CBLM Core

COMPETENCY BASED LEARNING
MATERIAL
LEARNER’S GUIDE
Sector:
METALS AND ENGINEERING
Qualification Title:
SHIELDED METAL ARC WELDING NC I
MLCHSH Tech.Voc.Dept.
Alangilan, Batangas City
MLCSHS Tech. Voc. Dept. SMAW NC I
Summary of Competencies
No. Unit of Competency Module Title Module Code
Receive and respond to Receiving and respond to

1 500311101
workplace communication workplace communication
2 Work with others Working with others 500311102
3 Demonstrate work values Demonstrating work values 500311103
Practice basic housekeeping Practicing basic housekeeping

4
procedures procedures 500311104
5 Apply Safety Practices Applying Safety Practices MEE721201
Interpret Drawing and Interpreting Drawing and
6
Sketches Sketches MEE721202
Perform Industry Performing Industry
7
Calculations calculations MEE721203
Contribute to Quality Contributing to Quality
8
System System MEE721204
9
Use Hand Tools Using Hand Tools MEE721205
10
Prepare Weld Materials Preparing Weld Materials MEE721206
11
Set up Welding Equipment Setting up Welding Equipment MEE721207
12
Fit up Weld Materials Fitting up Weld Materials MEE721208
13
Repair Welds Repairing Welds MEE721209
Weld Carbon Steel Plates Welding Carbon Steel Plates
14 MEE721301
Using SMAW Using SMAW
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LEARNER’S GUIDE
Sector:
METALS AND ENGINEERING
Qualification Title:
SHIELDED METAL ARC WELDING NC I

Unit of Competency:
WELD CARBON STEEL PLATES USING SMAW

Module Title:
WELDING CARBON STEEL PLATES USING MEE721301

SMAW
HOW TO USE THIS COMPETENCY-BASED LEARNING MATERIAL
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Welcome to this Competency-Base Learning Materials for the module WELD

CARBON STEEL PLATE USING SMAW
This learning material contains activities for you to complete. It covers the
knowledge, skills and attitudes required to complete the competency: WELD CARBON
STEEL PLATE USING SMAW one module in the Core Competency for SMAW NC I.
You are required to go through the series of learning activities in order to

complete the learning outcomes of the module. The module contains Reference
Materials for further reading to help you better understand the required activities.If you
have questions, don’t hesitate to ask your trainer/facilitator for assistance.
Recognition of Prior Learning (RPL)

You may have some or most of the knowledge and skills covered in this learner’s
guide because you have:
 been working for some time or

 Already completed training in this area.
If you can demonstrate to your trainer that you are competent in a particular skill,
you don’t have to do the same training again.
If you feel you have some of the skills, talk to your trainer about having them
formally recognized. If you have qualification or Certificate of Competence from previous
training, show it to your trainer. If the skills you acquired are still current and relevant to
the unit/s of competency, they may become part of the evidence you can present for
RPL.
This module was prepared to help you achieve the required competency in
Providing Housekeeping Services. This will be the source of information for you to
acquire knowledge and skills in this particular trade, with minimum supervision or help
from your instructor. With the aid of this material, you will acquire the competency
independently and at your own pace.
 Talk to your trainer and agree on how you will both organize the training of this
unit. Read the learning guide carefully. It is divided into sections, which cover all
the skills, and knowledge you need to successfully complete this module.
 Work through all the information and complete the activities in each section.
Read information sheets and complete the self-check. Suggested references are
included to supplement the materials provided in this module.
i) Most probably your trainer will also be your supervisor or manager. He/she
is there to support you and show you the correct way to do things. Ask for
help.
 Your trainer will tell you about the important things you need to consider in
completing the activities and it is important that you listen and take notes.
You will be given plenty of opportunities to ask questions and practice on the job. Make
sure you practice your new skills during regular work shifts. This way, you will improve
both your speed and memory and your confidence.
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 Talk to more experienced workmates and ask for their guidance.
 When you are ready, ask your trainer to watch you perform the activities outlined
in the learning guide.
 After you have completed this module (or several modules), and you feel
confident that you are competent, your trainer will arrange an appointment with a
registered assessor to assess you. The results of your assessment will
be recorded in your Competency Achievement Record.
INTRODUCTION
This module covers portion of the required knowledge, skills and attitude in WELD
CARBON STEEL PLATE USING SMAW
Upon completion of this module, you need to subject yourself for assessment by
your trainer by
SUMMARY OF LEARNING OUTCOMES
After completing of this module, the trainee should be able to:
LO1 Perform root pass
LO2 Clean root pass
LO3 Weld subsequent/ filling passes (all content refer to LO1)
LO4. Perform capping refer to LO1
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FIVE ESSENTIALS OF WELDING
Current Setting
Current is measured in amperes, or amps. Each type of electrode has recommended
amperage ranges for optimum performance. If the amperage is set above the suggested
operating range, the electrode melts too fast. This increases deposition and the weld
puddle becomes too large to control. It could also cause the electrode coating to
overheat and break down.
Amperage too high – The weld bead is wide and flat with excessive penetration and
spatter, and undercutting frequently occurs along the toes.
If the amperage is set below the designated range, there is insufficient heat to melt the
base metal, and the weld puddle is too small for proper control. The droplets forming on
the end of the electrode may bridge to the weld puddle periodically extinguishing the arc.
The weld bead will be irregular with a crowned appearance and insufficient penetration.
Amperage too low -The weld bead will be irregular with a crowned appearance and
insufficient penetration
Length of Arc
Arc length is the distance from the tip of the electrode core wire to the weld puddle. Arc
length can be deceiving, because the core wire is recessed inside a cup that forms at the
tip of the electrode. You have to take this into consideration when gauging arc length.
The correct arc length varies according to the electrode classification, diameter and
composition of the flux coating, as well as the amperage and welding position.
As a general rule, when amperage is set within the specified range, arc length should not
exceed the diameter of the core wire. Increasing the arc length increases the arc voltage,
and reduces the amperage slightly.
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Shortening the arc length reduces the arc voltage and increases the amperage slightly. If
the arc length is too short, the arc has a tendency to short out and the electrode freezes
to the work
Angle of Electrode
In shielded metal arc welding, the work and travel angles are used to control the shape
of the weld puddle and the amount of penetration. The travel angle is the angle between
the joint and the electrode along the axis of the weld.
A push angle exists when the electrode points in the direction of travel. And a drag angle
points away the direction of travel.
The work angle is pointing between the electrode and the work surface along the work
plane, which runs perpendicular to the axis of the weld. An incorrect work angle can
cause you to favor one side of the joint more than another. The result is undercut and
lack of fusion
Speed of Travel
Travel speed is the rate at which the electrode moves along the work. The key to correct
travel speed is “reading” the weld puddle, because the weld puddle is a liquid version of
the weld bead.
A properly formed weld bead has an oval shape with an oval crater and uniform ripple
pattern. Travel speed is influenced by the type of welding current (DCEN, DCEP or AC),
amperage, welding position, electrode melt rate, material thckness, surface condition of
the base metal, type of joint, joint fit up and electrode manipulation
If you travel too fast, the puddle cools too quickly trapping gasses and slag. The ripples
are pointed and narrow with irregular penetration and undercut along the toes.
If you travel too slowly, the weld metal piles up forming a high, wide weld-bead with too
much reinforcement that may result in overlap. So read the puddle, and keep the arc on
the leading edge.
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Size and Type of Electrode

Electrodes for shielded metal arc welding range in diameter from 3/32 to 3/16 and ¼ of
an inch and 9, 14 and 18 inches in length. Electrode diameter is based on the thickness
of the base metal, the welding position and the type of joint to be welded.
Larger diameter electrodes are used on thicker metals and for flat position welding
because they offer higher deposition rates.
Joint design also affects electrode diameter. On groove welds for example, the electrode
has to be small enough to access the root of the joint. The welder’s skill also has a
bearing on electrode diameter because a more capable welder can control a larger,
more fluid weld puddle.
DEPOSIT WELD BEAD ON PLATE
Weave bead is running a bead with electrode manipulation.
Stringer Bead is running a bead without manipulation or movement
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Surfacing Weld: These are welds composed of one or more strings or weave beads
deposited on an unbroken surface to obtain desired properties or dimensions. This type
of weld is used to build up surfaces or replace metal on worn surfaces.
Application of stringer and weave bead are according to:
 Weld size
 Welding position
 Size of electrode
 Weld layer/passes
Characteristics of good surfacing weld

 The width of weave bead is only 3-4 times diameter of electrode to be used
 The width of weave bead is only 1.5 to 2 times diameter of electrode to be used
 Strictly no undercut
 No Overlap
 For padding, minimum of 20% to maximum of 50% overlapping each weld bead
 The maximum tolerance for excess weld height is only 3 mm as per ASME and
AWS, if API 1104 is not exceed in 1.6mm.
 Proper tie ins
 Straightness of weld bead
 Uniformity of weld ripples
Surfacing weld ( Flat Position)

Procedure:
 Wear Proper Personal Proper Equipment (PPE)
 Prepare all necessary tools, equipment and materials.
 Cut the plate by using Oxy-Acetylene cutting (3’’x 6’’)
 Clean the surfaces, remove any contamination, burrs and mill scale with the
grinder or wire brush.
 Have your instructor to check your work piece
 Put your workpiece in the welding positioner at required height in flat position
 Remember the 5 essentials of welding
 Use E6013 3.2mm diameter electrode
 Set your polarity and amperage setting. DCRP at 90 - 120 amps
 Position your electrode angle, work angle must be perpendicular from vertical line
and travel angle of 20 degrees
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WELD PLATES IN MULTIPLE PASS FILLET JOINTS IN ALL POSITION
What is Carbon steel?

Carbon steel, also called plain-carbon steel is where the main interstitial alloying
constituent is carbon. The American Iron and Steel Institute (AISI) defines carbon steel
as: “Steel is considered to be carbon steel when no minimum content is specified or
required for chromium, cobalt, molybdenum, nickel, niobium, titanium, tungsten,
vanadium, or zirconium, or any other element to be added to obtain a desired alloying
effect; when the specified minimum for copper does not exceed 0.40 percent; or when
the maximum content specified for any of the following elements does not exceed the
percentages noted: manganese 1.65, silicon 0.60, copper 0.60.
The term “carbon steel” may also be used in reference to steel which is not stainless
steel; in this use carbon steel may include alloy papers.
As the carbon steel content rises, steel has the ability to become harder and stronger
through heat treating, but this also makes it less ductile. Regardless of the heat
treatment, a higher carbon content reduces weldability. In carbon steels, the higher the
carbon content lowers the melting point.
Mild Steel
The most common forms of steel because its price is relatively low while it provides
material properties that are acceptable for many applications. This contains 0.16 –
0.29%carbon content
Low Carbon Steel

Low carbon steel contains approximately
0.05 – 0.15% carbon.Mild steel and low carbon steel are malleable and ductile but it
cannot be hardened by heat treatment. Mild steel has relatively low tensile strength, but
it is cheap and malleable; surface hardness can be increased through carburizing.
Medium Carbon Steel

Approximately 0.30 – 0.59% carbon content. Balances ductility and strength and has
good wear resistance; used for large parts, forging and automotive components.
High Carbon Steel

Approximately 0.6 – 0.99% carbon content.
Very strong used for springs and high-strength wires.
Ultra-High Carbon Steel
Approximately 1.0 – 2.0% carbon content. Steels that can be tempered to great
hardness. Used for special purposes like (non-industrial-purpose)
knives, axles or punches. Most steel with more than 1.2% carbon
content are made using powder metallurgy. Note that the steel with
carbon content above 2.0 is considered cast iron
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LO1 Perform root pass

1. Drawing/Plan/ WPS
2. Materials and consumables (Electrodes, Base Metal
3. Welding Equipment and Tools
4. Basic Mathematics (Multiplication, Division, Addition and Subtraction)
5. Welding
6. Identification of weld defects
7. Measuring skills
8. Communication skills
9. Rectification of weld defects
10. Application of weld techniques ok
11. Handling of welding tools and equipment
12. Handling of welding materials and consumables
1. Drawing/Plan/ WPS interpretation
Drawing a picture or diagram made with a pencil, pen, or crayon rather than paint.
Similar, Sketch,,picture, illustration, representation, portrayal, delineation, depiction,
composition, study, diagram,,outline, design, plan, artist's impression, tracing
Interpretation planning is to describe a set of interpretive objectives to clearly define
why interpretation should be provided at a site and what it should aim to achieve. They
can be used as a baseline to evaluate the effectiveness of the interpretation.
Welding Procedure Specifications is a form that contains details of welding groove,
welding method to be employed, electrode and/or welding rod type and diameter,
current, voltage, welding position, welding run number and similar information prepared
in accordance with its codes relevant Project standard (ASME and/or EN Standards).
It contains sufficient details to enable any competent person to apply the information and
produce a weld of acceptable quality. The amount of detail and level of controls specified
on a WPS is dependant on the application and criticality of the joint to be welded.
Typical Items That Should Be Recorded On W.P.S:-

 Procedure number
 Process type
 Consumable Size, Type and full Codification.
 Consumable Baking Requirement if applicable
 Parent material grade and spec.
 Thickness range.
 Plate or Pipe, Diameter range
 Welding Position
 Joint Fit Up, Preparation, Cleaning, Dimensions etc.
 Backing Strip, Back Gouging information.
 Pre-Heat (Min Temp and Method)
 Interpass If Required (Maximum Temperature recorded )
 Post Weld Heat Treatment. If Required (Time and Temp)
 Welding Technique (weaving,max run width etc.)
 Arc Energy Limits should be stated if impact tests are required or if the material
being welded is sensitive to heat input.

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A sketch of the joint configuration is required which should include the basic dimensions
of the weld preparation.
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2. Materials and consumables (Electrodes, Base Metal)
Welding, using the correct consumable, or filler material, ensures a strong bond between
two metals.
The role of the consumable in arc welding is to not only fill in the seam, but also stabilize
the flame of the electric arc
Common SMAW welding Consumables
Electrodes Soft stone
( 6011,6013,7018)
Steel Plates Clear glass
Grinding disc Dark glass
Cutting disc Steel brush
Gas ( oxygen/ oxy
acetylene)
Choosing the Right Consumable

There are a variety of factors that go into selecting the right consumable for the job.
Choosing the right material increases weld strength and bead quality and makes cleanup
easier.
As you progress in your welding studies, you’ll gain more experience with these
essential welding components, as well as the various welding processes you’ll master
before you enter the field.
Stick welding can be used to weld steel, iron, aluminum, copper, and nickel.
HOW TO CHOOSE WELDING CONSUMABLES

In considering the choice of consumable to use for a particular welding job, the
composition of the consumables must be similar to that of the parent materials used,
which will yield a weld that is homogenous. In some cases, like when welding brittle cast
irons, a filler that has a different properties from the parent materials can be used. The
joint created is called a weldment and the weld formed is known to be heterogeneous.
It has been approved that when welding materials that have different tensile strengths,
the consumable chosen should match the material with the lower tensile strength while
the preheat temperature used should match what is required for the material with the
higher tensile strength
3.Welding Equipment and Tools
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3. Basic Mathematics (Multiplication, Division, Addition and Subtraction)
The four fundamental operation (addition, subtraction, multiplication and division) skills
should be developed in Shielded Metal Arc Work (SMAW) doing jobs. Inaccurate
operation would mean waste of time, effort, materials and the quality of the finish
product. The skill in measuring starts with the ability to add, subtract, multiply and divide.
ADDITION
Addition is the process of combining two or more arithmetical or algebraic quantities in
one sum. It is the most common operation in mathematics indicated by a plus (+) sign. It
is also used when numbers are added horizontally or vertically. When more than two
numbers are added vertically, no sign is required. The sum is the result obtained from
adding two or more numbers.
To add whole numbers horizontally is more difficult than adding them, vertically.
Example,
20 + 15 + 30 + 25 = 90, this method is not commonly used because mistakes can occur
more easily.
THE NUMBER PLACE VALUE
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We can find the value of a digit based on its place in the number.
Example: 3,452
 Digit 2 is in the Ones place
 Digit 5 is in the Tens place
 Digit 4 is in the Hundreds place
 Digit 3 is in the Thousands place
STEPS IN ADDING WITHOUT REGROUPING

 Always add the digits in the ones place first.
 Add the digits in the tens place next.
 Add the digits in the hundreds place.
 Add the digits in the thousands place and so on
SUBTRACTION Is the process of taking one number away from another number. It is
the opposite of addition. The minus (-) sign indicates subtraction. The Minuend is the
number from which the subtraction is made. The Subtrahend is the number which is
subtracted. The Remainder is the difference between the two numbers.
Subtracting Whole Numbers

Procedure:
 Subtract the subtrahend from the minuend to get the remainder.
To Check:
 Add remainder to subtrahend to get the minuend.
 5 6 8 – is the minuend
 43 – is the subtrahend
 5 2 5 – is the remainder
 8 – is in the ones place
 6 – is in the tens place
 5 – is in the hundreds place
To Check:
Add remainder 5 2 5 and 4 3 the subtrahend to get the minuend 5 6 8
Steps in Subtracting Without Regrouping

 Subtract the digits in the ones place first
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 Subtract the digits in the tens place

 Subtract the digits in the hundreds place and so on
MULTIPLICATION
Is the process of adding one number as many times as there are units in the other
number, for example 2 x 3 = 6. It can also produce the same result as adding 3 + 3 = 6.
The sign times or multiplied by (X) indicates multiplication. The Multiplicand is the
number which is multiplied. Multiplier is the number by which multiplication is done.
Product is the result of multiplication. Multiplying Whole Numbers
Procedure:
 Multiply the multiplicand by the multiplier to get the product.
To Check:
 Reverse multiplicand and multiplier the multiply again to get the product or divide the
product by the multiplier to get the multiplicand.
Multiplying Fractions
Procedure:
 Multiply the numerator of one fraction by the numerator of the other fraction.
 Do the same with the denominators.
 Reduce the answer to the lowest term as required.
Example:
3 / 5 x 1 / 5 = 3 / 25
- Multiply the numerators ( 3 x 1 = 3) to get 3 then

- Multiply denominators ( 5 x 5 = 25) to get 25, thus
- 3 / 5 x 1 / 5 = 3 / 25
DIVISION
Is the process of finding how many times one number contains the other number. It is the
reverse of multiplication. The sign divided by ÷ indicates division. Dividend is the number
to be divided. Divisor is the number by which division is done. Quotient is the result of
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division and Remainder is part of the quotient left whenever a quotient is not a whole
number.
Example: 25 ÷ 4 = 6 ¼ (25 ÷ 4 = 6 remainder 1)
Dividing Whole Numbers Procedure:

 Divide dividend by divisor to get the quotient
To Check:
 Multiply the divisor by the quotient or vice versa to get the dividend
5. Welding Codes
Welding is the process of joining metals and thermoplastics by means of coalescence.

Flux and filler metals together are known as welding consumables. ... Stick electrode,
flux-cored wires, solid wires, SAW wires and fluxes are some of the welding
consumables employed during the welding process
What are welding codes?
The most commonly used codes are from the AWS (D1. 1) and ASME (Section IX). The
difference between ASME and AWS is that ASME is for welding procedure and welder
qualification. AWS is for both welder and welding procedure qualification including
inspection, erection and fabrication.
American Welding Society
The American Welding Society (AWS) was founded in 1919 as a non-profit organization
to advance the science, technology and application of welding and allied joining and
cutting processes, including brazing, soldering and thermal spraying.
AWS D1.1 This code covers the welding requirements for any type of welded structure
made from the commonly used carbon and low-alloy constructional steels.
American Society of Mechanical Engineers

The American Society of Mechanical Engineers (ASME) is an American professional
association that, in its own words, "promotes the art, science, and practice of
multidisciplinary engineering and allied sciences around the globe" via "continuing
education, training and professional development, codes and standards, ...
ASME Section IX - Welding Qualifications, is a guide to the requirements of the ASME
Boiler and. Pressure Vessel Code Section IX -
What The Welding Code and Standard Generally Provides. ... Such variables are
typically the welding process, type and thickness of base metal, filler metal type,
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electrical parameters, joint design, welding position, and others. This section of the
document may also provide the qualification testing requirements.
List of welding codes

Contents
1. American Society of Mechanical Engineers (ASME) Codes
2. American Welding Society (AWS) Standards
3. American Petroleum Institute (API) Standards
4. Australian / New Zealand (AS/NZS) Standards
5. Canadian Standards Association (CSA) Standards
6. British Standards (BS)
7. International Organization for Standardization (ISO) Standards
8. European Union (CEN) standards
9. German Standards (DIN and others)
American Society of Mechanical Engineers (ASME) Codes

The American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel
Code (BPVC) covers all aspects of design and manufacture of boilers and pressure
vessels. All sections contain welding specifications, however most relevant information is
contained in the following:
Code Description
ASME BPVC
Rules for Construction of Power Boilers
Section I
ASME BPVC Part C: Specifications for Welding Rods, Electrodes, and Filler Metals.
Section II [a]
ASME BPVC Rules for Constructions of Nuclear Facility Components-Subsection
Section III NCA-General Requirements for Division 1 and Division 2
ASME BPVC
Rules for Construction of Heating Boilers
Section IV
ASME BPVC
Nondestructive Examination
Section V
ASME BPVC
Rules for Construction of Pressure Vessels Division 1 and Division 2
Section VIII
ASME BPVC
Welding and Brazing Qualifications
Section IX
ASME B16.25 Buttwelding ends
ASME B31.1 Power Piping
ASME B31.3 Process Piping
ASME B31.9 Building Services Piping
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American Welding Society (AWS) Standards[

The American Welding Society (AWS) publishes over 240 AWS-developed codes,
recommended practices and guides which are written in accordance with American
National Standards Institute (ANSI) practices.[1] The following is a partial list of the more
common publications:
Standard
Title
Number
Standard symbols for welding, brazing, and non-destructive
AWS A2.4
examination
AWS A3.0 Standard welding terms and definitions
Specification for carbon steel electrodes for shielded metal arc
AWS A5.1
welding
Specification for carbon steel electrodes and rods for gas shielded arc
AWS A5.18
welding
AWS B1.10 Guide for the nondestructive examination of welds
AWS B2.1 Specification for Welding Procedure and Performance Qualification
AWS D1.1 Structural welding (steel)
AWS D1.2 Structural welding (aluminum)
AWS D1.3 Structural welding (sheet steel)
AWS D1.4 Structural welding (reinforcing steel)
AWS D1.5 Bridge welding
AWS D1.6 Structural welding (stainless steel)
AWS D1.7 Structural welding (strengthening and repair)
AWS D1.8 Structural welding seismic supplement
AWS D1.9 Structural welding (titanium)
AWS D3.6R Underwater welding (Offshore & inland pipelines)
AWS D8.1 Automotive spot welding
AWS D8.6 Automotive spot welding electrodes supplement
AWS D8.7 Automotive spot welding recommendations supplement
AWS D8.8 Automotive arc welding (steel)
AWS D8.9 Automotive spot weld testing
AWS D8.14 Automotive arc welding (aluminum)
AWS D9.1 Sheet metal welding
AWS D10.10 Heating practices for pipe and tube
AWS D10.11 Root pass welding for pipe
AWS D10.12 Pipe welding (mild steel)
AWS D10.13 Tube brazing (copper)
AWS D10.18 Pipe welding (stainless steel)
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AWS D11.2 Welding (cast iron)

AWS D14.1 Industrial mill crane welding
AWS D14.3 Earthmoving & agricultural equipment welding
AWS D14.4 Machinery joint welding
AWS D14.5 Press welding
AWS D14.6 Rotating Elements of Equipment
AWS D15.1 Railroad welding
AWS D15.2 Railroad welding practice supplement
AWS D16.1 Robotic arc welding safety
AWS D16.2 Robotic arc welding system installation
AWS D16.3 Robotic arc welding risk assessment
AWS D16.4 Robotic arc welder operator qualification
AWS D17.1 Aerospace fusion welding
AWS D17.2 Aerospace resistance welding
AWS D17.3 Aerospace friction stir welding (aluminum)
AWS D18.1 Hygienic tube welding (stainless steel)
AWS D18.2 Stainless steel tube discoloration guide
AWS D18.3 Hygienic equipment welding
American Petroleum Institute (API) Standards

The American Petroleum Institute (API) oldest and most successful programs is in the
development of API standards which started with its first standard in 1924. API maintains
over 500 standards covering the oil and gas field.[2] The following is a partial list specific
to welding:
Standard Number Description
API RP 577 Welding Inspection and Metallurgy
API RP 582 Welding Guidelines for the Chemical, Oil, and Gas Industries
API 1104 Welding of pipelines and related facilities
Basic Inspection Requirements for New Pipeline
API 1169
Construction
British Standards (BS)

British Standards are developed, maintained and published by BSI Standards which is
UK's National Standards Body
The following is a partial list of standards specific to welding:
Standard
Description
Number
Welding terms and symbols. Glossary for welding, brazing and thermal
BS 499-1
cutting
BS 499-2C Welding terms and symbols. European arc welding symbols in chart form
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Specification for Class I arc welding of ferritic steel pipework for carrying
BS 2633
fluids
Specification for class II arc welding of carbon steel pipework for carrying
BS 2971
fluids
Specification for welding of steel pipelines on land and offshore - Part 1:
BS 4515-1
Carbon and carbon manganese steel pipelines
Specification for welding of steel pipelines on land and offshore. Duplex
BS 4515-2
stainless steel pipelines
Structural use of steel and aluminium. Recommendations for the
PD 6705-2
execution of steel bridges to BS EN 1090-2
Structural use of steel and aluminium. Recommendations for the
PD 6705-3
execution of aluminium structures to BS EN 1090-3
International Organization for Standardization (ISO) Standards[

International Organization for Standardization (ISO) has developed over 18500
standards and over 1100 new standards are published every year.
The following is a partial list of the standards specific to welding:
Standard
Description
Number
Welded, brazed and soldered joints - symbolic representation on drawings
ISO 2553
(1992)
Welding consumables. Covered electrodes for manual metal arc welding of
ISO 2560
non-alloy and fine grain steels. Classification
Covered electrodes for manual arc welding of creep-resisting steels - Code
ISO 3580
of symbols for identification
Covered electrodes for manual arc welding of stainless and other similar
ISO 3581
high alloy steels - Code of symbols for identification
ISO 3834 Quality requirements for fusion welding of metallic materials, five parts.
Welding and allied processes - Nomenclature of processes and reference
ISO 4063
numbers
Welding. Fusion-welded joints in steel, nickel, titanium and their alloys
ISO 5817
(beam welding excluded). Quality levels for imperfections
Welding and allied processes — Classification of geometric imperfections
ISO 6520-1
in metallic materials — Part 1: Fusion welding
Welding and allied processes — Classification of geometric imperfections
ISO 6520-2
in metallic materials — Part 2: Welding with pressure
ISO 6947 Welds. Working positions. Definitions of angles of slope and rotation
ISO 9606 Qualification test of welders — Fusion welding, parts 1 to 5
Welding and allied processes. Recommendations for joint preparation.
ISO 9692-1 Manual metal-arc welding, gas-shielded metal-arc welding, gas welding,
TIG welding and beam welding of steels
ISO 9692-2 Welding and allied processes. Joint preparation. Submerged arc welding of
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steels
Welding and allied processes. Joint preparation. Part 3: TIG and MIG
ISO 9692-3
welding of aluminium and its alloys
Petroleum and natural gas industries - Pipeline transportation systems -
ISO 13847
Welding of pipelines
Welding - Guidance on the measurement of preheating temperature,
ISO 13916
interpass temperature and preheat mainteanance temperature
ISO 13918 Welding - Studs and ceramic ferrules for arc stud welding
Welding - Electron and laser-beam welded joints - Guidance on quality
ISO 13919-1
level for imperfections - Part 1: Steel
Welding - Electron and laser-beam welded joints - Guidance on quality
ISO 13919-2
level for imperfections - Part 2: Aluminium and its weldable alloys
Welding - General tolerances for welded constructions - Dimensions for
ISO 13920
lengths and angles - Shape and position
ISO 14112 Gas welding equipment - Small kits for gas brazing and welding
Welding consumables — Gases and gas mixtures for fusion welding and
ISO 14175
allied processes. Replaced EN 439:1994 in Europe.
Welding consumables. Wire electrodes and deposits for gas shielded
ISO 14341
metal arc welding of non alloy and fine grain steels. Classification
ISO 14554 Resistance welding
ISO 14744 Electron beam welding, six parts
Specification and qualification of welding procedures for metallic materials
ISO 15607
- General rules
ISO/TR
Welding - Guidelines for a metallic material grouping system
15608
ISO 15609
- Welding procedure specification, five parts.
ISO 15610
— Qualification based on tested welding consumables
ISO 15611
— Qualification based on previous welding experience
ISO 15612
— Qualification by adoption of a standard welding procedure
ISO 15613
— Qualification based on pre-production welding test
ISO 15614
- Welding procedure test, 13 parts.
Gas welding equipment. Acetylene manifold systems for welding, cutting
ISO 15615
and allied processes. Safety requirements in high-pressure devices
Qualification testing of welders for under-water welding. Diver-welders for
ISO 15618-1
hyperbaric wet welding
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Qualification testing of welders for under-water welding. Diver-welders and

ISO 15618-2
welding operators for hyperbaric dry welding
ISO 17635 Non-destructive testing of welds. General rules for metallic materials
ISO 17660-1 Welding - Welding of reinforcing steel - Part 1: Load-bearing welded joints
Welding - Welding of reinforcing steel - Part 1: Non-load bearing welded
ISO 17660-2
joints
ISO/TR
Welding — Grouping systems for materials — European materials
20172
ISO/TR
Welding — Grouping systems for materials — American materials
20173
ISO/TR
Welding — Grouping systems for materials — Japanese materials
20174
Welding for aerospace applications. Qualification test for welders and
ISO 24394
welding operators. Fusion welding of metallic components
6. Identification of weld defects
Small defects such as these can be verified by Liquid Penetrant Testing (Dye check).
Slag inclusions and cracks just below the surface can be discovered by Magnetic
Particle Inspection.
Deeper defects can be detected using the Radiographic (X-rays) and/or Ultrasound
(sound waves) testing techniques.
Reminder: Actual identification of welding defects on their own output plate
1. Measuring skills
A measuring instrument is a device to measure a physical quantity. In the physical

sciences, quality assurance, and engineering, measurement is the activity of obtaining
and comparing physical quantities of real-world objects and events.
Measuring is not only checking the length, width or thickness of an objects but also
checking of the shape – things like the flatness, straightness, roundness or squareness.
Measuring tools are also used for inspecting a finished or partly finished product. All
measuring tools are precision tools.
What are the measuring tools in welding?
Common measuring and leveling tools for welders: (A) framing square, (B) carpenter's
square, (C) cabinet maker's square, (D) combination square, (E) torpedo level and (F)
builder's level. Compass and dividers – For scribing circles or stepping off a series of
equal intervals.
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(A) framing square carpenter's square,
Combination square
Torpedo level
Compass and deviders

Builders level
Push and pull rule Steel ruler
steel measuring tape Protractor
Vernier Caliper
Degree angle ruler
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Weld Fillet gauge Tempil stick
Angle meter Digital angle meter
8. Communication skills
Communication skills are the abilities you use when giving and receiving different kinds
of information. Some examples include communicating new ideas, feelings or even an
update on your project. Communication skills involve listening, speaking, observing and
empathising.
Types of communication
There are four main types of communication you might use on a daily basis, including:
1. Verbal: Communicating by way of a spoken language.
2. Nonverbal: Communicating by way of body language, facial expressions and vocalics.
3. Written: Communicating by way of written language, symbols and numbers.
4. Visual: Communication by way of photography, art, drawings, sketches, charts and
graphs.
Communication skills examples
There are different types of communication skills you can learn and practice to help you
become an effective communicator. Many of these skills work together in different
contexts, so it’s important to practice them together when possible.
Here are 10 key communication skills you might use and improve to succeed in your
career:
1. Active listening
Active listening means paying attention to the person who is communicating with you.
People who are active listeners are well-regarded by their coworkers because of the
respect they pay to those around them.
One great way to be a better listener is to focus on what people you’re interacting with
are actually saying. In addition to the content of their communications, you should also
pay attention to their facial expressions, body language and tone.
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2. Adapting your communication style to your audience

Different styles of communication are appropriate in different situations. To make the
best use of your communication skills, it’s important to consider your audience and the
most effective format to communicate with them in.
3. Friendliness
Friendly characteristics such as honesty and kindness can help foster trust and
understanding. Small gestures such as asking someone how they’re doing, smiling as
they speak or offering praise for work well done can help you foster productive
relationships with both colleagues and managers.
4. Confidence
In the workplace, people are more likely to respond to ideas that are presented with
confidence. There are many ways to appear confident, including by making eye contact
when you’re addressing someone, sitting up straight with your shoulders open and
preparing ahead of time so your thoughts are polished and you’re able to answer any
questions.
5. Giving and receiving feedback
Strong communicators are able to accept critical feedback and provide constructive input
to others. Feedback should answer questions, provide solutions or help strengthen the
project or topic at hand. Providing and accepting feedback is an essential workplace skill,
as it can help both you and the people around you make meaningful improvements to
their work and their professional development.
6. Volume and clarity
When you’re speaking, it’s important to be clear and audible. Adjusting your speaking
voice so you can be heard in a variety of settings is a skill, and it’s critical to
communicating effectively. Speaking too loudly may be disrespectful or awkward in
certain settings.
7. Empathy
Having empathy means that you can not only understand, but also share in the emotions
of others. This communication skill is important in both team and one-on-one settings.
8. Respect
A key aspect of respect is knowing when to initiate communication and respond. In a
team or group setting, allowing others to speak without interruption is seen as a
necessary communication skill tied to respectfulness. .
9. Understanding nonverbal cues
A great deal of communication happens through nonverbal cues such as body language,
facial expressions and eye contact. When you’re listening to someone, you should be
paying attention to what they’re saying as well as their nonverbal language.
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10. Responsiveness
Whether you’re returning a phone call or sending a reply to an email, fast communicators
are viewed as more effective than those who are slow to respond.
How to improve your communication skills
With experience and practice, you can learn and improve on your communication skills.
Start by identifying your strengths and then practice and develop those areas.
 Observe good communicators around you. Identify professionals, family and
friends who consistently communicate ideas and information clearly with respect,
empathy and confidence. Observe and take notes on the specific ways they
communicate with others.
 Ask a close friend or colleague for constructive criticism. It can be hard to

know how you are perceived as a communicator. To get an objective opinion, ask
a trusted friend for their honest feedback.
 Practice improving communication habits. Many communication skills are

habits you have developed over time. You can improve those skills by practicing
new habits that make you a better communicator.
 Attend communication skills workshops or classes. There are several online

and offline seminars, workshops and classes that can help you be a better
communicator.
 Seek opportunities to communicate. Seek out opportunities both on and off the job
that require you to use communication skills. This will help you keep good skills fresh
while also allowing you the opportunity to practice new skills.
9. Rectification of weld defects
What is Welding Defects – Types, Causes and Remedies?
What is Welding Defects?
Welding Defects can be defined as the irregularities formed in the given weld metal due
to wrong welding process or incorrect welding patterns, etc. The defect may differ from
the desired weld bead shape, size, and intended quality. Welding defects may occur
either outside or inside the weld metal. Some of the defects may be allowed if the
defects are under permissible limits but other defects such as cracks are never
accepted.
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Types
Welding defects can be classified into two types as external and internal defects
External Welding Defects:

1. Weld Crack
2. Undercut
3. Spatter
4. Porosity
5. Overlap
6. Crater
Internal Welding Defects:

1. Slag Inclusion
2. Incomplete Fusion
3. Necklace cracking
4. Incompletely filled groove or Incomplete penetration
External Welding Defects
The various types of external defects with their causes and

remedies are listed below:
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.
Crack can also appear at different temperatures:
Hot Crack – It is more prominent during crystallization of weld joints where the
temperature can rise more than 10,000-degree Celsius.
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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.
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 sulfur 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.
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.
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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.
Porosity
Porosity in the condition in which the gas or small bubbles gets trapped in the welded
zone.
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.
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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. Using a proper technique for welding.
2. Use small electrode.
3. Less welding current.
Crater
It occurs when the crater is not filled before the arc is broken, which causes the outer
edges to cool faster than the crater. This causes a stress and then crack is formed.
Causes of the crater:

1. Incorrect torch angle.
2. Use of large electrode:
3. Improper welding technique
Remedies for crater:

1. Using a proper torch angle may reduce the stress on the metal
2. Using a small electrode may also decrease the crater.
3. Use a proper technique.
Internal Welding Defects

The various types of internal welding defects with their causes and remedies are listed
below:
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.
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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
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
.
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. Unproper 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.
Necklace Cracking
It occurs in the use of electron beam welding where the weld does not penetrate
properly. Therefore, the molten metal does not flow into the cavity and results in a
cracking known as “Necklace Cracking”.
Causes of Necklace Cracking:

1. Improper welding technique.
2. It occurs in materials such as nickel base alloys, stainless steel, carbon steels and Tin
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alloys.
3. Using high speed of electron beam welding
Remedies for Necklace Cracking:

1. Using a proper welding technique reduce the chances of necklace cracking.
2. Using proper materials for welding.
3. Using a constant speed during the welding process.
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 are:

1. Less deposition of the weld metal
2. Use of improper size of the electrode
Remedies for Incomplete filled groove are:

1. More deposition of the weld metal.
2. Use a proper size of the electrode.
3. By using a proper welding technique.
Therefore, we have listed all types of welding defects present during any manufacturing
process.While welding, it is very important to remove all the defects of welding present in
the workpiece.
If there would be defects in the welding material, then in severe conditions the
components of the material would fail which may lead to loss of property and sometimes
also life.
Note: Small defects such as these can be verified by Liquid Penetrant Testing (Dye
check). Slag inclusions and cracks just below the surface can be discovered by Magnetic
Particle Inspection.
Deeper defects can be detected using the Radiographic (X-rays) and/or Ultrasound
(sound waves) testing techniques.
Reminder: Actual identification of welding defects on their own output plate
10. Application of weld techniques
DIFFERENT WELDING TECHNIQUES AND THEIR APPLICATIONS
Stick welding or shielded metal arc welding (SMAW) is the oldest and most common
form of the practice. Using an electrode coated with inert material, the wand creates an
Page 33
arc that vaporizes the shielding gas, fusing the metal together. The process generates
significant sparking, resulting in slag (waste byproducts from the filler), which requires
cleanup. The strength of the weld also depends on the types of welding rods and filler.
Additionally, different electrodes are available for different metals, offering versatility.
Because of the volatile nature of arc welding, proper shielding and ventilation is required.
Common Applications for SMAW Welding

Due to its simplicity and strength, stick welding is used for large-scale steel structure
creation, such as skyscrapers and mining equipment. Due to the roughness of the weld,
it is not ideal for finishing seams or precision bonds. However, it is less expensive and
simpler than other types of welding, perfect for large, quick connections. Stick welds are
common in many manufacturing processes:
 Heavy metal fabrication
 Structural steel construction materials
 Ship building
Metal Inert Gas Welding

Metal inert gas (MIG) welding is one of the most popular methods in product-grade
manufacturing. It is quicker and cleaner than stick welds, ideal for continuous seams.
MIG welding uses a charged wire electrode to create an arc. Beading is applied using a
wand or gun. Because the current flows constantly, welds are continuous and quick. Gas
shielding prevents spatter and slag for cleaner welds. However, because it uses gas
shielding, wind and airflow can disrupt the process. Therefore, the technique can only be
used indoors under controlled conditions.
Common Applications for MIG Welding

MIG welds are exceptionally useful when fusing thin aluminum sheets. As a result, the
practice is popular in the automotive and fabrication industries. As one of the fastest and
simplest techniques, it is particularly effective for mass production. It is also versatile,
capable of fusing steel, carbon steel, magnesium, aluminum and other alloys. However,
since MIG welds cannot be achieved outdoors, it is not as common in building
construction.
Tungsten Inert Gas Welding

Tungsten inert gas welding (TIG) is a versatile method that doesn’t produce any toxic
fumes or slag. As a result, welders can achieve clean bonds with nearly any type of
material. In fact, TIG welds can be used on steel, bronze, copper, aluminum,
magnesium, brass and even gold. TIG welds are possible in all types of welding
positions, ideal for precise connections. Because the process produces no harmful
vapors or smoke, it can be done in confined or indoor spaces.
Common Applications for TIG Welding

Due to its versatility and cleanliness, TIG welding is used across many industries. From
fabrication to repairs, TIG welds are effective on a range of materials and thickness.
Common applications include aerospace manufacturing, automotive and fine art
sculpting. The precise, clean welds leave a polished bond that is both aesthetically
pleasing and durable
11. Handling of welding tools and equipment
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The proper handling of tools?

1. Pointed tools such as chisels and screwdrivers should never be carried in a worker's
pocket.
2. Acceptable ways to carry them include in a toolbox, pointed down in a tool belt or
pocket tool pouch, or in the hand with the tip always held away from the body.
3. Tools should always be put away when not in use.
Hand tool safety?

1. Always carry pointed tools by your side with the points and heavy ends DOWN.
SECURE all small work & short work with a vise or clamp.
2. NEVER carry tools in your pockets.
3. DON'T use tools which are LOOSE or CRACKED.
4. KEEP your punches & chisels in good condition.
Hand tools are such a common part of our lives but they can also be dangerous if
misused incorrectly.
Reduce the chance of an accident by following the below safety measures.
1. Inspect regularly
 Regularly inspect your tools to make sure that they are in good condition.

2. Wear gloves
 Always wear appropriate personal protective equipment.

3. Carry with care
 Never carry tools up a ladder.
 If you need to take tools up to a height use a bag or hoist them up in a bucket.

4. Don't pocket sharp objects
 Never carry sharp or pointed tools in your pocket.
 Instead, carry them in a toolbox.

5. Be aware of your surroundings
 Always be aware of the people around you when using tools.

6. Use the right tools
 Always use the right tools for the job.
 Never use a tool for a different purpose than it was intended.
 You risk damaging the tools and injuring yourself.

7. Follow instructions
 Only operate tools according to manufacturers' instructions.

8. Clean and return
 After using a tool, clean it and return it to it's proper storage place.

9. Oily hands are dangerous
 Don't work with greasy or oily hands.
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10. Protect your eyes
 Always wear eye protection.
12. Handling of welding materials and consumables
Proper storage of both opened and unopened packages of welding consumables is

crucial. It should avoid quality issues such as porosity, excessive slag fluidity, rough
weld surface, difficult slag removal and more importantly, elevated levels of diffusible
hydrogen which can lead to cracking.
Handling
1. Welding should be carried out at room temperature and low relative humidity.
2. If relative humidity exceeds 60 %, cored wires should not be left unprotected for more
than 24 hours.
3. Once removed from the original protective packaging flux cored wires should be used
within 72 hours
Here are a few basic tips for properly storing your welding materials to keep them
working optimally for as long as possible.
1. Rod Storage. Always store rods in an upright position to prevent them from falling over
and becoming damaged. ...
2. Loose Hose Coiling. ...
3. Balance Welding Tanks. ...
4. Unplug, Turn Off.
Weld Carbon Steel Plates in 1F Position using SMAW Process
Supplies/Materials:
 2 pcs. Mild Steel plates 10 mm x 50mm x 150mm
 4 pcs. Electrode E6011
 10pcs. Electrode E6013/E7018
 1pc. Soft stone
Equipment/Tools:
 1 unit AC/DC Welding Machine with complete Accessories
 1 set Personal protective equipment
 1 pc. Chipping hammer
 1 pc. Ball peen Hammer
 1 unit Electric Angle Grinder
 1pc. Split joint pliers/ Tong
 Electrode oven
Page 36
Procedure:
First layer or Root Pass

 Use E 6011/6013, 3.2 mm electrode Ø
 Bead : Stringer Bead
 Current Setting: 70-100 A
 Arc Length: Approximately 3 mm
 Adjust the welding machine to correct current and amperage setting.
 Prepare and tack metal in Flat position.
 Strike arc at bottom of joint and hold a high arc length for 1 to 2 seconds to heat
plates.
 Position electrode in middle of joint making a 45º angle with each plate and 5º-
10ºdown from the flat
 Used manipulation technique if necessarily.
Note: Bead uniformity depends upon proper timing and manipulation of electrode. Check
with instructor for correct procedures.
 Remove slag and clean thoroughly after every pass.

Note:
Check with instructor at this point. Upon receiving instructor’s approval, additional beads
may be stringers or some form of weave weld.
Second layer or Hot Pass

 Use E6013/E7018, 3.2 mm electrode Ø
 Bead: Weave Bead
 Current Setting: 90 - 120 A
 Arc Length: Equal to the electrode diameter
 When welding second bead, pause at the edges of first bead to fill the crater and
avoid undercutting sides of joint.
Final layer or Capping

 Use: E6013/E7018, 3.2 mm electrode Ø
 Bead: Weave Bead
 Current Setting: 90 - 120 A
 Arc Length: Equal to the electrode diameter
 Cool metal and weld opposite side using the same procedure as on first side.
 After completion of joint, turn in for instructor’s approval.
 Repeat this exercises if needed
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Equipment and materials

 Arc welding machine and required tools
 1 pc. Soft stone
 Electrode E6010/ E6011, 1/8" Ø
 Electrode E6013/ E7018, 1/8” Ø
 1/8" - 75-130 amps
 Current: DCRP
 Personal Protective Equipment
 Electrode oven
Procedure
 Adjust welding machine to correct current and amperage
 Position plates on table to form a T-joint
 Tack plates on each end
 For first bead, angle electrode 45° from vertical plate and 5-10° in direction of travel.
 Strike arc at end of plate holding a high arc for 1 or 2 seconds
Note:
This allows for the end of the metal plates to heat prior to depositing the proper beads
and prevents cold lap.
 Move electrode to opposite side of T-joint and start depositing second bead using
same angle used in bead one
 Deposit beads about two times wider than electrode diameter.
Note:
Remember to alternate passes from one side to another of T- joint to minimize distortion
of the plates.
 Remove slag from bead one and two
Note:
Keep each bead dimension constant. It is necessary to overlap beads more than seems
necessary to avoid laying too much metal on bottom by side of joint.
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 Deposit bead three using a 30° degree angle from vertical plate with the electrode
slanting 5 to 10° in direction of travel
 Deposit bead four using same angle as used in depositing bead three.
 Deposit bead five using a 70° degree angle from vertical plate with the electrode
slanting 5 to 10° in direction of travel.
 Deposit bead six using same angle as used in bead five.
 After completing required number of passes, turn plate in for instructor's approval.
Page 39

 Electrode E6010/ E6011, 1/8" Ø
 Electrode E6013/ E7018, 1/8” Ø
 1/8" - 75-130 amps
 Current: DCRP
 Electrode oven
Procedure
 Adjust welding machine to correct current and amperage setting.

 Prepare and tack metal in vertical position.
 Strike arc at bottom of joint and hold a high arc length for 1 or 2 seconds to heat
plates.
Page 40
 Position electrode in middle of joint making a 45° angle with each plate, and 5-10°
down from horizontal.
 Deposit weld upward using some form of up and down whipping motion.
Note:
Bead uniformity/depends upon proper timing and manipulation of electrode. Check with
instructor for correct procedures.
 Remove slag and clean thoroughly after every pass

 Alter sides to minimize distortion
Note:
Check with instructor at this point. Upon receiving instructor’s approval, additional beads
may be stringers or some form of weave bead.
 After completing exercise, turn in plate for instructor's approval

 Electrode E6010/ E6011, 1/8" Ø
 Electrode E6013/ E7018, 1/8” Ø
 1/8" - 75-130 amps
 Current: DCRP
 Electrode oven
Procedure
 Adjust welding machine to correct current and amperage
Page 41
 Position plates on table to form a T-joint

 Tack plates on each end and slag
 For first bead, angle electrode 45° from vertical plate and 5-10° in direction of
travel.
 Strike arc at end of plate holding a high arc for 1 or 2 seconds
 Note:
This allows for the end of the metal plates to heat prior to depositing the proper beads
and prevents cold lap.
 Move electrode to opposite side of T-joint and start depositing second bead using
same angle used in bead one
 Deposit beads about three to four times wider than electrode diameter.
Note:
Remember to alternate passes from one side to another of T- joint to minimize distortion
of the plates.
 Remove slag from bead one and two
3
”
6
”
8
0 For Fillet
° welds
1 Work Angle
0 is an
° 10° Travel Approximat
Angle e 80°
Note:
Keep each bead dimension constant. It is necessary to overlap beads more than seems
necessary to avoid laying too much metal on bottom by side of joint.
 Deposit bead three using a 30° degree angle from vertical plate with the electrode
slanting 5 to 10° in direction of travel
 Deposit bead four using same angle as used in depositing bead three.
 Deposit bead five using a 70° degree angle from vertical plate with the electrode
slanting 5 to 10° in direction of travel.
 Deposit bead six using same angle as used in bead five.
 After completing required number of passes, turn plate in for instructor's approval.
Weld Carbon Steel Plates in Flat Position 1G
Page 42

 Electrode E6010/ E6011, 1/8" Ø
 Electrode E6013/ E7018, 1/8” Ø
 1/8" - 75-130 amps
 Current: DCRP
 Electrode oven
Procedure
 Adjust welding machine for correct current and amperage settings

 Prepare metal for welding
 Bevel edges of plates 30°
 Bevel One Long side of each plate
 Remove all burrs and slag
 Place metal together parallel to each other leaving a root gap from 3/32" to 1/8" in
flat position
 Tack pieces together at both ends and feather tack with a right angle finder
Page 43
NOTE: Place a strip of metal under each piece to hold it off table top when welding
 Position electrode straight into plate and angle 5°-10° away from weld puddle.


 Strike high arc length to heat plates, then
move to end and weld plates together
using a stringer bead
Note:
The root pass should have 100% penetration on
both plates extending through the root and
overlapping 1/16" of an inch on each side. Also,
the back of the root pass should have a convex
appearance when observed from the bottom of the plate.
CAUTION: Avoid undercutting races of groove.

Chip slag and brush weld clean.
Page 44
 Deposit necessary filler passes to fill out the V, using care to remove all slag
deposits between each pass
Note: Filler passes can be stringers or weaves.
 Make cover pass or passes slightly convex overlapping edge of groove 1/16" on
each side
 Cool plates slowly
CAUTION: Do not place plates in water

Turn in plate to instructor for testing
Weld Carbon Steel Plates in Flat Position 2G

 Electrode E6010/ E6011, 1/8" Ø
 Electrode E6013/ E7018, 1/8” Ø
 1/8" - 75-130 amps
 Current: DCRP
 Electrode oven
Procedure
Page 45
Adjust welding machine for correct current and amperage settings
 Prepare metal for welding

 Bevel edges of plates 30°
 Bevel One Long side of each plate
 Remove all burrs and slag

 Place metal together parallel to each other leaving a root gap from 3/32" to 1/8" in
flat position.
 Tack pieces together at both ends and feather tack with a right angle finder
 Hold electrode 900 or straight into joint tilting 50-100 in direction of travel as
shown in the figure.
Page 46
 Strike arc and hold high arc length to heat plates and use root pass
Note:
The root pass should have 100% penetration on both plates extending through the root
and overlapping 1/16" of an inch on each side. Also, the back of the root pass should
have a convex appearance when observed from the bottom of the plate.
 Chip slag and brush weld clean after each pass

 Deposit additional welds as stringers or weaves as determined by instructor
 Make cover pass or passes slightly convex and overlapping top edge of groove
1/16" on each side
 Cool plate in still air slowly
Page 47
CAUTION: Do not cool in water

Turn in plate to instructor for testing
Weld Carbon Steel Plates in Vertical Position 3G

 Electrode E6010/ E6011, 1/8" Ø
 Electrode E6013/ E7018, 1/8” Ø
 1/8" - 75-130 amps
 Current: DCRP
 Electrode oven
Procedure
Page 48
 Prepare all necessary tools, equipment and materials.

 Grind the surfaces to be welded, grind the top and bottom 1/8 inch beyond the
weld area.
 Fit up align and tack the pieces before welding
 Clamp the joint in a fixture or tack weld it to the arm tube at a comfortable height.
 Use E6011/E6010 electrode for penetration 70 - 90 amperes
 E7018/E6013 electrode for second pass 100-120 amperes
 E7018 electrode 110-125 amperes for capping
 Perform root pass using a half moon or whipping motion pushing the keyhole
alone.
 Grind your tie -in
 Do not weld over the top edges of the V-Groove until the final cover layer.
 Use the edges as a guide for laying the first weld bead of each layer.
 Chip the slag off and brush clean after each weld bead.
 The electrode angle must be 10 degrees work angle.
 Look for even weld beads with consistent ripples good overlap, and no undercut.
 Check with the instructor for evaluation.
Note: Consult your Instructor for recording purposes before starting such every
Reference:
10 Basic Safety Rules For Using Hand Tools– Teng Tools USA
tengtoolsusa.com › blogs › news › 10-basic-safety-rules-f
Storage and handling - Welding Alloys Group

www.welding-alloys.com › welding-alloys-consumables
Storage Tips for Welding Materials | Wasatch Steel

www.wasatchsteel.com › storage-tips-welding-materials
www.google.com
CBLM SMAW NC II
End of WELD CARBON STEEL PLATES USING SMAW
Page 49

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COMPETENCY BASED LEARNING

No. Unit of Competency Module Title Module Code

Receive and respond to Receiving and respond to

Practice basic housekeeping Practicing basic housekeeping

SHIELDED METAL ARC WELDING NC I

WELD CARBON STEEL PLATES USING SMAW

WELDING CARBON STEEL PLATES USING MEE721301

HOW TO USE THIS COMPETENCY-BASED LEARNING MATERIAL

Welcome to this Competency-Base Learning Materials for the module WELD

You are required to go through the series of learning activities in order to

Recognition of Prior Learning (RPL)

 been working for some time or

 Talk to more experienced workmates and ask for their guidance.

SUMMARY OF LEARNING OUTCOMES

After completing of this module, the trainee should be able to:

LO1 Perform root pass

LO2 Clean root pass

LO3 Weld subsequent/ filling passes (all content refer to LO1)

LO4. Perform capping refer to LO1

FIVE ESSENTIALS OF WELDING

Size and Type of Electrode

DEPOSIT WELD BEAD ON PLATE

Weave bead is running a bead with electrode manipulation.

Stringer Bead is running a bead without manipulation or movement

Application of stringer and weave bead are according to:

Characteristics of good surfacing weld

Surfacing weld ( Flat Position)

WELD PLATES IN MULTIPLE PASS FILLET JOINTS IN ALL POSITION

What is Carbon steel?

Low Carbon Steel

Medium Carbon Steel

High Carbon Steel

LO1 Perform root pass

1. Drawing/Plan/ WPS interpretation

Typical Items That Should Be Recorded On W.P.S:-

2. Materials and consumables (Electrodes, Base Metal)

Choosing the Right Consumable

HOW TO CHOOSE WELDING CONSUMABLES

3.Welding Equipment and Tools

3. Basic Mathematics (Multiplication, Division, Addition and Subtraction)

THE NUMBER PLACE VALUE

STEPS IN ADDING WITHOUT REGROUPING

Subtracting Whole Numbers

Steps in Subtracting Without Regrouping

 Subtract the digits in the tens place

- Multiply the numerators ( 3 x 1 = 3) to get 3 then

Dividing Whole Numbers Procedure:

Welding is the process of joining metals and thermoplastics by means of coalescence.

American Society of Mechanical Engineers

List of welding codes

American Society of Mechanical Engineers (ASME) Codes

American Welding Society (AWS) Standards[

AWS D11.2 Welding (cast iron)

American Petroleum Institute (API) Standards

British Standards (BS)

International Organization for Standardization (ISO) Standards[

Qualification testing of welders for under-water welding. Diver-welders and

6. Identification of weld defects

A measuring instrument is a device to measure a physical quantity. In the physical

(A) framing square carpenter's square,

Compass and deviders

Push and pull rule Steel ruler