Republic of the Philippines

Department of Education
PUBLIC TECHNICAL-VOCATIONAL
HIGH SCHOOLS
PUBLIC TECHNICAL-VOCATIONAL
HIGH SCHOOLS

Unit of Competency: WELD ON CARBON STEEL PLATES

Module Title: WELDING GROOVE WELD ON CARBON

Module No.: 1
STEEL PLATES (1G, 2G, 3G)
 ACKNOWLEDGMENT

Copyright Department of Education 2008

First Published JUNE 2008

This draft was prepared at the Competency-Based Learning Materials

Development Workshop conducted at the Marikina Hotel on February 18-22,
2008.

This learning instrument was developed by the following personnel:

Technology Teachers:

Val A. Canarias
Gen. Mariano Alvarez Technical High School
GMA, Cavite

Benjie R. San Juan

Community Vocational High School
Calapan City

Resource Person:

Mr. Clodualdo Paiton

TESDA Specialist

Facilitators/Specialists:

Mr. Jose D. Gonzales Jr.

Principal III
RESPSCI

Contextual Teacher:

May L. Sangalang
AFG Bernardino Memorial Trade School
Lias, Marilao, Bulacan
(English)

Encoders:

Maria Eliza R. Rivera

Catherine P. Gonzales
Department of Education

This work was produced with funding provided by the Department of

Education.
 ACKNOWLEDGMENT

The Department of Education (DepED), Central Office through Technical

Vocational Task Force wishes to extend its gratitude and appreciation to all the
Module Writers for sharing their time and expertise in the Refinement and
Enrichment of Competency-Based Learning Materials for Strengthening Technical
Vocational Education Program (STVEP) held at the Marikina Hotel, Marikina City
on April 20-25, 2009.

MODULE WRITERS:

WELDING

JIMMY P. OCAMPO
Rizal Experimental Station and Pilot School of Cottage Industries
(RESPSCI)
Maybunga, Pasig City NCR

JIMMY P. DOMINGO
San Pedro Relocation Center NHS
San Pedro, Laguna Region IV-A

JEFFREY G. MORENOS
Assemblywoman Felicita G. Bernardino
Memorial Trade School
Lias, Marilao, Bulacan Region III

BENJIE R. SAN JUAN

Community VHS (Calapan City NHS)
Calapan City, Oriental Mindoro Region IV-B

SCIENCE

EDNA M. PASAMONTE
B.S. Aquino National High School
Concepcion, Tarlac Region III

MATH

FRANCISCO M. JAVIER
Muntinlupa Business High School
Espeleta St., Buli, Muntinlupa City NCR

ENGLISH

MA. NONELA B. CASTILLO

Rizal Experimental Station and Pilot School of Cottage Industries
(RESPSCI)
Maybunga, Pasig City NCR

FACILITATOR :

VICTORIO N. MEDRANO
Principal IV
San Pedro Relocation Center NHS
San Pedro, Laguna Region IV-A

EDITOR:

MRS. CAROLINA F. CHAVEZ

Principal II
Muntinlupa Business High School
 Muntinlupa City NCR

ENCODER :

MA. RIZA B. ZAMO RA

DepED – Budget Division, Meralco Ave., Pasig City

EVANGELINE C. NUESCA
Magara, Roxas, Palawan

This work was produced with funding provided by the Department of

Education.
 TABLE OF CONTENTS

Page

How to Use this Module ................................................................................... i

Introduction .................................................................................................... ii
Technical Terms……………………………………………………… ........................iii-iv
Learning Outcome 1 Weld Carbon Steel Plates in Flat
Position (1G)……………………………………………………….. ....................... 1
 Learning Experiences/Activities ............................................................. 2
 Activity Sheet 1.1…………………………………………………………………..3-5
 Self-Check 1.1 ....................................................................................... 6
Learning Outcome 2 Weld Carbon Steel Plates in Horizontal
Position (2G)…………………………………..……………………………………….7
 Learning Experiences/Activities…………………………………………………..8
 Activity 2.1 …………………………………………………………………………9-10
 Self-Check 2.1 ……………………………………………………………………….11
Learning Outcome 3 Weld Carbon Steel Plates in Vertical
Position (3G)…………………………………………………….……………………12
 Learning Experiences/Activities………………………………………………….13
 Information Sheet # 3.1..………………………………………………………14-17
 Operation Sheet 3.1…………………………………………………………………18
 Self-Check 3.1 ………………………………………………………………………19
 Answer Keys…………………………………………………………………………..20
 HOW TO USE THIS MODULE

Welcome to the Module “WELDING GROOVE WELD ON CARBON STEEL

PLATES (1G, 2G, 3G)”. This module contains training materials and activities
for you to complete.

The unit of competency “Weld on Carbon Steel Plates” contains the

knowledge, skills and attitudes required for Shielded Metal Arc Welding
(SMAW) required to obtain the National Certificate (NC) level I.

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

complete each of the learning outcomes of the module. In each learning
outcome there are Information Sheets, Job Sheets, Operation Sheets and
Activity Sheets. Do these activities on your own and answer the Self-Check at
the end of each learning activity.

If you have questions, do not hesitate to ask your teacher for assistance.

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in
this module.

If you can demonstrate competence to your to your teacher in a particular

skill, talk to your teacher so you do not have to undergo the same module
again. If you have a qualification or Certificate of Competency from previous
trainings show it to him/her. If the skills you acquired are consistent with and
relevant to this module, they may become part of the evidence. You can
present these for RPL. If you are not sure about your competence skills,
discuss this with your teacher.

After completing this module, ask your teacher to assess your competence.
Result of your assessment will be recorded in your competency profile. All the
learning activities are designed for you to complete at your own pace.

In this module, you will find the activities for you to complete and relevant
information sheets for each learning outcome. Each learning outcome may have
more than one learning activity.

This module is prepared to help you achieve the required competency,

in receiving and relaying information. This will be the source of information
that will enable you to acquire the knowledge and skills in Shielded Metal
Arc Welding (SMAW) independently at your own pace with minimum
supervision from your teacher.

i
Unit of Competency WELD ON CARBON STEEL PLATES

Module Title: WELDING GROOVE WELD ON CARBON STEEL

PLATES (1G, 2G,3G)

INTRODUCTION:

This module contains information and suggested learning activities on

Welding Groove. It includes instruction and procedure on how to Weld Groove
on Carbon Steel Plates.

Completion of this module will help you better understand it for future
reference.

This module consists of three (3) learning outcomes. Each learning

outcome contains learning activities supported by instruction sheets. Before
you perform the instruction, read the information sheets and answer the self-
check and activities provided. To ascertain your competence, your teacher will
assess what you have acquired when the knowledge necessary to perform the
skill portion of what particular learning outcome.

Upon completing this module, report to your competence teacher for

assessment to check your achievement of knowledge and skills requirements of
this module. If you pass the assessment, you will be given a certificate of
completion.

SUMMARY OF LEARNING OUTCOMES:

Upon completion of the module the students should be able to:

LO1 Weld Carbon Steel Plates in Flat Position (1G);

LO2 Weld Carbon Steel Plates in Horizontal Position (2G);
LO3 Weld Carbon Steel Plates in Vertical Position (3G)

ASSESSMENT CRITERIA:

Refer to assessment criteria of learning outcomes 1-8 of this module.

PREREQUISITE:

ii
 TECHNICAL TERMS

Angular distortion is shifting of metal parts so they are out of alignment,

caused by weld shrinkage.

Bevel is an angular edge preparation.

Bevel angle is the angle at which a bevel is cut.

Butt joint is a joint between two members lying approximately in

the same plane.

Complete fusion is where fusion has occurred over the entire base metal
surfaces exposed for welding between all layers and
passes.

Continuous weld is a weld that is completely welded from one end of a

joint to the other. If the joint is round the weld extends
completely around the joint.

Coupon is a test piece for welding.

Flat welding is a welding done on the upper side of the joint with the
face of the weld parallel to the ground, also called down
hand welding.

Groove angle is the total included angle of the groove.

Groove face is the surface of a piece included in the groove.

Groove radius is the radius of a J- or U- groove also called root radius.

Groove weld is a weld made in the groove between two pieces

to be joined.

Horizontal welding it is a welding position with the axis of the weld parallel
to the ground and the face perpendicular to the ground.

Root crack is a crack in the weld or heat-affected zone at the root

of the weld.

Root edge is a root face with no width.

Root face is that part of the groove face followed as part of the
note preparation next to weld joint.

Root of joint is that part of the joint where the pieces come too
closest to each other. In cross-section, the root of the
joint may be a point, a line or an area.
iii
Root of weld is the point in cross-section where the back of the weld
crosses the base metal surfaces.

Root opening is the area between the pieces to be joined at the root of
the joint also called root gap.

Root penetration is the depth that a groove weld extends into the root of
a joint, measured at the center of the root cross-section.

Root reinforcement is a weld reinforcement on the other side on which the

welding.

Root surface is the exposed weld surface on the side opposite the
side on which the welding was done.

Square groove a space left between two plain joint edges.

Stringer bead is a type of weld bead made with little side- to-side
movement.

Tack weld is a small, temporary weld used to hold strongly the

parts of a weldment in alignment until the final welds
are made.

V-groove is a straight angular groove on both metal pieces to

be joined.

iv
 Program/Course
Unit of Competency
Module Title
Learning Outcome 1:
SHIELDED METAL ARC WELDING (SMAW) NC-1
Weld Carbon Steel Plates
WELDING GROOVE ON CARBON STEEL PLATES
(1G, 2G, 3G)

Weld Carbon Steel Plates in flat Position (1G)

Assessment Criteria:

1. Welding procedure in striking an arc is applied according to weld

standard.
2. Methods of striking an arc are applied accordingly.

REFERENCES:

Welding Technology
2nd Edition
Gower A. Kennedy

Welding Guide
Fabrication Shop
Ismael V. Palabrica

Metal Works 1
SEDP Series
Industrial Technology

Basic Manual Metal Arc Welding

National Training Center
for Technical Education and Staff Dev.

Welding Principles and Applications

Larry Jeffus and Harold V. Johnson

1
LEARNING EXPERIENCES/ACTIVITIES

Learning Outcome No. 1: Weld carbon Steel Plates in Flat Position (1G)

Learning Activities Special Instructions

1. Read the procedure in activity

for welding carbon steel plates
in flat position (1G).

2. Perform step-by-step
procedure with caution.
 Try to pass the self-check for
3. Rate the quality of your weld welding carbon steel plates in
using the marking schedule. flat position (1G)

4. If you did not pass the marking

points, repeat the activity for
welding carbon steel plates in
flat position (1G).

5. When you are ready, you can

proceed to the next LO

2
 ACTIVITY 1.1

Single-V Butt Joint Flat Position (1G)

1. Mild steel plates 6.0mm x 100mm x 150mm (2pcs)

2. Electrode, E-6013, 3.2mm diameter.

Tools and Equipment

1. AC welding machine with accessories
2. chipping hammer
3. steel brush
4. welding helmet/shield
5. gloves
6. apron
7. portable grinder.

Plan/Illustration

3
 SINGLE-V BUTT JOINT FLAT POSITION (1G)

Welding Procedure

1. Tack weld the plates 6 mm

from each end with uniform
gap of 3.0 mm between the
plates.

2. Preset the plates for

angular distortion.

3. Lay the plate on the

table with the side
which is not tacked
on top.
4. Deposit the root pass
with the electrode at
the center with 70
travel angle and 90
work angle.
5. Remove the slag and clean the root pass.

6. Deposit the second bead on

top of the root pass. It must
completely fused the plates
and the first.

NOTE: Maintain an arc

length of 2-3 mm.

7. Clean the bead and

inspect for any defects.

NOTE: Wear safety glasses

when cleaning and
removing slag.

8. Deposit the remaining bead.

NOTE: Proceed to the weld

joint maintaining a
uniform bead width of
8 mm

4
 SAFETY MEASURES IN ARC WELDING

● Insulate welder from work piece and ground using dry insulation. Rubber
mat dry wood.

● Wear dry, hole-free gloves (Change as necessary to keep dry).

● Do not touch electrically “ hot: parts of electrode with bare skin or wet
clothing.

● If the area is wet and the welder cannot be insulated from work piece with
dry insulation, use a semi-automatic, constant-voltage or stick welder with
voltage reducing device.

● Keep electrode holder and cable insulation in good condition. Do not use if
insulation is damaged or missing.

● Use ventilation or exhaust to keep air breathing zone clear, and

comfortable.

● Use welding helmet and positioning of head to minimize fume in breathing

zone.

● Read warnings on electrode container and material safety data sheets for
electrode.

● Provide additional ventilation/exhaust were special ventilation

requirements exist.

● Use special care when welding in contained area.

● Do not weld unless ventilation is adequate.

● Do not weld on containers which have held combustible materials. Check

before welding.

● Remove flammable materials from welding area or shield from sparks,

heat.

● Keep a fire extinguisher in the welding area.

● Wear fire retardant clothing and hat. Use earplugs when welding overhead.

5
 ASSESSMENT (SELF-CHECK) 1.1

The marking system below will guide you in assessing the quality of your weld.
Follow the marking schedule in rating your weld and record the marks on the
table provided for the purpose. Subtract the total marks from 30 points, which
is the highest rating to determine your final points.

THE PASSING MARK IS 15 POINTS

MARKING TABLE

CRITERIA MARKS SUBTRACTED

1. Straightness
2. Width of bead
3. Height of bead
4. Ripple
5. Plate Alignment

TOTAL MARKS SUBTRACTED

FINAL POINTS = 30 - Total Marks Subtracted

30 - ______________________
FINAL POINTS = ______________________
MARKING SCHEDULE
1. Straightness

Subtract 1 mark for each degree of deflection from the line of weld.

2. Width of Bead

Subtract 2 marks for each 10mm length of bead which is 1mm less than
or more than the bead width of 8mm.

3. Height of Bead

Subtract 2 marks for 10mm length of bead which exceeds the bead height
of 3mm.

4. Ripple

Subtract 3 points for uneven and coarse ripple.

5. Plate Alignment
Subtract 1 mark for each 2 degrees of angular misalignment.
Subtract 1 mark for each millimeter of offset between plates.

6
 Program/Course SHIELDED METAL ARC WELDING (SMAW) NC-1
Unit of Weld Carbon Steel Plates
Competency
Module WELDING CARBON STEEL PLATES

Learning Outcome 2:

Weld Carbon Steel Plates in Horizontal Position (2G)

Assessment Criteria:

1. Weld procedure in striking arc is applied according to weld standard.

2. Methods of striking an arc are applied accordingly.

REFERENCES:

Welding Technology
2nd Edition
Gower A. Kennedy

Welding Guide
Fabrication Shop
Ismael V. Palabrica

Metal Works 1
SEDP Series
Industrial Technology

Basic Manual Metal Arc Welding

National Training Center
for Technical Education and Staff Dev.

Welding Principles and Applications

Larry Jeffus
Harold V. Johnson

7
LEARNING EXPERIENCES/ACTIVITIES

Learning Outcome No. 2: Weld carbon Steel Plates in Horizontal Position (2G)

Learning Activities Special Instructions

1. Read the procedure in activity

for welding carbon steel plates
in flat position (2G).

2. Perform the step-by-step

procedure with caution.
a. Try to pass the self-check for
3. Rate the quality of your weld welding carbon steel plates in
using the marking schedule. flat position (2G)

4. If you did not pass the marking

points, repeat the activity for
welding carbon steel plates in
flat position (2G).

5. When you are ready, you can

proceed to the next LO

8
 ACTIVITY 2.1

Single-V Butt Joint Horizontal Position (2G)

1. Mild steel plates 6.0mm x 100mm x 150mm (2pcs)

2. Electrode, E-6013, 3.2mm diameter.

Tools and Equipment

1. AC welding machine with accessories
2. chipping hammer
3. steel brush
4. welding helmet/shield
5. gloves
6. apron
7. portable grinder.

Plan/Illustration

9
 SINGLE-V BUTT JOINT HORIZONTAL POSITION (2G)

Welding Procedure

1. Tack weld the plates

10mm from each end
with uniform gap of 3.0
mm between the plates

2. Preset the plates for

angular distortion.

3. Clamp the plate in the

position with the edge of
the plate parallel to the
ground.
NOTE: Position the joint
line just below eye
to have a clear view
of the arc when
welding commerce.
4. Deposit the root pass with
the electrode at the center
with 75 - 85 travel angle
and 95 work angle.

NOTE: Manipulate the

electrode using a
circular weaving
motion. Maintain
the width of bead
at 8 mm

5. Remove the slag and

clean the root pass.
NOTE: Wear safety
goggles when
chipping slag.

6. Deposit the second bead on top of the

root pass. It must completely fused the
plates and the first bead.

7. Deposit the remaining bead.

NOTE: The slag must be chipped off
each weld before the next weld
bead is put in place.

10
 ASSESSMENT (SELF-CHECK) 2.1

The marking system below will guide you in assessing the quality of your weld.
Follow the marking schedule in rating your weld and record the marks on the
table provided for the purpose. Subtract the total marks from 30 points, which
is the highest rating to determine your final points.

THE PASSING MARK IS 15 POINTS

MARKING TABLE

CRITERIA MARKS SUBTRACTED

1. Straightness
2. Width of bead
3. Height of bead
4. Ripple
5. Plate Alignment

TOTAL MARKS SUBTRACTED

FINAL POINTS = 30 - Total Marks Subtracted

30 - ______________________
FINAL POINTS = ______________________
MARKING SCHEDULE
1. Straightness

Subtract 1 mark for each degree of deflection from the line of weld.

2. Width of Bead

Subtract 2 marks for each 10mm length of bead which is 1mm less than
or more than the bead width of 8mm.

3. Height of Bead

Subtract 2 marks for 10mm length of bead which exceeds the bead
height of 3mm.

4. Ripple

Subtract 3 points for uneven and coarse ripple.

5. Plate Alignment
Subtract 1 mark for each 2 degrees of angular misalignment.
Subtract 1 mark for each millimeter of offset between plates.

11
 Program/Course SHIELDED METAL ARC WELDING (SMAW) NC-1
Unit of Weld Carbon Steel Plates
Competency
Module WELDING CARBON STEEL PLATES

Learning Outcome 3:

Weld Carbon Steel Plates in Vertical Position (3G)

Assessment Criteria:

1. Weldment sides are maintained free from defects.

2. Weld appearance if not greater than 2mm side lap weld deposits observed
3. Weld appearance if not greater than 3.25 weld reinforcement is
maintained.
4. work angle 90 and travel angle 10-180 are observed.

REFERENCES:

Welding Technology
2nd Edition
Gower A. Kennedy

Welding Guide
Fabrication Shop
Ismael V. Palabrica

Metal Works 1
SEDP Series
Industrial Technology

Basic Manual Metal Arc Welding

National Training Center
for Technical Education and Staff Dev.

Welding Principles and Applications

Larry Jeffus
Harold V. Johnson

12
LEARNING EXPERIENCES/ACTIVITIES

Learning Outcome No. 3: Weld carbon Steel Plates in Vertical Position (3G)

Learning Activities Special Instructions

1. Read the procedures in activity

for welding carbon steel plates
in vertical position (3G).

2. Perform the step-by-step

procedure with caution.
a. Try to pass the self-check
3. Rate the quality of your weld for welding carbon steel
using the marking schedule. plates in vertical position (3G)

4. If you did not pass the marking

points, repeat the activity for
welding carbon steel plates in
vertical position (3G).

5. When you are ready, you can

proceed to the next LO

13
 INFORMATION SHEET 3.1

WELDING GROOVE WELD ON CARBON STEEL PLATES (3G)

THE VERTICAL POSITION

In the fabrication of many structures such as steel buildings, bridges,

tanks, pipelines, ships, and machinery, the operator must frequently make
vertical weld is one with a seam or line of weld running up and down.
One of the problems of vertical welding position is that gravity has a
tendency to sag the molten puddle from the electrode and plates being welded.
To prevent this from happening, fast-freeze types of electrodes should be used.
Puddle control can also be achieved by proper electrode manipulation and
selecting electrodes specifically designed for vertical position welding.

POSITION AND MOVEMENT OF THE ELECTRODE

Vertical welding is done by depositing beads either in an upward or

downward direction, (sometimes referred to as uphill and downhill). Downward
welding is very practical for welding light page metal because penetration is
shallow, thereby forming an adequate weld without burning through the metal.
Moreover, downward welding can be performed much more rapidly, which is
important in production work. Although it is generally recommended for welding
lighter materials, it can be used for most metal thickness.

100 to 150
0 0
15 to30

150

Position of the electrode for downward (left) and upward

(right) vertical welding

On heavy plates of ¼ “ or more in thickness, upward welding is often

more practical, since deeper penetration can be obtained. Welding upward also
makes it possible to create a shelf for successive layers of beads.
For downward welding, tip the electrode at about 60° travel angle and 90°
work angle. Start at the top of the seam and move downward with little or no
weaving motion. If a slight weave is necessary, swing the electrode so the
crescent is at the top.
For upward welding, start with the electrode at right angles to the plates.
Then, lower the rear of the electrode, keeping the tip in place, until the electrode
forms an angle of 10-15 with the horizontal.

14
Laying Straight Beads in Vertical–Downhill Method

Set up a practice piece in vertical position with a series of straight lines

drawn on it. Start at the top of the plate with the electrode pointed upward
about 60 from the vertical plate. Keep the arc short and draw the electrode
downward to form the bead. Travel just fast enough to keep the molten metal
and slag from running ahead of the crater. Do not use any weaving motion to
start with. Once this technique is mastered try weaving the electrode but very
slightly with the crest at the top of the craters.

Laying Straight Beads in a Vertical Position-Uphill Method

1. Obtain a ½ “ plate and draw a series of straight lines. Then fasten the
piece so the lines are in a vertical position.
2. Strike the arc on the bottom of the plate. As the metal is deposited, move
the tip of the electrode upward in a rocking motion as shown in the
picture below.

This is often called a whipping motion. In rocking the electrode, do not

break the arc but simply pivot it with a wrist movement so the arc is moved

15
 up ahead of the weld long enough for the bead to solidify. Then return it to
the crater and repeat the operation, working up along the line to the top of
the plate. Remember; do not break the arc while moving the electrode
upward. Withdraw it just long enough to permit the deposited metal to
solidify and form a shelf so additional metal can be deposited. Continue to
lay beads from bottom to top until each line is smooth and uniform in width.

Laying Vertical Beads with a Weaving Motion

On many vertical seams in uphill welding, it is necessary to form beads of

various widths. The width of the bead can control by using one of the
weaving patterns. Each pattern will produce a bead approximately twice the
diameter of the electrode. Notice that each weave is shaped so the electrode
can dig into the metal at the bottom of the stroke, and the upward motion
momentarily removes the heat until the metal can solidify. When a smooth
weld is required on the final pass of a wide joint, the wash bead should be
used.

Before applying these weaving motions on the actual joints, practice

running them on a vertical plate. Continue this practice until a smooth bead
of uniform width can be deposited.

16
 ARC WELDING SAFETY PRECAUTION

1. ELECTRIC SHOCK Can Kill

1.a. The electrode and work (or ground) circuits are electrically “hot” when
the welding machine is on. Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

1.b. Insulate yourself from work and ground using dry insulation. Make
certain the insulation is large enough to cover your full area of physical
contact with work and ground. In addition to the normal safety precaution,
if welding must be perform under electrical hazardous condition ( in dump
location or while wearing wet clothing; on metal structures such as floors,
gratings or scaffolds; when in cramped positions such as sitting, kneeling
or lying, or lying, if there is a high risk of unavoidable or accidental contact
with the work piece or ground) use the following equipment:

● semi-automatic DC Constant Voltage (Wire Welder)

● DC Manual (Stick) welder
● AC welder with Reduced Voltage Control

1.c. In semi-automatic or automatic wire welding, the electrode, electrode reel,

welding head, nozzle or semi-automatic welding gun are also electrically
“hot”

1.d Always be sure the work cable makes a good electrical connection with the
metal being welded. The connection should be as close as possible to the
area being weld.

1.e Ground the work or metal to be welded to a good electrical (earth) ground.

1.f. Maintain the electrode holder, work clamp, welding cable and welding
machine in good, safe operating condition. Replace damaged insulation.

1.g. Never dip the electrode in water for cooling.

1.h. Never simultaneously touch “ hot” parts of electrode holders connected to

two welders because voltage between the two can be the total of the open
circuit voltage of both welders.

17
 OPERATION SHEET 3.1

GROOVE WELD SINGLE V VERTICAL POSITION

To produce a butt weld on 10mm mild steel plate using the vertical up
technique

MATERIALS/SUPPLIES
600 to
1. mild steel plate, 10mm x 75mm x 700
200mm
2. electrode E6011, 3.2mm diameter Joint
3. electrode E6013, 4.0mm diameter Preparation
2 1.
5
TOOLS AND EQUIPMENT

1. AC welding machine with accessories

2. chipping hammer
3. steel brush
4. welding helmet/shield
5. gloves
6. apron

WELDING PROCEDURE
WHIP
UPHILL
1. Prepare the plate with the
angle of level: 30˚-50˚
roof face: ± 8mm

2. Lay the plate to be weld in the working table TACK WELD

3. Tack weld both ends to give an included angle of 60˚-70˚ and a gap of 2±
0.8mm
4. Clamp the work piece in vertical manner
5. Start welding from bottom to top of the plate.
Note: Maintain an arc length of 2mm to 3mm

6. Using the chipping hammer, chip off slog from the bead and by using a
steel.

Note Always wear a clear eye glasses when chipping slog.

7. Inspect the bead uniformity.
8. Present the work piece to your teacher.

Note: Used any weaving pattern to control the puddle in uphill

motion.
• Circular
• Triangle
• Whipping
• Side to side

18
 ASSESSMENT (SELF-CHECK) 3.1

Directions:

Rate the quality of welding output using the marking schedule provided
below and record the marks in the marking table. Subtract the marks from 40
points, which is the highest rating.
The passing mark is 20 points

Marking Points
Criteria Marks (Subtracted)
1. Straightness
2. Width of bead
3. Height of bead
1. Ripple
2. Plate alignment
Total Marks Subtracted

Final points = 40 – total marks subtracted

Final points =

Marking Schedule:

1. Straightness
Subtract 2 marks for each degree of depletion from the line of weld.

2. Width of Bead
Subtract 4 marks for each 10mm length of bead, which is 1mm less, or more
than required 8mm bead width.

3. Height of Beads
Subtract 4 marks for each 10mm length of bead exceeds the height of 3mm.

4. Ripple
Subtract 4 marks for uneven and coarse ripple.

5. Plate Alignment
Subtract 3 marks for each 2 degrees of angular misalignment.
Subtract 3 marks for each millimeter of offset between plates.

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 ANSWER KEYS

Rate your performance output, using the following:

Self Check 1.1 - Page 6

Self Check 2.1 - Page 9-10

Self Check 3.1 - Page 19

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