Smaw Profesionalism
Smaw Profesionalism
Smaw Profesionalism
7 - N/A
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
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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.
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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.
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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
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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
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
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
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
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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)
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
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
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The term variable as used in this text means something the welder has to
control of either before welding or during 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.
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Current Ranges
3/32” 60 - 90 70 – 100
A B C
A – Amperage correct
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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 correct arc length may vary according to the type and size of
electrode and the position of welding.
3. Angle of Electrode
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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
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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 last digit indicates the type of flux or electrode covering and in
turn determines the type of current, penetration and appearance of the weld.
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___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
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
____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
2. c 7. a
3. d 8. c
4. a 9. a
5. d 10. a
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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.
E. Put on welding helmet and adjust machine to correct amperage by running a test bead on
scrap metal.
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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.
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.
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
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
up, and be sure to clean each pass before starting the next one.
V. Use the E 7018 electrode and with a weaving technique, lay a cap pass to finish the weld
with overhead welding.
Assessment Method
Demonstration of Practical Skills
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?
5 Did you put on welding helmet and adjust machine to correct amperage by
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
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?
21. Did you use the E 7018 electrode and with a weaving technique, lay a cap pass
to finish the weld with overhead welding
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This code covers the welding requirements for any type of welded
structure made from the commonly used carbon and low-alloy steels.
- 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.
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- 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.
- 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.
- 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 D3.5-93R
- Guide for Steel Hull Welding. This guide is referenced in many contract
specifications for building vessels from barges to tugboats
AWS D3.7
- 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
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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AWS D14.5
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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.
___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.
____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.
1. True 6. True
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
2. True 7. True
3. True 8. True
4. True 9. True
Note: Convexity C of a weld or individual surface bead with dimension W shall not
exceed the value of the following table
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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
___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
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1. b
2. c
3. b
4. d
5. a
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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
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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1.7 Poor Penetration – happens when the joint or root weld penetration does
not meet the weld requirement for full strength
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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
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Direction: Read each statement carefully. Write the letter of the correct
answer on space provided before each number.
___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
II. DEFINITION:
Define the following weld defects.
1. Poor Penetration
2. Porosity
3. Slag Inclusion
4. Crater Cracks
5. Longitudinal Cracks
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
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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.
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
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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.
Direction: Read the statement carefully. Write the letter of the best answer on
space provided before each number.
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II. EXPLAINATION:
Direction: Explain the proper Welding Procedure and specification on your own words.
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.
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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.
(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?
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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]
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]
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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:
Figure 5-31 provides examples of operator’s technique and welding machine settings.
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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]
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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]
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.
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]
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.
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.
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
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.
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.
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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]
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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]
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
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
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 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
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
ENUMERATION
A. List down the 7 positions of welding plate and pipes.
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.
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
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
The practice in which a welder used proper welding gears to avoid/prevent any
incident/accident during performing welding/hot works.
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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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
Write the correct answer in the blank from the statements below:
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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
9. SEIKETSU (STANDARDIZE)
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