Shs11 Smaw11 q1 Mod1 Grooveweld Version3

Senior High School
Shielded Metal Arc

Welding NC II
Quarter 1
Module 1
Perform Groove Weld on Carbon
Steel Plates and Pipes
Department of Education • Republic of the Philippines

Shielded Metal Arc Welding – Grade 11
Alternative Delivery Mode
Quarter 1-4 – Module 1-4:
First Edition, 2020
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Senior High School
Shielded Metal Arc

Welding NCII
Quarter 1 -Module 1:
Perform Groove Weld on
Carbon Steel Plates and Pipes
This instructional material was collaboratively developed and reviewed by

educators from public and private schools, colleges, and/or universities. We
encourage teachers and other education stakeholders to email their feedback,
comments, and recommendations to the Department of Education at
action@deped.gov.ph.
We value your feedback and recommendations.
Department of Education • Republic of the Philippines
3
Introduction
Shielded Metal Arc Welding(SMAW) is an arc welding process in which the

fusing of metals is produced by heat from an electric arc that is maintained between
the tip of a consumable covered electrode and the surface of the base metal in the
joint being welded. Shielded Metal Arc welding is one of the most widely used welding
processes, particularly for short welds in production, maintenance, repair work, and
field construction.
This module entitled “Perform Groove Weld on Carbon Steel Plates and Pipes
using SMAW” is one of the learning outcomes of SMAW NC II offered by DepEd in
Senior High School under the track Technical Vocational Livelihood strand Industrial
Arts. It is a training program which comprises the knowledge, skills and attitude of a
welder. This module contains training materials and activities related to the welding
activities. This module will equip you the fundamentals of welding and mechanics on
how to apply safety practices, weld on groove in flat position, identify the acceptable
weld profile, and weld defects so that you can apply corrective actions to be certified
as welder and will also serve as a vital tool for Distance Learning. In this module, you
are required to go through a series of learning activities in order to complete each
learning outcome. This module provides Lesson Information and Self-Checks that will
help you deepen your understanding of the concepts, competencies, and learning
outcomes. Follow and answer the activities on your own. If you have questions, do not
hesitate to ask for assistance from your facilitator/teacher.
Remember the following instructions:
• Read Lesson Information and complete self-checks.

• Perform the Performance Task until you are confident that your outputs conform
to the Performance Criteria that follows after every lesson.
• Submit answers of the Self-Checks and outputs of the Task Sheets to your
facilitator/teacher for evaluation and recording in the Accomplishment Chart.
Outputs shall serve as your portfolio during the Institutional Learning Outcome
Evaluation.
• When you feel confident that you have had sufficient practice, ask your trainer
to evaluate you. The results of your assessment will be recorded in your E-
Class Record and your progress will be recorded in your Achievement Chart.
4
Table of Contents
Quarter 1
Lesson 1 Weld Carbon Steel Plate in Flat Position(1G)
Pretest………………………………………………………………….........................4
Definition of Terms……………………………………………………….....................8
Lesson Information 1.1: Fundamentals of Welding…………………………9
Self-Check 1.1……………………………………...11
Lesson Information 1.2: Safety Welding Practices………………………….12
Self-Check 1.2……………………………………...16
Lesson Information 1.3: 5S of Good Housekeeping………………………..17
Self-Check 1.3……………………………………...19
Lesson Information 1.4: Acceptable and (Unacceptable) Welding Profile..20
Self-Check 1.4………………………………………21
Lesson Information 1.5: Welding Defects, Causes, and Remedies……….24
Self-Check 1.5………………………………………31
Lesson Information 1.6: Perform Root Pass and Multi-Layer Deposit in …32
Flat Position
Application………………………………………………………………………………..41
Progress Chart…………………………………………………………………………..42
Generalization……………………………….............................................................43
Posttest…………………………………………………………………………………...44
Answer Key……………………………………………………………………………....47
Reference………………………………………………………………………………...50
5
Pretest
Let us determine your prior knowledge on the topic/task in
Performing Groove Weld on Carbon Steel Plates and Pipes by taking this
pretest.
I. Multiple Choice:
Directions: Read and analyze the statements carefully. Choose the correct answer
and write the letter only on your separate answer sheet.
1. ______________________ are generated in a welding job due to the faulty or
poor technique used by the inexperienced or unskilled welder or due to
fundamental difficulties in the welding operation.
a. Spatter c. Penetration
b. Welding defects d. Porosity
2. ____________________ occurs when the depth of the welded joint is
insufficient.
a. Incomplete penetration c. Spatter
b. Porosity d. Welding defects
3. ___________________ cracking is due to tearing of the grain boundaries of
weld metal before complete hardening has taken place and metal is still in the
plastic state.
a. Hot tear c. Distortion
b. Solidification d. Undercut
4. ________________ is also known as solidification cracking state.

a. Hot tear c. Groove
b. Distortion d. Undercut
5. ____________________ is defined as the distance from the base plate top

surface to the maximum extent of the weld nugget.
a. Porosity c. Undercut
b. Distortion d. Penetration
6. It refers to organization of necessary items in good order and easy access.

a. Seiri (Sort) c. Seiton (Systematize)
b. Seiso (Sweep) d. Shitsuke (Self Descipline)
7. It means taking out and disposing unnecessary items.

a. Seiri (Sort) c. Seiketsu (Sanitize/Standardize)
b. Seiso (Sweep) d. Seiton (Systematize)
8. It is used to protect arms from falling flux or hot sparks.

a. Welding mask c. Welding sleeve
b. Leggings d. Safety apron
6
9. It is a working suit that is used in workplace as whole body protection from
sparkling of equipment.
a. Full body harness c. Safety shoes
b. Cover all d. Safety apron
10. They protect feet from hot sparks or falling objects.

a. Welding sleeves c. Safety glass
b. Safety shoes d. Welding gloves
11. A shallow fusion between weld metal and based metal.

b. Porosity d. Incomplete penetration
12. It is due to excessive heat input and creates hole.

a. Burn-through c. Penetration
13. ____________________ is a group of small voids and blowholes that are

comparatively bigger isolated holes or cavities.
14. _________________ is a kind of weld defect which forms a groove in the

parent metal along with the sides of the weld bead.
a. Groove c. Distortion
b. Hot tear d. Undercut
15. It is cause of not following the welding principle or procedures and lack of skill
of a welder.
7
II. Matching Type
Directions: Match the pictures of Column A with the words or group of words in
column B. Write only the letter of your choice in your separate answer
sheet.
Item Column A Letter Column B
No.
16 a Excessive
undercut
17 b Insufficient throat
18 c Insufficient leg
19 d Desirable fillet
weld profiles
20 e Butt joint-unequal
thickness plate
8
21 f Incomplete fusion
22 g Maximum
1/16 in. (1.6mm) convexity
1/8 in. (3mm)
3/16 in. (5mm)
23 h Overlap
24 i Excessive
convexity
25 j Desirable fillet
weld profiles
9
Definition of Terms
Alternate Current - it is when electrical current alternates or reverses the direction

of electron flow.
Amperage - is a measure of electrical current flowing through a circuit and is an
indication of the heat being produced.
Arc Welding - uses electricity to heat and melt the metal.
Direct Current - electron flow in one direction.
Electricity - is the flow of tiny particles called electrons through a conductor.
Electrode - is a bare metal rod which is usually coated with chemical compounds
called flux.
Fumes - are produced when cutting metal containing zinc and are injurious when
inhaled.
Hazard - is any source of potential damage, harm or adverse health effects on
something or someone.
Penetration - is the distance that the fusion line extends below the surface of the
material being welded.
Polarity - is the direction the current is flowing.
Rays - are given off by the arc are the same as those transmitted by sunlight and
can cause severe burn.
Reverse Polarity- it is when the electrons flow from work piece to the electrode.
Risk - the combination of the likelihood of the occurrence of a harm and severity of
that harm.
Straight Polarity - it is when the electrons flow from the electrode to the workpiece.
Welding - is the melting, flowing together and freezing of metals under controlled
conditions.
Voltage - is a measure of electrical pressure.
10
What is it?
Lesson 1 Weld Carbon Steel Plate in Flat Position (1G)
Lesson Information 1.1
Fundamentals of Welding
After reading the Information Sheet, the trainee must be able to determine the
fundamentals of welding.
Weld quality and consistency can only be maintained with respect to the five
fundamentals. The five fundamentals of welding include the use of correct electrode
size, current, arc length or voltage, travel speed and electrode angles. All five must
be collectively and consistently maintained to successfully control the puddle and
produce a weld that is uniform in appearance, has consistent ripples, smooth face
contour, and no noticeable defect. Once the welder masters the ability to consistently
maintain the five fundamentals, the ability to control the puddle will follow.
Current Setting
The correct current setting is vital for maintaining consistency in weld quality.
If the current is too high, the electrode melts too fast, and the molten pool is larger
and irregular. If the current is too high when welding single vee groove, it may blow
holes through the joint and cause large molten metal droplets to fall out of the
groove. If the current is too low, there is not enough heat to melt the base metal.
The molten pool appears too small, piles up, and looks irregular. I t c a n re s u lt t o
poor penetrat ion and incomplete fusion in the joint.
Length of an Arc
Is very important for weld puddle control. Correct arc length will cause the
deposit to be neat of even ripple and of good penetration. Too long arc length will
cause the deposit to coarse ripple and flatter than normal with an increase in spatter.
When welding a root pass in an open root vee groove, the keyhole can grow too large
and loose of weld control can result.
Too short an arc will cause deposited to be narrow, uneven and irregularly
rippled and with poor fusion. The arc length reduces the voltage and increases the
amperage slightly but the electrode may stick to the work. When welding root passes,
too short an arc length often results in loss of the keyhole.
11
Angle of Electrode
One of the fundamentals is the use of the correct electrode angles. For
fillet and groove welds, correct electrode angles are vital for pre venting undercut
and inadequate fill. When depositing a fillet weld, the electrode should be held so
that it bisects the angle between the plates and is perpendicular to the line of the
weld. On groove weld, the technique is much the same; although varying slightly with
multiple pass welding. There are two teams to specify electrode angles. These are
travel angle and work angle.
The travel angle applies to the position the electrode makes with a reference
perpendicular to the axis of the weld in plane of the weld axis. It can be either a
drag angle or a push angle. A drag angle is when the electrode is pointing
backward, which means, the welder’s hand and electrode holder precede the puddle.
A push angle is when electrode is pointing just the opposite of the drag.
The work angle is the position the electrode makes with reference to the
surface of the plate on a plane perpendicular to the weld axis. On butt joints, the work
angle is usually 90 degrees to the surface of the plate.
To some degree, you can correct for an improper condition by varying the
essential variables. It is better though to have all conditions as correct as possible.
Manipulation of Electrode
Choosing the correct electrode size involves many factors. If a smaller

recommended electrode is used, welding time and heat to the joint will increase. It
can result in increased costs, heat affected zone, cracking or distortion.
Larger electrode can cause melt through and can be difficult to control in out
of position joint.
Poor appearance and possible defects can result. The welding procedure
designates the correct electrode size, generally based on metal type and thickness.
However, if no procedure or instruction is available, the welder will have to choose
the correct electrode size.
Speed of Travel
Incorrect travel is a common mistake. Sometimes travel speed is the only

condition a welder may need to change. Travelling fast causes the puddle to freeze
too quickly. Because of this, impurities and gases can be entrapped, making the bead
face narrow with pointing ripple. Incomplete penetration due to loss of the keyhole in
root pass is possible.
Travelling too slow will cause the puddle to be large, with pile up, and a
straight ripple pattern. For out of position welding, slow travel speed can cause the
puddle to drip out the joint.
12
Assessment
Self-Check 1.1
I. TRUE OR FALSE
Directions: Read each statement below carefully. Write TRUE if the statement is
correct and FALSE if the statement is not correct on your separate
answer sheet.
1. Using a larger electrode diameter can cause melt through/ burn through.
2. Travelling too fast will make the bead face narrow with pointing ripple.
3. If the current is too low, the electrode melts too fast.
4. Quality or sound weld is the result of correct current, constant voltage, travel
speed, electrode angle and correct electrode size.
5. In fillet weld, electrode angle is not necessary for preventing undercut and
under fill.
6. Welding is the process of joining together two pieces of metal so that bonding
takes place at their original boundary surfaces.
7. Electrode circumference is based on the thickness of the base metal, the
welding position, and the type of joint to be weld.
8. Each type of electrode has recommended amperage ranges for optimum
performance.
9. High amperage could also cause the electrode coating to overheat and break
down.
10. Arc length is the distance from the tip of the electrode core wire to the
electrode handle.
13
What is it?
Safe Welding Practices

What are the safety practices that should be observed when doing shielded
metal arc welding?
The following are suggested practices and tips that will help to eliminate shop
accidents when arc welding.
1. Wear a welding mask. Wear leather or welding gloves at all times when arc welding
to protect against hot electrodes, particles of spatter and slag, or the metal being
welded.
Welding Mask Welding Gloves Safety Helmet

Source: https://www.alibaba.com/trade
2. Wear safety shoes to protect your feet and ankles from burns caused by weld
spatter.
Safety Shoes
14
3. Do not wear clothing with turned up cuffs. Keep your collar and pockets buttoned.
Do not wear ragged, oily or greasy clothing. Never weld when your body is exposed,
as when not wearing a shirt, or wearing a short-sleeved shirt or shorts. If welding apron
is not available, wear cover all clothing rather than cotton. Cover all does not ignite as
readily and provides better protection from heat.
Leather Jacket Full Body Harness

4. Inspect welding cables for broken insulation and frayed conductors. Check
electrode holder and ground clamps for positive connections before beginning to weld.
Loose connections and grounds may prove dangerous. Provide a dry wooden platform
to stand on or wear rubber soled shoes where there are damp floors.
Source: www.MillerWelds.com
15
5. Clear all flammable materials away from the welding area before beginning to weld.
Flying sparks from the spatter may ignite flammable material several feet from the
welding operation. Clear the welding area of rags, straw, paper, shavings, and other
flammable items before starting to weld.
Flammable Sparks
6. Keep matches, lighters, papers, and cellophane wrappers out of pockets as these
items ignite quickly and/or may explode.
Explode
7. Turn on an exhaust system or industrial fan before beginning to weld. Welding
fumes soon spread to all parts of the shop and may be injurious when inhaled. Take
special measures to avoid noxious fumes that occur when welding or cutting metals
containing zinc. Inhaling zinc fumes will cause you to feel ill for several hours after
welding.
Injured Fumes Cut Hands

8. Do not strike an arc before covering face and eyes with the protective welding mask.
The ultraviolet light rays given off by the arc are the same as those transmitted by
sunlight, except that they are more intense and concentrated. Exposure to these rays
will cause a severe burn. Eye irritation and burn will result if your eyes are not shielded.
Protective Equipment
16
9. Protect other workers by using a welding screen to enclose your area. Warn persons
standing nearby, by saying “cover”, to cover their eyes when you are ready to strike
an arc.
10. Never look directly at the arc without protecting your eyes. The rays can penetrate
through closed eyelids if you are welding at close range. Do not wear contact lenses
while welding or around a welder.
11. Do not weld barrels, tanks or other containers which may have held combustible
material. These operations are best performed by professional welders.
12. Do not chip slag from a weld unless your eyes and those of others near you are
protected by safety glass.
Safety Glass Respirator

13. Be alert for fires at all times because when the operator’s welding mask is lowered,
clothing may catch fire without being noticed. Use your senses of touch, smell, and
hearing to indicate that something is wrong. In case of a clothing fire, strip off the
clothing if possible. Do not run, as running fans the flames, instead, wrap yourself in a
fire blanket, or improvise with a coat or a piece of canvas. If there is nothing at hand
to wrap in, drop to the floor and roll slowly.
Ear Muff
14. Handle all hot metals with tongs or pliers to prevent burning your hands or gloves.
Place all hot metals where no one will come in contact with. Develop the habit of feeling
all metals cautiously before picking them up. Do not leave hot metals where anyone
may pick them up or step on them.
15. Guard against saturation of clothing by perspiration or moisture. This increases
the shock hazard.
16. Disconnect the welding machine when repairing or adjusting it.
17. Always unplug the welding machine and put all equipment away when you have
finished for the day.
18. In case of eye or skin burns, get first-aid treatment. Report immediately to the
instructor all burns and injuries.
19. Protect fuel tanks and fuel lines with wet sheet asbestos when welding near motors
or power units. The paint on machinery also may start to burn from the heat of welding.
17
Assessment
Self-Check 1.2
I. TRUE or FALSE
Directions: In the following suggested welding practices and tips listed below,
answer T if the statement is TRUE and F if it is FALSE. Write your
answers on your separate answer sheet.
1. Wear a welding helmet.
2. Wear leather or special fabric gloves at all times when arc welding to protect
from hot electrodes, particles of spatter and slag, or the metal being welded.
3. Wear high-top shoes to protect your feet and ankles from burns caused by
weld spatter.
4. Wear clothing with turned up cuffs.
5. Keep your collar and pockets unbuttoned.
6. Do not wear ragged, oily or greasy clothing.
7. Never weld when your body is exposed, as when not wearing a shirt, or
wearing a short-sleeved shirt or shorts.
8. Wool does not ignite as readily and provides better protection from heat.
9. Inspect welding cables for broken bones and frayed conductors.
10. Check electrode holder and ground clamps for positive connections before
beginning to weld.
II. Multiple Choice:

Determine the appropriate Personal Protective Equipment (PPE) to be used.
Write your answers on your separate answer sheet.
2. It protects the body from hot sparks.
a. Leather Jacket c. Cover all
b. Safety glass d. Respirator
3. It is a Personal Protective Equipment (PPE) that is used in working heights.
a. Leggings c. Full body harness
b. Welding Mask d. Safety glass
18
What is it?
5S of Good Housekeeping
What is the 5S system?

1. SEIRI - SORT
• Taking out and disposing unnecessary items.
• Unneeded items are thrown away or disposed.
Source: http://www.oshc.dole.gov.ph/images/5S.jpg
2. SEITON – SYSTEMATIZE
• Organizing of necessary items in good order and easy access.
• Items in the workplace are arranged for ease of access and repeated use.
19
3. SEISO- SWEEP
• Cleaning of the workplace after usage or even if things are not dirty.
4. SEIKETSU- SANITIZE/STANDARDIZE
• Maintaining the workplace in high standard of housekeeping and sanitation.
• Disinfection prevents the spread of microorganism
that cannot be seen with your naked eyes.
5. SHITSUKE – SELF DISCIPLINE

• Doing things spontaneously without being told.
• Even if you have the knowledge and skills
but you do not practice self-discipline,
they are still considered as useless.
20
Assessment
Self-Check 1.3
Directions: Give an idea of the following based on your own understanding. Write
your answers on your separate answer sheet.
1. Sort
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
2. Systematize
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
3. Sweep
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
4. Standardize
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
5. Self-Discipline
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
21
What is it?
Acceptable (and Unacceptable) Weld Profiles
Source: http://nattesting.com/acceptable_weld.htm
22
Assessment
Self-Check 1.4
Matching Type
Directions: Match the pictures of Column A with the words or group of words in
column B. Write only the letter of your choice on your separate answer
sheet.
Item Column A Letter Column B
No.
1 a Desirable fillet weld

profiles
2 b Acceptable fillet
weld profiles
3 c Insufficient throat
4 d Excessive
convexity
5 e Excessive undercut
23
6 f Overlap
7 g Insufficient leg
8 h Incomplete fusion
9 i Butt joint-equal
thickness plate
10 j Butt joint-unequal
1/16 in. (1.6mm) thickness plate
1/8 in. (3mm)
3/16 in. (5mm)
11 k Butt joint-Excessive
convexity
12 l Butt joint-
insufficient throat
24
13 m Butt joint-excessive
undercut
14 n Butt joint-overlap
15 o Maximum
convexity
25
What is it?
Weld Defects, Causes and Remedies
What are Welding Defects?
Welding defects are generated in a welding job due to the faulty or poor
technique used by the inexperienced or unskilled welder or due to fundamental
difficulties in the welding operation. An ideal weld or good weld should be such that
adequate fusion exists between the filler metal and edge preparation together with
good penetration.
Types of Welding Defects:

Welding defects are broadly classified into two categories, and these are:
1. External welding defects (Defects occur on the upper surface of the welded
work).
2. Internal welding defects (Defects occur under the surface of the welded
work).
I. External Welding Defects:

The various types of external defects with their causes and remedies are listed
below:
A. Weld Crack
This is the most unwanted defect of all the other welding defects. Welding cracks
can be present at the surface, inside of the weld material or at the heat affected zones.
Source: www.theweldingmaster.com
Crack can also appear at different temperatures:

1. Hot Crack – It is more prominent during crystallization of weld joints where the
temperature can rise more than 10,000-degree Celsius.
2. Cold Crack – This type of crack occurs at the end of the welding process where
the temperature is quite low. Sometimes cold crack is visible several hours after
welding or even after few days.
26
Causes of Weld Crack:
1. Poor ductility of the given base metal
2. The presence of residual stress can cause a crack on the weld metal.
3. The rigidity of the joint which makes it difficult to expand or contract the metals.
4. If there is high content on sulphur and carbon then also the cracks may appear.
5. Using hydrogen as a shielding gas while welding ferrous materials.
Remedies for Weld crack:

1. Using appropriate materials may decrease the chances of crack.
2. Preheating the weld and reducing the cooling speed joint helps in reducing crack.
3. Reduce the gap between the weld joints by using reasonable weld joints. 4. While
welding releases the clamping force slowly which increases fill to capacity of
welding material.
B. Undercut
When the base of metal melts away from the weld zone, then a groove is formed
in the shape of a notch, then this type of defect is known as undercut. It reduces the
fatigue strength of the joint.
Causes of Undercut:
1. If the arc voltage is very high then this defect may occur.
2. If we use the wrong electrode or if the angle of the electrode is wrong, then also
the defect may form.
3. Using a large electrode is also not advisable.
4. High electrode speed is also one of the reasons for this defect.
Remedies for Undercut:

1. Reduce the arc length or lower the arc voltage.
2. Keep the electrode angle from 30 to 45 degree with the standing leg.
3. The diameter of the electrode should be small.
4. Reduce the travel speed of the electrode.
27
C. Spatter
When some metal drops are expelled from the weld and remain stuck to the
surface, then this defect is known as spatter.
Causes of Spatter:
1. High welding current can cause this defect.
2. The longer the arc the more chances of getting this defect.
3. Incorrect polarity
4. Improper gas shielded may also cause this defect.
Remedies for Spatter:

1. Reducing the arc length and welding current
2. Using the right polarity and according to the conditions of the welding
3. Increasing the plate angle and using proper gas shielding
D. Porosity
Porosity refers to small cavities or holes resulting from gas pockets in weld metal.
Causes of Porosity:
1. It occurs when the electrode is not coated properly.
2. Using a longer arc may also increase its chances.
3. Increased welding currents.
4. Rust or oil on the welding surface.
Remedies for Porosity:

1. Proper selection of the electrode
2. Decreasing the welding current
3. Using smaller arc and slowing the process to allow the gases to escape
4. Remove rust or oil from the surface and use a proper technique
28
E. Overlap
When the weld face extends beyond the weld toe, then this defect occurs. In this
condition the weld metal rolls and forms an angle less than 90 degrees.
Causes of Overlap:
1. Improper welding technique
2. By using large electrodes this defect may occur.
3. High welding current
Remedies for Overlap:

1. Use a proper technique for welding.
2. Use small electrode.
3. Less welding current.
F. Distortion
Distortion means contraction of weld metal during welding that forces base metal
to move.
Causes of Distortion:
1. A great number of passes with small diameter electrodes
2. Slow arc travel speed
3. High residual stresses in the plate to be welded
4. Using improper welding sequences
Remedies of Distortion:
1. Use the proper amount of weld metal as per the requirement of the joint. It will
reduce the contraction forces.
2. Use an appropriate number of weld passes.
3. Place the weld near the neutral axis.
4. Use proper welding sequences.
G. Burn-Through
29
Burn- Through refers to weld metal melting completely through base metal
resulting in holes where no metal remains.
Cause of Burn-Through:
1. Excessive heat input
Remedies of Burn-Through:
1. Select lower amperage. Use smaller electrode.
2. Increase and/or maintain steady travel speed.
II. Internal Welding Defects:

The various types of internal defects with their causes and remedies are listed
below:
A. Slag Inclusion
If there is any slag in the weld, then it affects the toughness and metal
weldability of the given material. This decreases the structural performance of the weld
material. Slag is formed on the surface of the weld or between the welding turns.
Causes of Slag:
1. Slag is formed if the welding current density is very small, as it does not provide
the required amount of heat for melting the metal surface.
2. If the welding speed is too fast then also slag may occur.
3. If the edge of the weld surface is not cleaned properly then also slag may form.
4. Improper welding angle and travel rate of welding rod
Remedies for Slag Inclusion:

1. Increase the current density.
30
2. Adjust the welding speed so that the slag and weld pool do not mix with each
other.
3. Clean the weld edges and remove the slags of previous weld layers.
4. Have a proper electrode angle and travel rate.
B. Incomplete Fusion
Incomplete fusion occurs when the welder does not accurately weld the
material and the metal pre solidifies which leads to a gap which is not filled with the
molten metal.
Causes of Incomplete fusion:

1. It occurs because of the low heat input.
2. When the weld pool is very large and runs ahead of the arc.
3. When the angle of the joint is too low.
4. Incorrect electrode and torch angle may also lead to incomplete fusion.
5. Improper bead position
Remedies for Incomplete Fusion:

1. Increasing the welding current and decreasing the travel speed helps in
removing the chances of incomplete fusion.
2. Reducing the deposition rate.
3. Increasing the joint angle.
4. Try to position the electrode and torch angle properly so that the edges of the
plate melt away.
5. Positioning the bead properly so that the sharp edges with other beads can be
avoided.
31
C. Incompletely Filled Groove or Incomplete Penetration
These defects occur only in the butt welds where the groove of the metal is not
filled completely. It is also called as incomplete penetration defect.
Causes of an Incomplete Filled Groove:
1. Less deposition of the weld metal

2. Use of improper size of the electrode
3. Improper welding technique
Remedies for Incomplete Filled Groove:
1. More deposition of the weld metal.

2. Use a proper size of the electrode.
3. By using a proper welding technique.
32
Assessment
Self-Check 1.5
Multiple Choice: Directions: Read and analyze the statement carefully.
Choose the correct answer and write the letter only on your separate answer sheet.
b. Porosity d. Welding Defects
2. ____________________ occurs when the depth of the welded joint is insufficient.
a. Incomplete Penetration c. Penetration
4. ____________________ is a group of small voids and blowholes are
5. ____________________ is the small metal particles that are thrown out of the
arc during welding and get deposited on the base metal around the weld bead
along its length.
6. __________________ is the change in the shape and difference between the
position of two plates before and after welding due to the temperature gradient
present at various points along the joints.
7. _________________ is a kind of weld defect which forms a groove in the parent
metal along with the sides of the weld bead.
8. ________________________ reduces the thickness of the plate and also
reduces the strength of the weld.
weld metal before complete solidification has taken place and metal is still in
the plastic state.
33
What is it?
Perform Root Pass and Multi-Layer Deposit in Flat Position
Things to Take Note in Arc Welding
Prepare the Metal to be Welded
Arc welding is more tolerant to slightly rusty metal than other electric welding
processes but at the least, you should remove any paint, grease, rust, or other
contaminants with steel brush, sandpaper or angle grinder to avoid weld contamination
or inclusion.
Source: https://www.nccer.org
34
Attach Clamps on Work Pieces (Steel Plate) and Grounding
Ensure there is a clean location so that the electrical circuit can be completed
with minimal resistance at the ground location. Again, rust or paint will interfere with
the grounding of your work piece, making it difficult to create an arc when you begin
welding. Perform Tack for temporary joint of two metals.
35
Select the correct electrode and amperage range for the work you are
attempting.
Insert the electrode into the insulated holder. Set amperage at levels
recommended by the electrode manufacturer.
As an example, 1⁄4 inch (0.6 cm) plate steel can be welded effectively using an
E6011, 1⁄8 inch (0.3 cm) electrode, at between 80-100 amps.
36
Electrode Angle (Lead Angle)
When welding on the work piece, the rod should be angled around 10 to 20
degrees from vertical and pulled in the direction towards the welder. The angle of the
rod prevents the slag overtaking the rod (inclusions in the weld will occur if welding is
carried over the slag). Use your spare hand to support the top of the electrode to
improve control of the electrode if necessary.
Arc Length
The arc length is the distance between the electrode and the weld pool. It
should be roughly the same as the diameter of the electrode. You will get used to the
arc length after some practices.
The arc length can be easily determined by the sound and visible light from the
arc. The arc should be kept short and hide the majority of the light from the weld
without pushing the electrode into the slag pool. A good short arc length will result in
a consistent sharp crackling sound. The appearance of the completed weld will provide
further clues.
37
Maintaining Lead Angle and Arc Length
As the welding electrode gets shorter during the weld process, it takes a minded
effort to reduce the length of the arc. Excessive arc length will lead to an unstable arc
with excess heat and undercutting. This is one of the most common mistakes by
beginners.
The angle of the electrode should be maintained over the length of the weld.
Practice is necessary to avoid decreasing the lead angle as the weld progresses, as
this can lead to slag inclusions and even cause the arc to stall. The easy approach to
maintain electrode angle is to focus on moving the electrode holder rather than the
electrode as the weld progresses.
First Weld Pass
Note: View this link for hands on presentation
https://www.youtube.com/watch?v=HOG2ypThBpc
Second Weld Pass
38
Third Weld Pass
Complete Weld Pass
Note: View this link for hands on presentation
https://youtu.be/rb72AT-YK0Y
Note: Performing weld passes depends on the thickness of the Based Metal and
applying waving patterns that best suited to your performance.
39
Slag
After welding, you may want to remove the slag and clean up your weld. Chip
off the slag and steel brush the weld to remove any foreign material and remaining
slag. Ensure eye protection is worn as the brittle slag can fly off to distance. A clean
weld after grinding is easier to examine for any welding defects.
Source: https://weldguru.com/smaw-tips-techniques/
40
Visual Examination After Welding- Completed Weldment
The trainer is expected to determine that weldment conforms to the working

drawing and specifications for which it is designed and constructed. The weld must all
be made to the size specified.
The following items must be considered:
1. All welds should be inspected to see that they do not have any of the following
defects:
a. Surface cracks
b. Crater cracks or underfill
c. Surface porosity
d. Incomplete root penetration
e. Undercut
f. Underfill on face, groove (concave)
g. Excessive face reinforcement, groove (convex)
h. Overlap
i. Misalignment (high-low)
j. Arc strikes
k. Excessive spatter
2. Other weldment defects that must be checked:

a. Warpage – beyond allowable or acceptable limits
b. Base metal defect – scabs or seams in the base metal
c. Backing welds – a question about quality of root fusion
41
Testing the Weld
Weld Strength Test Diagram

Test Welds Using a Ballpeen Hammer in the direction shown below Weakness can
be Due to Porosity (holes in the weld), Incorrect Heat or Fast Travel Speed.
Use a hammer to strike the joint on the material welded to the base. The weld should
bend slightly and not break. Breakage could be due to too many holes (porosity) in the
weld, or if the weld contains slag. Also note if any of the bevelled area is visible. If it
is, this could indicate that the filler material was not fully melted due to traveling too
fast with the electrode or by not using enough heat.
42
Application
Performance Task No. 1.6

Activity 1: Hands-on Activity
Directions: Follow the procedure given in Lesson Information 1.6. This activity will be
done individually and should last only for 2-4 hours. Your uniformity of
weld beads will be graded based on the rubric below.
Rubric for Uniformity of Weld Beads According to Techniques, Appropriate
Conditions, and Welding Standards
Performance Criteria
Categories/
5 Points 4 Points 3 Points 1Point
Dimensions
Smoothness All beads were Most beads Some beads Almost all
and uniformity smooth and were smooth were not beads were not
of beads uniform and uniform smooth and smooth and
uniform uniform
Proper use of Used tools and Used tools and Used tools and Unable to use
tools and equipment with equipment with equipment with tools and
equipment confidence less confidence the help of equipment
others properly
Application of Effective Application of Application of Application of

procedures application of procedure was procedure was procedure was
procedures was acceptable inconsistent unacceptable
evident
Safety work Observed safety Observed Observed Observed

habits practices at all safety practices safety safety
times most of the practices practices once
times sometimes
Note: Performing this task will be given by your teacher on specific schedule.
43
Sample Template
Republic of the Philippines
Department of Education
Region X – Northern Mindanao
Division of Misamis Oriental
Poblacion, Lugait, Misamis Oriental
G-11 COMPETENCE SMAW NC II MODULE 1 LESSON 1 WELD CARBON STEEL PLATE IN FLAT
POSITION (1G)
PROGRESS CHART
Name Lesson Lesson Lesson Lesson Lesson Lesson Generalizati Remarks
Information Information Information Information Information Information on
1.1- 1.2-Safety 1.3-5S of 1.4- 1.5-Welding 1.6-Perform
Fundamenta Welding Good Acceptable Defects Root Pass
ls of Welding Practices & Housekeepin and Causes and and Multi-
& Self-Check Self-Check g & Self- Unacceptable Remedies & Layer
1.1 1.2 Check 1.3 Welding Self-Check Deposit &
Profile & Self- 1.5 Performance
Check 1.4 Task 1.6
1.
Prepared by:
Name of the Teacher
Subject Teacher
44
Generalization
From all the Lesson Information you have learned, what are your realizations about
the following?
A. Enumerate the personal protective equipment of a welder.

___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
B. How will you apply the 5S in your home? Give each an example.
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
C. Give at least two examples of external and internal welding defects. List down the
possible causes and corrective actions in each example.
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
D. In your observation, what is the most applicable electrode in performing root pass
on flat position groove weld 1G and why?
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
45
Posttest
Let us determine your learning on the task in Performing Groove
Weld on Carbon Steel Plates and Pipes by taking this posttest.
I. Multiple Choice:
Directions: Read and analyze the statement carefully. Choose the correct answer
and write the letter only on your separate answer sheet.
1. Welding standard root face.
a. 1.6mm c. 1.6m
b. 1.6cm d. 1.6ft
2. In preparation of based metal what is the standard bevel required.
a. 2mm c. 37.5degrees
b. 3mm d. 1.6cm
3. It is the required range angle of electrode position in based metal.
a. Hot tear c. 10-30degrees
4. It refers to organization of necessary items in good order and easy access.
a. Seiri (Sort) c. Seiton (Systematize)
b. Seiso (Sweep) d. Shitsuke (Self Descipline)
5. It means taking out and disposing unnecessary items.
a. Seiri (Sort) c. Seiketsu (Sanitize/Standardize)
b. Seiso (Sweep) d. Seiton (Systematize)
a. Hot tear c. Groove
b. Distortion d. Undercut
a. Porosity c. Undercut
b. Distortion d. Penetration
11. A shallow fusion between weld metal and based metal.
46
12. _________________ is a kind of weld defect which forms a groove in the
parent metal along with the sides of the weld bead.
13. It is cause of not following the welding principle or procedures and lack of skill
of a welder.
14. It is due to excessive heat input and creates hole.
a. Burn-through c. Penetration
15. ____________________ is a group of small voids and blowholes that are
16. It will cause deposited to be narrow, uneven and irregularly rippled and with
poor fusion if not follow.
a. Current setting c. Length of an Arc
b. Speed of travel d. Incomplete penetration
17. This fundamentals is very vital for weld quality and can create blow holes or
incomplete fusion.
a. Angle of electrode c. Penetration
b. Current setting d. Speed of travel
18. It will cause the puddle to be large, with pile up, and a straight ripple
pattern if this fundamental is not follow.
a. Speed of travel c. Current setting
b. Manipulation of electrode d. Length of an arc
19. Reinforcement R should not exceed to ________________.
a. 1mm c. 3mm
b. 2mm d. 4mm
20. A defects that occur under the surface of the welded work.
a. Spatter c. Groove
b. External d. Internal
21. A defects occur on the upper surface of the welded work.
a. External c. Weld beads
b. Internal d. Incomplete penetration
22. It is a welding fundamental that designates the correct electrode size,
generally based on metal type and thickness.
a. Manipulation of electrode c. Current setting
b. Porosity d. Angle of electrode
47
b. Welding defects d. Porosity
24. ____________________ occurs when the depth of the welded joint is
insufficient.
a. Incomplete penetration c. Spatter
weld metal before complete hardening has taken place and metal is still in the
plastic state.
a. Hot tear c. Distortion
48
49
Pretest
I. Multiple Choice:
1. b
2. a
3. b
Pretest 4. a
II. Matching Type: 5. d
16. b 6. c
Self-Check 1.1
17. a 7. a
TRUE or FALSE
18. b 8. c
1. TRUE
19. a 9. b
2. TRUE
3. FALSE 20. d 10. b
4. TRUE 21. c 11. d
5. FALSE
22. a 12. a
6. TRUE
7. TRUE 23. c 13. b
8. TRUE 24. b 14. d
9. TRUE
25. b 15. d
10. FALSE
Answer Key
50
Self-Check 1.2
I. T or F
Self-Check 1.2 1. T
2. T
II. Multiple Choice
3. T
Self-Check 1.3 1. b 4. F
1. Sort 2. a 5. F
2. Systematize 6. T
3. c 7. T
3. Sweep
4. Standardize 4. c 8. T
5. Self-Discipline 9. F
5. b
10. T
Answer Key
51
Posttest
Multiple Choice:
1. a
2. c
3. c
4. c
5. a
6. a
7. d
8. c
9. b
10. b
11. d
12. d
13. d
Self-Check 1.4
14. a
15. b Matching Type
16. c 1. c
2. e
17. b Self-Check 1.5 3. l
18. a 4. i
Multiple Choice
5. k
19. c 1. d 6. g
20. d 2. a 7. a
3. c 8. d
21. a 4. b 9. f
22. a 5. a 10. o
6. c 11. h
23. b 7. d 12. j
24. a 8. a 13. b
9. b 14. n
25. b
10. b 15. m
Answer Key
References:
Books:
1. Shielded Metal Arc Welding NCII CBLM by Manny P. Daleon
2. SMAW NCII Training Regulations by Technical Education and Skills Development
Authority
3. SMAW Welding Units
Internet Sources:
1. https://www.Wikipedia.org
2. https://www.West Virginia Toxics Release Inventory Database Search
//gis.wvdep.org/tri/cheminfo/msds452.txt
3. https://en.wikipedia.org/wiki/Welding_Procedure_Specification
4. https://commons.wikimedia.org/w/index.php?curid=8678506)
5. https://learnmech.com/what-is-welding-procedure-specification-wps/
6. https://weldguru.com/smaw-tips-techniques/
7. https://pwfsi.wordpress.com/2015/02/23/5-essentials-of-shielded-metal-arc-
welding/
8. https://www.theweldingmaster.com/welding-defects/
9. https://www.flight-mechanic.com/arc-welding-procedures-techniques-and-
welding-safety-equipment-part-one/
10.https://www.flight-mechanic.com/arc-welding-procedures-techniques-and-
welding-safety-equipment-part-two/
11.https://www.theweldingmaster.com/shielded-metal-arc-welding/
12.https://www.esabna.com/us/en/education/blog/welding-codes-and-standards.cfm
13.https://weldguru.com/weld-quality-testing/
14.https://toolsfocus.com/common-welding-defects-causes-and-remedies/
15.https://www.durametal-alloy.com/technical-resources/basic-technique-of-arc-
welding
16.https://www.weldinginfocenter.org/health/hs_05.html
17.https://www.deir.qld.gov.au/workplace/documents/showDoc.html?WHS%20Public
ations/manufacturing%20-%20welder
18.https://www.ehow.com/list_6458303_safety-procedures-welding.html
19.https://www.osha.gov/doc/outreachtraining/htmlfiles/weldhlth.html
20.https://www.tws.edu/articles/safe-practices-for-welders/
21.https://weldinghelmetpros.com/smaw-stick-welding
22.https://www.welding-advisers.com/Welding-codes.html
23.https://www.mechanicalgeek.com/welding-defects-causes-remedies/
24.https://www.weldingandndt.com/welding-procedure-specification-wps/
25.https://weldinghelmetpros.com/smaw-stick-welding
52
26.https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDAR
DS&p_id=9911
DS&p_id=9853
DS&p_id=9778
DS&p_id=9785
30. https://safety.blr.com/analysis/hazardous-substances-and-materials/welding-
cutting-and-brazing/National/
31. https://www.aws.org/technical/facts/fs18-201212.pdf
32. http://www.oshc.dole.gov.ph/images/5S.jpg
33. https://www.ccohs.ca/oshanswers/hsprograms/hazard_risk.html
34. https://www.esabna.com
35. www.MillerWelds.com
36. http://nattesting.com/acceptable_weld.htm
37. https://www.nccer.org
38. https://youtu.be/rb72AT-YK0Y
40. https://www.alibaba.com/trade
41. https://www.tesda.gov.ph
53
KING ROMY SEAN C. OCULAM, LPT, TMC1, NTTC, ASSESSOR
Teacher II
Lugait Senior High School
Bachelor of Science in Information Technology
Pipe Fitting NCII
Shielded Metal Arc Welding NCI
Shielded Metal Arc Welding NCII
Trainers Methodology I
RANDY C. NADERA, MBA, LPT, TMC1, NTTC, ASSESSOR

Teacher II
Medina Comprehensive
National High School
Senior High School
Master in Business Administration
DRIVING NC II
GTAW NC II
Pipe Fitting NCII
Shielded Metal Arc Welding NCI
Shielded Metal Arc Welding NCII
Shielded Metal Arc Welding NCIII
Shielded Metal Arc Welding NCIV
Trainers Methodology I
Printed in the Philippines by
Department of Education – Region 10

Office Address: Zone 1, DepEd Building, Masterson Avenue, Upper Balulang,
Cagayan de Oro City
Contact Number: (088) 880 7072
E-mail Address: region10@deped.gov.ph
54

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Senior High School

Shielded Metal Arc

Department of Education • Republic of the Philippines

Published by the Department of Education

Development Team of the Module

Printed in the Philippines by ______________________________________

Shielded Metal Arc

This instructional material was collaboratively developed and reviewed by

We value your feedback and recommendations.

Department of Education • Republic of the Philippines

Shielded Metal Arc Welding(SMAW) is an arc welding process in which the

Remember the following instructions:

• Read Lesson Information and complete self-checks.

4. ________________ is also known as solidification cracking state.

5. ____________________ is defined as the distance from the base plate top

6. It refers to organization of necessary items in good order and easy access.

7. It means taking out and disposing unnecessary items.

8. It is used to protect arms from falling flux or hot sparks.

10. They protect feet from hot sparks or falling objects.

11. A shallow fusion between weld metal and based metal.

12. It is due to excessive heat input and creates hole.

13. ____________________ is a group of small voids and blowholes that are

14. _________________ is a kind of weld defect which forms a groove in the

Alternate Current - it is when electrical current alternates or reverses the direction

Lesson 1 Weld Carbon Steel Plate in Flat Position (1G)

Lesson Information 1.1

Choosing the correct electrode size involves many factors. If a smaller

Incorrect travel is a common mistake. Sometimes travel speed is the only

Lesson Information 1.2

Safe Welding Practices

Welding Mask Welding Gloves Safety Helmet

Leather Jacket Full Body Harness

Injured Fumes Cut Hands

Safety Glass Respirator

II. Multiple Choice:

Lesson Information 1.3

What is the 5S system?

5. SHITSUKE – SELF DISCIPLINE

Lesson Information 1.4

Acceptable (and Unacceptable) Weld Profiles

1 a Desirable fillet weld

Types of Welding Defects:

I. External Welding Defects:

Crack can also appear at different temperatures:

Remedies for Weld crack:

Remedies for Undercut:

Remedies for Spatter:

Remedies for Porosity:

Remedies for Overlap:

II. Internal Welding Defects:

Remedies for Slag Inclusion:

Causes of Incomplete fusion:

Remedies for Incomplete Fusion:

1. Less deposition of the weld metal

Remedies for Incomplete Filled Groove:

1. More deposition of the weld metal.

Perform Root Pass and Multi-Layer Deposit in Flat Position

Things to Take Note in Arc Welding

Prepare the Metal to be Welded

Second Weld Pass

The trainer is expected to determine that weldment conforms to the working

The following items must be considered:

2. Other weldment defects that must be checked:

Weld Strength Test Diagram