and not on the outer portion of the bevel.
P. Weld up from the smaller tack weld to the bigger one.

Q. Chip slag off stringer bead and brush it, or grind the entire stringer bead with a hand grinder.

R. Inspect the root pass for good fusion and penetration and for defects such as undercutting on
both outside and inside surfaces.

S. Adjust amperage to proper setting for E 7018 electrode.

T. Use the E 7018 electrode, with a weaving technique, lay stringer beads for remainder of fill-
Date Developed: Document No: CBLM-SMAWNCII-BC-03
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up, and be sure to clean each pass before starting the next one.

U. Clean fill-up stringer beads thoroughly.

V. Use the E 7018 electrode and with a weaving technique, lay a cap pass to finish the weld
with overhead welding.

W. Clean and inspect cap pass


a. Have your instructor check your work?
b. Power off SMAW machine
c. Conduct a bend test as outlined in a previous job sheet.
d. Have your instructor check your bend test?
e. Check in tools and materials and clean up area, or prepare for next job sheet as
directed by your instructors.

Assessment Method
 Demonstration of Practical Skills

Performance Criteria Checklist for Task Sheet No. 1.4-1

Criteria YES NO

1. Did you check work area to make sure it is free of flammable materials and well
ventilated, and note the location of the nearest fire extinguisher?

2. Did you attach ground cable to work table or work piece?

3. Did you select correct polarity for electrode?

4. Did you turn on SMAW machine?

5 Did you put on welding helmet and adjust machine to correct amperage by
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running a test bead on scrap metal?

6. Did you place the plates on work table positioned with a 1/16” gap wire placed
between the two plates?
7. Did you make sure that the area (work table) is plain to attain a good alignment
upon fitting the two plates?
8. Did you tack weld the members in place according to the detailed procedure?

9. Did you feather all tack welds with a grinder, but be careful not to grind all the
way through the tack weld?

10. Did you place the nipples so that they are in the position indicated in
specifications?

11. Did you place E 6011 electrode in the electrode holder and adjust to correct
electrode angle?

12. Did you strike an arc on end of the feathered tacks and quickly adjust to proper
arc length?
13. Did you make a puddle and immediately form a keyhole?

14. Did you whip the rod slightly forward the keyhole to solidify, then whip the rod
back to deposit more metal n the keyhole?

15. Did you weld up from the smaller tack weld to the bigger one?

16. Did you chip slag off stringer bead and brush it, or grind the entire stringer bead
with a hand grinder?

17. Did you inspect the root pass for good fusion and penetration and for defects
such as undercutting on both outside and inside surfaces?

18. Did you adjust amperage to proper setting for E 7018 electrode?

19. Did you use the E 7018 electrode, with a weaving technique, lay stringer beads
for remainder of fill-up, and be sure to clean each pass before starting the next one?

20. Did you clean fill-up stringer beads thoroughly?

21. Did you use the E 7018 electrode and with a weaving technique, lay a cap pass
to finish the weld with overhead welding

22. Did you clean and inspect cap pass?

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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Information Sheet No. 1.4-2

International Welding Codes and Standards


Learning Objectives:
After reading this information sheet, trainees must be able to;

1. Identify the different welding codes and standards.


2. Familiarize and explain the application of the different welding codes and
standards.
3. Know the Codes and standards help to standardize welding.

Some of the common codes and standards in welding:

1. American Welding Society (AWS)

This code covers the welding requirements for any type of welded
structure made from the commonly used carbon and low-alloy steels.

The following AWS Standards

AWS D1.1 Structural Welding (Steel)

- This code contains the requirements for fabricating and erecting welded steel
structures. This code applies to steels with a thickness of 1/8 inch (3.2mm) or
more. When this code is specified in a contract, most of the provisions are
mandatory. Optional provisions and examples are shown in an annex included
within this code.

AWS D1.2 Structural Welding (Aluminum)


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- This is the Structural Welding Code-Aluminum. The welding requirements are


applicable to any type of welded aluminum alloy structure. This code is
appropriate for use in fabrication of supporting structures and appurtenances. It is
not intended to supplant codes developed for use in specialized fabrication such
as the ASME Boiler and Pressure Vessel Code, aerospace codes, or military
codes.

AWS D1.3 Structural Welding (Sheet Steel)

- This is the Structural Welding Code-Sheet Steel. This code covers the arc welding
of structural steel sheet/strip steels including cold formed members which are
equal to or less than 3/16 inch (.188 in./4.8mm) in nominal thickness. Three weld
types unique to sheet steel, arc spot, arc seam, and arc plug welds are included in
this code.

AWS D1.4 Structural Welding (Reinforcing Steel)

- This is the Structural Welding Code-Reinforcing Steel. This code shall apply to
the welding of reinforcing steel to reinforcing steel and of reinforcing steel to
carbon or low-alloy structural steel. This code shall be used in conjunction with
the prescribed general building code specifications and is applicable to all
welding of reinforcing steel using the processes listed in Section 1.4, and
performed as a part of reinforced concrete construction. When reinforcing steel is
welded to structural steel, the provisions of AWS D1.1 shall apply to the
structural steel component.

AWS D1.5 Bridge Welding

- This is the Bridge Welding Code. This code covers welding fabrication
requirements applicable to welded highway bridges. It is to be used in
conjunction with the AASHTO Standard Specification for Highway Bridges or
the AASHTO LRFD Bridge Design Specifications. This code is not intended to
be used for the following: steels with a minimum specified yield strength greater

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than 690 MPa (100ksi), pressure vessels or pressure piping, base metals other
than carbon or low alloy steels, or structures composed of structural tubing.

AWS D1.6 Structural Welding (Stainless Steel)

- Structural Welding Code-Stainless Steel. This code covers welding requirements


applicable to stainless steel weld mesh subject to design stress. It shall be used in
conjunction with any complementary code or specification for the design or
construction of stainless steel weld mesh.

AWS D1.7 Structural Welding (Strengthening and Repair)

AWS D10.11 `Root Pass Welding for Pipe

AWS D10.12 Pipe Welding (Mild Steel)

AWS D10.18 Pipe Welding (Stainless Steel)

AWS D3.5-93R

- Guide for Steel Hull Welding. This guide is referenced in many contract
specifications for building vessels from barges to tugboats

AWS D3.6M Specification for Under-Water Welding.

AWS D3.7

- Guide for Aluminum Hull Welding. Similar to the Steel Hull Welding Guide, but
with a special emphasis on the unique properties of aluminum.
AWS D8.8-97 Specification for Automotive and Light Truck Weld Quality: Arc
Welding.

AWS D14.1
- Specification for Welding Earth Moving and Construction Equipment.
Applies to all structural welds used in the manufacture of earthmoving and
construction equipment. This specification reflects the welding practices
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employed by manufacturers within the industry and incorporates various


methods which have been proven successful by individual manufacturers.

AWS D14.5

- Specification for Welding Presses and Press Components. The purpose of


this specification is to establish minimum acceptable requirements for
weld joint design and the fabrication by welding of presses and press
components, and is not intended to apply to material feed mechanisms and
tooling. It shall also apply to the modification or repair by welding of new
or existing presses or press components.

2. American Society of Mechanical Engineers (ASME) IX

The American Society of Mechanical Engineers (ASME) Boiler and


Pressure Vessel Code (BPVC) cover all aspects of design and manufacture of
boilers and pressure vessels. All sections contain welding specifications,
however most relevant information is contained in Sections V and IX.

 ASME BPVC Section V: "Non-destructive testing"


 ASME BPVC Section IX: "Welding and Brazing Qualifications"
 ASME B16.25: "Butt-welding ends" (of pipes and piping components)
3. American Petroleum Institute (API) 1104
This code applies for gas and oil pipeline facilities. When segments of
pipe nipples are used, they shall be supported so that typical flat, vertical, and
overhead welds are produced.

Self – Check No. 1.4-2

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Welding Codes and Standards

TRUE OR FALSE:

Direction: Write True on the space provided before each number if the statement is true;
write False if it is False.

___1 American Welding Society made from the commonly used carbon and low – alloy steels.

___2. American Welding Society (AWS) covers the welding requirements for any type of welding
structures.

___3. American Society of Mechanical Engineers (ASME)IX covers all aspects of design and
manufacturers of boilers.

___4. American Petroleum Institute (API) 1104 applies for gas and oil pipeline facilities.

___5. Only one sections contain welding specifications.

___6. AWS D3.5-93R referenced in many contract specifications for building vessels from barges to
tugboats

____7. AWS D14.5 is the Specification for Welding Presses and Press Components.

____8. AWS D3.6M is the reference for Under-Water Welding.

____9. AWS D10.11 is the reference for Root Pass Welding for Pipe.

____10. AWS D1.6 is the specification for Structural Welding Code-Stainless Steel.

Answer Key 1.4-2

Welding Codes and Standards

1. True 6. True
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2. True 7. True

3. True 8. True

4. True 9. True

5. False 10. True

Information Sheet No. 1.4-3


Acceptable Weld Profiles
Objective:
After reading this information sheet, trainees must be able to:

1. Identify the acceptable weld profiles.


The profile of a completed weld could possibly have considerable affect for
the performance of that weld operating. It is your welding inspector’s function to
distinguish these discontinuities by way of visual inspection and quite often to
evaluate his/her acceptance, or negativity.

Note: Convexity C of a weld or individual surface bead with dimension W shall not
exceed the value of the following table

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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Self – Check No. 1.4-3

Acceptable Weld Profiles

Multiple Choice:

Direction: Read the statement carefully. Choose the best answer and write the
letter of the correct answer on space provided before each number.

___1. Acceptable convexity of weld reinforcement in groove weld shall not exceed
a. 3 mm c. 5 mm
b. 4 mm d. 6 mm

___2.The maximum root face made in preparing single-V groove is


a. 3/32” c. 1/8”
b. 5/32” d. 1/4"

___3. The appropriate size of tack weld in joining the work piece is
a. 5 mm c. 15 mm
b. 10 mm d. 20 mm

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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___4. The correct groove angle in preparing butt joint is


a. 30 deg. c. 50 deg.
b. 40 deg. d. 60 deg.

___5. The correct bevel angle in preparing butt joint is


a. 30 deg. c. 50 deg.
b. 40 deg. d. 60 deg.

Answer Key 1.4-3

Welding Codes and Standards

1. b

2. c

3. b

4. d

5. a

Information Sheet No. 1.4-4

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Weld Defects, Causes, and Remedies


Objectives:

After reading this information sheet, trainees must be able to;


1. Identify the different weld defects.
2. Enumerate the causes and remedies of welding defects.
Weld Defects
A weld should have a good appearance. However, a defective weld is
one that will be strong enough to do the job and may fail after it is put into
used. Weld defects usually happen when the correct preparation and/or
welding techniques are not used.
General Classification of Weld Defects:
1. Structural Defects – include surface and internal cracks and defects
Types of Structural Defects:
1.1 Crater Cracks – cracks left at the depression at the end of the bead

Cause: Improper termination of the electrode at the end of the weld

1.2 Longitudinal Cracks – cracks run parallel to the weld bead. They may be
in the bead itself or in the metal along the edge of the
bead.
Causes: a. Wrong electrode
b. Improper joint design
c. Poor edge preparation
d. Poor clamping of the welded joint
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1.3 Cross-sectional Crack – cracks across the weld bead.


Causes: a. Wrong electrode
b. Improper joint design
c. Poor edge preparation
d. Poor clamping of the welded joint
1.4 Undercutting – depression at the toe of the weld – the weld metal is below
the level of the base metal.
Causes: a. Faulty electrode manipulation
b. Current too high
c. Travel speed is too slow

1.5 Slag Inclusion – entrapment of non-metallic materials such as cellulose or


limestone at the weld and base metal.
Causes: a. Poor edge preparation
b. Dirty filler metal and parent metal
c. Incorrect use of the different welding techniques

1.6 Porosity – small gas pockets or holes in the welded metal


Causes: a. Dirty filler metal and parent metal
b. Too short arc length
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c. Insufficient puddling time

1.7 Poor Penetration – happens when the joint or root weld penetration does
not meet the weld requirement for full strength

1.7.1 Incomplete Penetration


Causes: a. Poor edge preparation
b. Travel speed is too fast
c. Low current setting

1.7.2 over Penetration


Causes: a. Poor edge preparation
b. Travel speed too slow
c. Too short arc length
d. Current too high
1.8 Incomplete Fusion – when the filler. Metal and parent metal are not
completely fused
Causes: a. Poor edge preparation

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b. Travel speed is too fast


c. Low current setting

2. Dimensional Defects – if the joint preparation, weld size, and/or weld shape differ
from the specification
Types of Dimensional Defects:
2.1 War page – (also known as bowing or cambering) shrinkage of the weld
bends the metal or pulls the metal parts out of alignment
Causes: a. Poor joint alignment
b. Current too high
2.2 Angular Distortion or Angular War page – when the metal parts are at an
angle to one another and the shrinkage changes the angle.
Causes: a. Poor joint alignment
b. Current too high
2.3 Longitudinal Shrinkage – distortion along the length of the weld.
Causes: a. Poor joint alignment
b. Current too high
2.4 Transverse Shrinkage – distortion across the weld
Causes: a. Poor joint alignment
b. Current too high

Self – Check No. 1.4-4

Weld Defects, Causes, and Remedies


I. Multiple Choice:

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Direction: Read each statement carefully. Write the letter of the correct
answer on space provided before each number.

___1. Incomplete sidewall fusion is found between


a. Heat affected zone and base metal c. Weld and base metal
b. Root pass and hot pass d. Weld passes

___2.The most probable cause for incomplete side wall fusion is


a. Insufficient cleaning c. Presence of oil or moisture
b. Insufficient dwell d. Presence of oil or moisture

___3.When electrode coatings absorbs moisture, it is most likely that the weld will have
a. Excess penetration c. Too much undercut
b. Shallow penetration d. Too much undercut

___4.What cause undercut?


a. Low amperes c. Too long arc
b. High amperes d. Poor preparation of work piece

___5.Welding distortion, war page and stresses are cause by


a. High temperature c. Intermittent welding
b. Strong backs d. Back step welding

II. DEFINITION:
Define the following weld defects.

1. Poor Penetration

2. Porosity

3. Slag Inclusion

4. Crater Cracks

5. Longitudinal Cracks

Answer Key 1.4-4

Weld Defects, Causes and Remedies

1. c

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2. b

3. d

4. b

5. a

DEFINATIOON OF TERMS

1.happens when the joint or root weld penetration does not meet the weld requirement
for full strength

2. small gas pockets or holes in the welded metal


3. entrapment of non-metallic materials such as cellulose or limestone at the weld and
base metal.

4. cracks left at the depression at the end of the bead


5. cracks run parallel to the weld bead. They may be in the bead itself or in the metal
along the edge of the bead

Information Sheet No. 1.4-5

Welding Procedures and Specifications


Objectives:

After reading this information sheet, trainees must be able to:

1. List welding procedures.


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2. Identify the welding specifications.


Welding Procedures and Specifications (WPS) is a document that describes
how welding is to be carried out in production. They are recommended for all welding
operations and many application codes and standards make them mandatory.

Before any welding can be done on a structure, the procedure that will be used
must first be approved or qualified. Welding Procedures Specification (WPS) is
written to specify welding requirements for commercial jobs such as bridges,
pipelines, or steel structures. Outlines exactly how each weld is to be made and
generally prepared by engineers.

A welding procedure qualification record shows the properties of a weld that


was made by following the welding procedures specification is said to be qualified.
Once welding procedure specifications are written and qualified, the WPS can be
followed and welding can begin on the project. Both the WPS and the WPQR must be
kept on file.

Sample
Welding Procedures Specification No: PRACTICE 6-7
Date: _______________
TITLE:
Welding SMAW of plate to plate
SCOPE:
This procedure is applicable for V-groove plate with a backing strip within a
range of 3/8 “ (10mm) through 3/4" (20 mm)
Welding may be performed in the following positions: 1G, 2G, 3G and 4G
BASE METAL:

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The base metal shall conform to AWS specification No. E 6010 or E 6011 root
pass and E 7018 for the cover pass from AWS specification A5.1. This filler metal
falls into F-number: F3 and F4 and A –number: A-1
SHIELDING GAS
The shielding gas or gases shall conform to the following compositions and
purity: N/A
JOINT DESIGN AND TOLERANCES

PREPARATION OF BASE METAL:


The V-groove is to be ground, flame cut, or machined on the deg of the plate
before the parts are assembled. All parts must be cleaned prior to welding of all
contaminants, such as paints, oils, grease, or primers. Both inside and outside surfaces
within 1” (25.4 mm) of the joint must be mechanically cleaned using a wire brush or
grinder.
ELECTRICAL CHARACTERISTICS:
The current shall be AC or DCRP. The base metal shall be on the work lead or
negative side of the line.
PREHEAT:
The parts must be heated to a temperature higher than 70º F (21º C) before any
welding is started.
BACKING GAS: N/A
WELDING TECHNIQUE:
Tack welds the plates together with the strip. There should be about a 1/8” (3.2
mm) root gap between the plates. Use the E 6010 or E 6011 arc welding electrodes to
make a root pass to fuse the plates and backing strip together. Clean the slag from root
pass and use either a hot pass or grinder to remove any trapped slag.
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Using E 7018 arc welding electrode, make a series of filler welds in the groove until
the joint is filled.
INTERPASS TEMPERATURE:
The plate should not be heated to a temperature higher than 400º F (205º C)
during the welding process. After each weld pass is completed, allow it to cool, the
weld meant must not be quenched in water.

CLEANING:
The slag can be chipped and/or ground off between passes but can only be
chipped off of the cover pass.
INSPECTION:
Visually inspect the weld for uniformity and other discontinuities. If the weld
passes the visual inspection, then it is to be prepared and guided bend tested according
to Guided Bend Test. Repeat each of the weld until you can pass this test.

Self – Check No. 1.4-5

Welding Procedures and Specifications


I. Multiple Choice:

Direction: Read the statement carefully. Write the letter of the best answer on
space provided before each number.

___1.The maximum root gap made in preparing single-V groove is


a. 2mm c. 4mm
b. 3mm d. 5mm

___2.The maximum root face made in preparing single-V groove is


a. 3/32” c. 1/8”
b. 5/32” d. 1/4"
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___3.The correct bevel angle in preparing butt joint is


a. 30 deg. c. 50 deg.
b. 40 deg. d. 60 deg.

___4.The correct groove angle in preparing butt joint is


b. 30 deg. c. 50 deg.
c. 40 deg. d. 60 deg.

___5.The appropriate size of tack weld in joining the work piece is


a. 5 mm c. 15 mm
b. 10 mm d. 20 mm

II. EXPLAINATION:

Direction: Explain the proper Welding Procedure and specification on your own words.

Answer Key 1.4-5

Welding Procedures and Specifications

I. MULTIPLE CHOICE

1. b

2. c

3. a

4. d

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5. b

II. EXPLANATION

The Welding Procedure Specification is a required document for all code welding. Your
customer either directly or indirectly specifies to what code your company must qualify. The
WPS outlines all of the parameters required to perform your welding operation.

In short the WPS is the recipe for your welding operation. It describes the welding
process or processes used, the base materials used, the joint design and geometry, gases and
flow rates, welding position and includes all of the process conditions and variables. Each
code has a recommended format.

Information Sheet No. 1.4-6


Welding techniques and procedures
Objectives:
After reading this information sheet, trainees must be able to:

1. Perform correct welding procedures and techniques


2. Understand the art of welding is something that is mastered in
progressive steps

Different Welding Techniques


Welding is the process in which two pieces of metal are joined using heat and
electricity. The type of metal you are welding will determine the technique that will provide
you with the best possible result. Like many specialized skills, the art of welding is
something that is mastered in progressive steps of increasing difficulty with stick welding
being the easiest welding process to learn; however, more advanced techniques will require
the welder to practice and have some patience during the learning process.

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Most welding is performed on more common metals such as steel. While steel
may be the most common metal used in welding, aluminum, copper and other metals can also
be joined using welding techniques. Different types of welding require the welder to use
shielding gases that help keep the metal being welded free of contaminants, allowing for a
solid weld to be produced. Welds that are properly performed using shielding gases often
have a cleaner look to them than those welded without the protection of a shielding gas. The
welder uses electrodes and welding wire to melt the metal surface and provide a filler
material to create the joint. Whenever you are going to be welding you should always take
the time to put on the proper safety gear. This includes a welding helmet, welding gloves,
welding apron and the proper clothing underneath.

Arc Welding Procedures, Techniques, and Welding Safety Equipment

(Part One)

Arc welding, also referred to as stick welding, has been performed successfully on
almost all types of metals. This section addresses the procedures as they may apply to fusion
welding of steel plate and provides the basic steps and procedures required to produce an
acceptable arc weld. Additional instruction and information pertaining to arc welding of other
metals can be obtained from training institutions and the various manufacturers of the
welding equipment.

The first step in preparing to arc weld is to make certain that the necessary
equipment is available and that the welding machine is properly connected and in good
working order. Particular attention should be given to the ground connection, since a poor
connection results in a fluctuating arc, that is difficult to control.

When using a shielded electrode, the bare end of the electrode should be clamped
in its holder at a 90° angle to the jaws. (Some holders allow the electrode to be inserted at a
45° angle when needed for various welding positions.)

Before starting to weld, the following typical list of items should be checked:

• Is the proper personal safety equipment being used, including a welding helmet,
welding gloves, protective clothing, and footwear; if not, in an adequately ventilated area,
appropriate breathing equipment?

• Has the ground connection been properly made to the work piece and is it making a
good connection?

• Has the proper type and size electrode been selected for the job?

• Is the electrode properly secured in the holder?


Date Developed: Document No: CBLM-SMAWNCII-BC-03
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• Does the polarity of the machine coincide with that of the electrode?

• Is the machine in good working order and is it adjusted to provide the necessary
current for the job?

The welding arc is established by touching the base metal plate with the electrode and
immediately withdrawing it a short distance. At the instant the electrode touches the plate, a
rush of current flows through the point of contact. As the electrode is withdrawn, an electric
arc is formed, melting a spot on the plate and at the end of the electrode.

Correctly striking an arc takes practice. The main difficulty in confronting a beginner in
striking the arc is sticking the electrode to the work. If the electrode is not withdrawn
promptly upon contact with the metal, the high amperage flows through the electrode causing
it to stick or freeze to the plate and practically short circuits the welding machine. A quick roll
of the wrist, either right or left, usually breaks the electrode loose from the work piece. If that
does not work, quickly unclamp the holder from the electrode, and turn off the machine. A
small chisel and hammer frees the electrode from the metal so it can be re-gripped in the
holder. The welding machine can then be turned back on.

There are two essentially similar methods of striking the arc. One is the tough or tapping
method. When using this method, the electrode should be held in a vertical position and
lowered until it is an inch or so above the point where the arc is to be struck. Then, the
electrode is lightly tapped on the work piece and immediately lifted to form an arc
approximately ¼-inch in length. [Figure 5-29]

Figure 5-29. Touch method of starting an arc.

The second (and usually easier to master) is a scratch or sweeping method. To strike the arc
by the scratch method, the electrode is held just above the plate at an angle of 20°–25°. The
arc should be struck by sweeping the electrode with a wrist motion and lightly scratching the
plate. The electrode is then lifted immediately to form an arc. [Figure 5-30]

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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Figure 5-30. Scratch/sweeping method of starting the arc.

Either method takes some practice, but with time and experience, it becomes easy. The key is
to raise the electrode quickly, but only about ¼-inch from the base or the arc is lost. If it is
raised too slowly, the electrode sticks to the plate.

To form a uniform bead, the electrode must be moved along the plate at a constant speed in
addition to the downward feed of the electrode. If the rate of advance is too slow, a wide
overlapping bead forms with no fusion at the edges. If the rate is too fast, the bead is too
narrow and has little or no fusion at the plate.

The proper length of the arc cannot be judged by looking at it. Instead, depend on the sound
that the short arc makes. This is a sharp cracking sound, and it should be heard during the
time the arc is being moved down to and along the surface of the plate.

A good weld bead on a flat plate should have the following characteristics:

• Little or no splatter on the surface of the plate.


• An arc crater in the bead of approximately 1⁄16-inch when the arc has been broken.
• The bead should be built up slightly, without metal overlap at the top surface.
• The bead should have a good penetration of approximately 1⁄16-inch into the base
metal.

Figure 5-31 provides examples of operator’s technique and welding machine settings.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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Figure 5-31. Examples of good and bad stick welds.

When advancing the electrode, it should be held at an angle of about 20° to 25° in the
direction of travel moving away from the finished bead. [Figure 5-32]

Figure 5-32. Angle of electrode.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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If the arc is broken during the welding of a bead and the electrode is removed quickly, a
crater is formed at the point where the arc ends. This shows the depth of penetration or fusion
that the weld is getting. The crater is formed by the pressure of the gases from the electrode
tip forcing the weld metal toward the edges of the crater. If the electrode is removed slowly,
the crater is filled.

If you need to restart an arc of an interrupted bead, start just ahead of the crater of the
previous weld bead. Then, the electrode should be returned to the back edge of the crater.
From this point, the weld may be continued by welding right through the crater and down the
line of weld as originally planned. [Figure 5-33]

Figure 5-33. Re-starting the arc.

Once a bead has been formed, every particle of slag must be removed from the area of the
crater before restarting the arc. This is accomplished with a pick hammer and wire brush and
prevents the slag from becoming trapped in the weld.

Arc Welding Procedures, Techniques, and Welding Safety


Equipment (Part Two)
Multiple Pass Welding

Grove and fillet welds in heavy metals often require the deposit of a number of beads to
complete a weld. It is important that the beads be deposited in a predetermined sequence to
produce the soundest welds with the best proportions. The number of beads is determined by
the thickness of the metal being welded.

Plates from 1⁄8-inch to ¼-inch can be welded in one pass, but they should be tacked at
intervals to keep them aligned. Any weld on a plate thicker than ¼-inch should have the
edges beveled and multiple passes.

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The sequence of the bead deposits is determined by the kind of joint and the position of the
metal. All slag must be removed from each bead before another bead is deposited. Typical
multiple-pass grove welding of butt joints is shown in Figure 5-34.

Figure 5-34. Multiple-pass groove welding of butt joints. [click image to enlarge]

Techniques of Position Welding

Each time the position of a welded joint or the type of joint is changed, it may be necessary to
change any one or a combination of the following:

• Current value
• Electrode
• Polarity
• Arc length
• Welding technique

Current values are determined by the electrode size, as well as the welding position.
Electrode size is governed by the thickness of the metal and the joint preparation. The
electrode type is determined by the welding position. Manufacturers specify the polarity to be
used with each electrode. Arc length is controlled by a combination of the electrode size,
welding position, and welding current.

Since it is impractical to cite every possible variation occasioned by different welding


conditions, only the information necessary for the commonly used positions and welds is
discussed here.

Flat Position Welding

There are four types of welds commonly used in flat position welding: bead, groove, fillet,
and lap joint. Each type is discussed separately in the following paragraphs.
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Bead Weld

The bead weld utilizes the same technique that is used when depositing a bead on a flat metal
surface. [Figure 5-35] The only difference is that the deposited bead is at the butt joint of two
steel plates, fusing them together. Square butt joints may be welded in one or multiple passes.
If the thickness of the metal is such that complete fusion cannot be obtained by welding from
one side, the joint must be welded from both sides. Most joints should first be tack-welded to
ensure alignment and reduce warping.

Figure 5-35. Proper bead weld.

Groove Weld

Groove welding may be performed on a butt joint or an outside corner joint. Groove welds
are made on butt joints where the metal to be welded is ¼-inch or more in thickness. The butt
joint can be prepared using either a single or double groove depending on the thickness of the
plate. The number of passes required to complete a weld is determined by the thickness of the
metal being welded and the size of the electrode being used.

Any groove weld made in more than one pass must have the slag, spatter, and oxide carefully
removed from all previous weld deposits before welding over them. Some of the common
types of groove welds performed on butt joints in the flat position are shown in Figure 5-36.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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Figure 5-36. Groove welds on butt joints in the flat position.

Fillet Weld

Fillet welds are used to make tee and lap joints. The electrode should be held at an angle of
45° to the plate surface. The electrode should be tilted at an angle of about 15° in the
direction of welding. Thin plates should be welded with little or no weaving motion of the
electrode and the weld is made in one pass. Fillet welding of thicker plates may require two
or more passes using a semicircular weaving motion of the electrode. [Figure 5-37]

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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Figure 5-37. Tee joint fillet weld.

Lap Joint Weld

The procedure for making fillet weld in a lap joint is similar to that used in the tee joint. The
electrode is held at about a 30° angle to the vertical and tilted to an angle of about 15° in the
direction of welding when joining plates of the same thickness. [Figure 5-38]

Figure 5-38. Typical lap joint fillet weld.

Vertical Position Welding

Vertical positing welding includes any weld applied to a surface inclined more than 45° from
the horizontal. Welding in the vertical position is more difficult than welding in the flat
position because of the force of gravity. The molten metal has the tendency to run down. To
control the flow of molten metal, the voltage and current adjustments of the welding machine
must be correct.

The current setting, or amperage, is less for welding in the vertical position than for welding
in the flat position for similar size electrodes. Additionally, the current used for welding
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upward should be set slightly higher than the current used for welding downward on the same
work piece. When welding up, hold the electrode 90° to the vertical, and weld moving the
bead upward. Focus on welding the sides of the joint and the middle takes care of itself. In
welding downward, with the hand below the arc and the electrode tilted about 15° upward,
the weld should move downward.

Overhead Position Welding

Overhead position welding is one of the most difficult in welding since a very short arc must
be constantly maintained to control the molten metal. The force of gravity tends to cause the
molten metal to drop down or sag from the plate, so it is important that protective clothing
and head gear be worn at all times when performing overhead welding.

For bead welds in an overhead position, the electrode should be held at an angle of 90° to the
base metal. In some cases, where it is desirable to observe the arc and the crater of the weld,
the electrode may be held at an angle of 15° in the direction of welding.

When making fillet welds on overhead tee or lap joints, a short arc should be held, and there
should be no weaving of the electrode. The arc motion should be controlled to secure good
penetration to the root of the weld and good fusion to the plates. If the molten metal becomes
too fluid and tends to sag, the electrode should be whipped away quickly from the center
ahead of the weld to lengthen the arc and allow the metal to solidify. The electrode should
then be returned immediately to the crater of the weld and the welding continued.

Anyone learning or engaged in arc welding should always have a good view of the weld
puddle. Otherwise there is no way to ensure that the welding is in the joint and keeping the
arc on the leading edge of the puddle. For the best view, the welder should keep their head off
to the side and out of the fumes so they can see the puddle.

SELF-CHECK#1.4-6
Welding Procedures and Techniques
Date Developed: Document No: CBLM-SMAWNCII-BC-03
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ENUMERATION
A. List down the 7 positions of welding plate and pipes.

B. What are the important things to be considered in welding?


C. What are the two type of welding manipulation

ANSWER KEY #1.2-6


Welding Procedures and Techniques
ENUMERATION

A. Welding positions for Plates Welding positions for Pipes

a. FLAT POSITION – 1G a. FLAT POSITION – 1G

b. HORIZONTAL POSITION – 2G b. Pipe 5G position

c. VERTICAL POSITION - 3G c. Pipe 6G position

d. OVERHEAD POSITION – 4G

B. a. The proper personal safety equipment being used, including a welding helmet,
welding gloves, protective clothing, and footwear; if not, in an adequately ventilated
area, appropriate breathing equipment

b. The ground connection been properly made to the work piece and is it making a
good connection.

c. The proper type and size electrode been selected for the job.

d. The electrode properly secured in the holder.

e. The polarity of the machine coincides with that of the electrode.

f. The machine in good working order and is it adjusted to provide the necessary
current for the job
Date Developed: Document No: CBLM-SMAWNCII-BC-03
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Information Sheet No. 1.4-7

Safe welding practices


Objectives:

After reading this information sheet, trainees must be able to:


1. Understand the importance of using proper Personal Protective
Equipment (PPE)
2. Know the Do’s and Don’ts upon performing welding
3. Familiarize with the 5S + 1 of Housekeeping Systems.

WELDING SAFETY PROCEDURES

The practice in which a welder used proper welding gears to avoid/prevent any
incident/accident during performing welding/hot works.

Personal Protective Equipment (PPE)

1. safety shoes
2. safety goggles
3. welding apron
4. welding gloves

5. leggings
6. welding mask w/ clear glass and dark glass
7. welding jackets
8. fire extinguisher
- basic wearable (except fire extinguisher) gears needed by a welder to
avoid and prevent any unwanted incidents on the working area.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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SAFETY PRECAUTIONS
Symbol Usage
 DANGER! – Indicates a hazardous situation which, if not avoided, will
result in death or serious injury. The possible hazards are shown in the
adjoining symbols or explained in the text.

 NOTICE – Indicates statements not related to personal injuries.

This group of symbols means Warning!, Watch Out!, ELECTRIC SHOCK,


MOVING PARTS, and HOT PARTD hazards. Consult symbols and related
instructions below for necessary actions to avoid the hazards.

Arc Welding Hazards


- The symbols shown are used throughout this manual to call attention to
and identify possible hazards. When you see the symbol, watch out,
and follow the related instructions to avoid the hazard.
- During operation, keep everybody especially children away.

1. ELECTRIC SHOCK can kill


Date Developed: Document No: CBLM-SMAWNCII-BC-03
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Touching live electrical parts can cause fatal shocks or severe burns.
The electrode and work circuit is electrically live whenever the output is on.
The input power circuit and machine internal circuits are also live when power
is on. In semi-automatic or automatic wire welding, the wire, wire reel, drive
roll housing, and all metal parts touching the welding wire are electrically live.
Incorrectly installed or improperly grounded equipment is a hazard.

 Do not touch live electrical parts.


 Wear dry, hole-free insulating gloves and body protection.
 Insulate yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact with
the work or ground.
 Do not use AC output in damp areas, if movement is confined,
or if there is a danger of falling.
 If AC output is required, use remote output control if present on
unit.
 Use AC output ONLY if required for the welding process.
 Additional safety precautions are required when any of the
following electrically hazardous conditions are present:
 In damp location or while wearing wet clothing
 On metal structure such as floors, gratings, scaffolds
 When in cramped positions such as sitting, kneeling, or
lying
 Or when there is high risk of unavoidable or accidental
contact with the work piece or ground.
 For these conditions, use the following equipment in order
presented;
 A semi-automatic DC constant voltage (wire) welder
 A DC manual (stick) welder
 An AC welder with reduced open-circuit voltage.
Date Developed: Document No: CBLM-SMAWNCII-BC-03
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In most situations, use at a DC, constant voltage wire welder is


recommended. And do not work alone.

 Properly install and ground this equipment according to its


owner’s manual and national, state, and local codes.
 Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground
terminal in disconnect box or that cord plug is connected to a
properly grounded receptacle outlet.
 When making input connections, attach proper grounding
conductor first – double check connections.
 Keep cords dry, free of oil and grease, and protected from hot
metal and sparks.
 Frequently inspect input power cord for damage or bare wiring
– replace cord immediately if damaged – bare wiring can kill.
 Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tag-out input power
according to OSHA 29 CFR 1910 (Safety Standard). Do not
use worn, damaged, undersized, or poorly spliced cables.
 Do not drape cables over your body.
 If the earth grounding of the work-piece is required, ground it
directly with a separate cable.
 Don not touch electrode if you are in contact with the work,
ground, or another electrode form a different machine.
 Do not touch electrode holder connected to two welding
machines at the same time since double open-circuit voltage
will be present.
 Clamp work cable with good metal-to-metal contact to work
piece or work table as near the weld as practical.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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 Insulate work clamp when not connected to work piece to


prevent contact with any metal object.
 Do not connect more than one electrode or work cable to any
single weld output terminal.

2.HOT PARTS can burn

 Do not touch hot parts bare handed


 Allow cooling period before working on equipment.
 To handle hot parts, use proper tools and/or wear heavy, insulated
welding gloves and clothing to prevent burns.
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3. CYLINDERS can explode if damaged

 Shielding gas cylinder contain gas under high pressure. If damaged, a


cylinder can explode. Since gas cylinders are normally part of the
welding process, be sure to treat them carefully.
 Protect compressed gas cylinders from excessive heat, mechanical
shocks, physical damaged, slag, open flames, sparks, and arcs.
 Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
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 Keep cylinders away from any welding or other electrical circuits.


 Never drape a welding torch over a gas cylinder.
 Never allow a welding electrode to touch any cylinder.
 Never weld on a pressurized cylinder - explosion will result.
 Use only correct shielding gas cylinders, regulators, hoses, and fittings
designed for the specific applications; maintain them an associated part
in good condition.
 Turn face away from valve outlet when opening cylinder valve
 Keep protective cap in place over valve except when cylinder is in use
or connected for use.
 Use the right equipment, correct procedures, and sufficient number of
persons to lift and move cylinders.
 Read and follow instructions on compressed gas cylinders, associated
equipment, and COMPRESSED GAS ASSOCIATION (CGA).

4. 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.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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5.FUMES AND GASES can be hazardous.


Welding produces fumes and gases. Breathing these fumes and gases can be
hazardous to your health.
 Keep your head out of the fumes. Do not breath the fumes.
 If inside a confined space, ventilate the area and/or use local forces
ventilation at the arc to remove welding fumes sand gases.
 If ventilation is poor, wear an approved air-supplied respirator.
 Read and understand the Material Safety Data Sheets (MSDS) and the
manufacturer’s instructions for metal, consumables, coatings, cleaners,
and degreasers.
 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 the oxygen level
causing injury or death. Be sure that the breathing air is safe.
 Do not weld on coated metals, such as galvanized, lead, or cadmium
plated steel, unless coating is removed from the weld areas. The
coatings and any metals containing these elements can give off toxic
fumes if welded.

6. 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.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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 Wear an approved welding helmet fitted with a proper shade of filter


lenses to protect your face and eyes from arc rays and sparks when
welding or watching.
 Wear approved safety glasses with side shields under your helmet.
 Use protective screens or barriers to protect others from flash, glare
and sparks; warn others not to watch the arc.
 Wear protective clothing made from durable, flame-resistant material
(leather, heavy cotton, or wool) and foot protection.

7. FLYING PARTICLES METAL or DIRT can injure eyes.

 Welding, chipping, wire brushing, and grinding cause sparks and flying
particles of metals. As welds cool, they can throw off slag.
 Wear approved safety glasses with side shields even under your
welding helmet.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


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8. WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them
to blow up. Sparks can fly off from the welding arc. The flying sparks, hot
work piece, 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 or hot works.

 Remove all flammables within 35 ft. (10.7 m) of the welding arc. If


this not possible, tightly cover them with approved covers.
 Do not weld where flying sparks can strike flammable materials.
 Protect yourself and others from flying sparks and hot metal.
 Be alert that welding sparks and hot materials from welding can easily
go through small cracks and openings to adjacent areas.
 Watch for fire, and keep fire extinguisher nearby.
 Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on a hidden side.
 Do not weld where the atmosphere may contain flammable dust, gas,
or liquid vapors (such as gasoline).
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Connect work cable to the work as close to the welding area as practical to
prevent welding current from traveling long, possibly unknown paths and
causing electric shock, sparks, and fire hazards.

 Do not use welder to thaw frozen pipes. Remove stick electrode from
holder or cut off welding wire at contact tip when not in use.
 Wear oil-free protective garments such as leather gloves, heavy shirt,
cuff less trousers, safety shoes, and a cap.
 Remove any combustibles, such as butane lighter or matches, from
your person before doing any welding.
 After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
 Use only correct fuses or circuit breakers. Do not oversize or bypass
them.

9. NOISE can damage hearing.

 Noise from some processes or equipment can damage hearing.


 Wear approved ear protection if noise level is high.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


Shielded Metal Arc January 2022
Issued by:
Welding Academia De Sta. Celia
NC II Foundation , Inc. Page 1 of 67
Developed by:
Ernesto T. Bandong Jr

Revision #: 0

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The 5s + 1 Housekeeping Systems


1. SEISO (SWEEP)
 CLEANLINESS: Cleaning of the workplace.
 Cleaning even if things are NOT DIRTY. A regular cleaning schedule prevents things
from having change to get dirty.
 Indicates the needs to keep the workplace clean as well as neat. Cleaning in Japanese
companies is a daily activity. At the end of each shift, the work area I cleaned up
everything restored to its place.

2. SEIRI (SORT)
 TIDINESS, ORGANIZATION,
 Taking out and disposing of unnecessary items.
 Unneeded items are thrown away or disposed.
 Refers to the practice of sorting and through all the tools, materials etc., Everything else
stored or discarded. The leads to fewer hazards and less clutter to interfere with
productive work.
 Things that clutter the workplace that are not needed should be taken out. They usually
occupy space and restrict physical movement. Further, this condition has a psychological
effect that usually clutters one attitude.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


Shielded Metal Arc January 2022
Issued by:
Welding Academia De Sta. Celia
NC II Foundation , Inc. Page 1 of 67
Developed by:
Ernesto T. Bandong Jr

Revision #: 0

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3. SEITON (SYSTEMATIZE)
 ORDERLINESS. Focuses on the need for orderly work place. Tools, equipment and
materials must be systematically arranged for the easiest and most efficient access.
 Arrangement/ organization of necessary items in good order for use.
 Items in the work place are arranged for ease of access and repeated use.
 Assign a place for everything. The most often used item should be nearest and
ergonomically situated, meaning- there should be little effort required in accessing, using
and returning the equipment, tools and parts, even documents. There must be a pace for
everything and everything must be in place.

4. SEIKETSU (STANDARDIZE)
 STANDARDS: Maintaining the workplace in high standard housekeeping.
 Allows for control and consistency. Basic housekeeping standard apply everywhere in the
facility. Everyone knows exactly what his or her responsibilities are. Housekeeping duties
are part of regular work routines.
 Prepare Housekeeping checklist. Checklist should be very detailed and stringent.
Remember that thoroughness is a requirement of EXCELLENCE.
 EVALUATE workstation according to the Housekeeping Standard Checklist.
 IMPLEMENT a periodic clean- up schedule; and an award and sanction scheme.

5. SHITSUKE (SELF-DISCIPLINE)
 SUSTAINING DISCIPLINE. Doing things spontaneously without having to be told.
 “teach by doing”
 It is good discipline to leave the workplace cleaner than when it is found.
 Refers to maintaining standards and keeping the facility in safe and efficient order day
after day, year after year.

6. SAFETY
Date Developed: Document No: CBLM-SMAWNCII-BC-03
Shielded Metal Arc January 2022
Issued by:
Welding Academia De Sta. Celia
NC II Foundation , Inc. Page 1 of 67
Developed by:
Ernesto T. Bandong Jr

Revision #: 0

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 As defined may be the freedom from danger injury or damage.


 According to Japan standard, a new addition to the 5S is safety, hence it will become
5s+1. Still part of the housekeeping system, safety becomes an important task to be
performed.

Self – Check No. 1.4-7

Safe welding practices


Fill in the blanks:

Write the correct answer in the blank from the statements below:

1.____________ Protect eyes from the arc rays.

2.____________ Protect from fumes and gases made by welding.

3.____________ Device to put off fire.

4.____________ Protection if noise level is high.

5.____________ Body protection from arc rays and burns.

6.____________ Do not touch hot parts without this.

Date Developed: Document No: CBLM-SMAWNCII-BC-03


Shielded Metal Arc January 2022
Issued by:
Welding Academia De Sta. Celia
NC II Foundation , Inc. Page 1 of 67
Developed by:
Ernesto T. Bandong Jr

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7.____________ Used when grinding or chipping slag.

8. ___________ SUSTAINING DISCIPLINE. Doing things spontaneously without having to


be told.

9. ___________ Maintaining the workplace in high standard housekeeping.

10. __________ Cleaning of the workplace.

Answer Key 1.4.7

Safe welding practices


1. Welding mask

2. Dust/gas mask

3. Fire extinguisher

4. Ear plug

5. Welding apron

6. Leather gloves

7. Face shield/goggles

8. SHITSUKE (SELF-DISCIPLINE)
Date Developed: Document No: CBLM-SMAWNCII-BC-03
Shielded Metal Arc January 2022
Issued by:
Welding Academia De Sta. Celia
NC II Foundation , Inc. Page 1 of 67
Developed by:
Ernesto T. Bandong Jr

Revision #: 0

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9. SEIKETSU (STANDARDIZE)

10. SEISO (SWEEP)

Date Developed: Document No: CBLM-SMAWNCII-BC-03


Shielded Metal Arc January 2022
Issued by:
Welding Academia De Sta. Celia
NC II Foundation , Inc. Page 1 of 67
Developed by:
Ernesto T. Bandong Jr

Revision #: 0

Downloaded by SUROY ni BLAM ([email protected])

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