Republic of the Philippines

Department of Education
National Capital Region
Division of City Schools – Manila

SHIELDED METAL ARC WELDING

Grade 9

PREPARE WELD MATERIALS

(WM)
(Set-up Cutting Equipment)

QUARTER 1
Week 2 Module 2

Most Essential Learning Competency

1.1 PREPARE WELD MATERIALS (WM) Set-up Cutting Equipment.

1
 HOW DO YOU USE THIS MODULE?

Before starting the module, I want you to set aside other tasks that will disturb you
while enjoying the lessons. Read the simple instructions below to successfully enjoy the
objectives of this kit. Have fun!

1. Follow carefully all the contents and instructions indicated in every page of this
module.

2. Write on your notebook the concepts about the lessons. Writing enhances learning
that is important to develop and keep in mind.

3. Perform all the provided activities in the module.

4. Let your facilitator/guardian assess your answers using the answer keycard. 5.
Grade 10
Analyze conceptually the posttest and apply what you have learned.

6. Enjoy studying!
SHIELDED
PARTS OF THE MODULE

• METAL
Expectations - These are what you will be able to know after completing the
lessons in the module.
•
ARC
Pre-test - This will measure your prior knowledge and the concepts to be
mastered throughout the lesson.
• Looking Back to your Lesson - This section will measure what learnings and skills

•
WE MODULE
did you understand from the previous lesson.
Brief Introduction- This section will give you an overview of the lesson.
• Activities - This is a set of activities you will perform with a partner.
• Remember - This section summarizes the concepts and applications of the
lessons.
Check your Understanding- It will verify how you learned from the lesson.
•
• Grade 10
Post-test - This will measure how much you have learned from the entire module.

2
 LESSON 1 - LO 1. Set-up cutting equipment
(1)
111222221111(
EXPECTATION:
SHIELDEE
1. Set-up cutting equipment in conformity with the occupational health and
safety standards
2. Check cutting equipment fittings, connection, and power source in
accordance with workplace procedure

PRE-TEST:

1. What are the advantages of Oxy-Acetylene Welding:

a. It's easy to learn.

b. equipment is cheaper than most other types of welding rigs
c. equipment is more portable than most other types of welding rigs
d. equipment can also be used to "flame-cut" large pieces of material.
e. All of the above

2. This type of flame is the one you will use most often in the metalwork room
because it has no chemical effect upon the metal during welding.

a. neutral flame
b. oxidizing flame
c. carburizing flame
d. none of the above

3. The blue flame is divided into three different color regions in oxyacetylene
welding.

a. long yellowish tip

b. blue middle section
c. whitish-blue intense inner section
d. none of the above

3
4. This is called as the improper operation of the torch that causes the flame to go
out with a loud snap or pop.

a. backfiring
b. test firing
c. open firing
d. none of the above

5. These cylinders are made of steel and are usually painted green ranging in size
from less than 20 cu ft. to over 300 cu ft.

a. acetylene cylinder
b. oxygen cylinder
c. gas cylinder
d. none of the above

6. Acetylene should never be used at a pressure that exceeds _________ as it

becomes highly unstable which, depending on the condition, could cause it to
decompose and explode.

a. 11 psi
b. 12 psi
c. 13 psi
d. 15 psi

7. Backfiring in oxyacetylene welding can be caused by touching the,

a. tip against your work piece

b. overheating the tip
c. operating the torch at other than recommended gas pressures
d. a loose tip or head or by dirt on the seat.
e. None of the above

4
8. When opening an Acetylene bottle, open the valve slowly, no more than _____
turns.

a. 1
b. 1 1/3
c. 1 1/2
d. 2
9. Oxygen is a _____________ gas.
a. combustible
b. non-combustible
c. flammable
d. explosive

10. In regards to regulators, you should do all of the following EXCEPT:

a. Use for line checks
b. Use to control output pressure
c. Keep petroleum products away
d. Avoid cleaning

5
LOOKING BACK TO YOUR LESSON

6
BRIEF INTRODUCTION

Oxyacetylene welding also known as Oxy-fuel Welding (OFW), includes any

welding operation that uses combustion with oxygen as a heating medium. With this
family of processes, the base metal and a filler rod are melted using a flame produced
at the tip of a welding torch. Fuel gas and oxygen are combined in the proper
proportions inside a mixing chamber in the torch. Molten metal from the plate edges and
filler metal, if used, intermix in a common molten pool and join when cooling.
Commonly-used fuel gases include acetylene, propylene, propane and natural gas.

The equipment used in oxyacetylene welding is low in cost, usually portable,

and versatile enough to be used for a variety of related operations such as bending and
straightening, preheating, post-heating, surfacing, brazing, and braze welding. Among
commercially available fuel gases, acetylene most closely meets the requirements for
all these applications. Cutting attachments, multi-flame heating nozzles and a variety of
special application accessories add greatly to the overall versatility of the basic
oxyacetylene welding equipment. With relatively simple equipment changes, manual
and mechanized oxygen cutting operations can be performed. Metals normally welded
include carbon and low alloy steels and most nonferrous metals.

LESSON 1 - LO 1. Set-up cutting equipment

Objectives:

1. Set-up cutting equipment in conformity with the occupational health and

safety standards.

2. Check cutting equipment fittings, connection, and power source in

accordance with workplace procedure.

7
 Setting Up the Oxy-acetylene Equipment
Step 1: First Things First

As you can see in the picture, we store the oxy-acetylene rig with the bottles facing
forward. We do this so that you can make sure that they are securely fastened to the
cart. If they are not securely fastened, tighten the wing nut.

Step 2: Get the Kit Out of the Welding Cage

8
Step 3: Choose Your Torch Kind and Size

Step 4: Check for Your O-rings

9
Step 5: Install Torch Top to the Torch Body

Step 6: Preparing to Open the Tanks

10
Oxy-Acetylene (OA) welding

Is one of the many types of welding? It is extremely versatile, and with enough
skill and practice you can use this type of welding for virtually any metal. In fact, the oxy-
acetylene flame burns at 6000 °F, and is the only gas flame that is hot enough to melt
all commercial metals. Oxy-acetylene welding is simple in concept - two pieces of metal
are brought together, and the touching edges are melted by the flame with or without
the addition of filler rod.

Advantages of Oxy-Acetylene Welding:

· It's easy to learn.

· The equipment is cheaper than most other types of welding rigs (e.g. TIG welding)

· The equipment is more portable than most other types of welding rigs (e.g. TIG
welding)

· OA equipment can also be used to "flame-cut" large pieces of material.

Disadvantages of Oxy-Acetylene Welding:

· OA weld lines are much rougher in appearance than other kinds of welds, and
require more finishing if neatness is required.

· OA welds have large heat affected zones (areas around the weld line that have
had their mechanical properties adversely affected by the welding process)

Materials Suitable for OA Welding

Preparation:

1) Assemble all of the materials needed to make the weld. This includes parts, OA
equipment, fixturing, tools, safety mask, gloves, and filler rod.

2) Clean the parts to be welded to remove any oil, rust, or other contaminants. Use a
wire brush if needed to remove any rust.

11
3) Assemble and fixture the parts in place - the parts need to be stable for a good
weld line. Ceramic bricks, vise grips, pliers, and clamps are available in a file
cabinet in the weld room for fixturing.

4) Select the nozzle you plan to use for welding. Nozzles come in a variety of sizes,
from 000 (for a very small flame - typically used for thin materials) to upwards of
3 (for a large flame - needed for thick materials). Larger nozzles produce larger
flames and, in general, are more appropriate for thicker material. Choosing the
right size nozzle becomes easier with more experience.

5) Clean the nozzle. Carbon deposits can build up on the nozzles which interfere
with flame quality and cause backfiring. The cleaning tool has a wide flat blade
(with a file-like surface) which is used to clean carbon deposits on the exterior of
the nozzle. Use it to scrape any deposits from the flat face of the tip. Use the
wire-like files to clean the interior of the nozzle. Pick the largest wire which will fit
inside the nozzle and the scrape the edges of the hole to remove any carbon
buildup.

6) Attach the nozzle to the gas feed line by hand. Don't over-torque - the nozzle and
hose fitting are both made of brass which doesn't stand up well to abuse. A snug,
finger tight fit is the sufficient.

7) Check the pressure levels in the oxygen and acetylene tanks. There should be at
least 50 psi in the acetylene tank. The oxygen tank can be used until it is
completely empty. . Note: The oxygen used in OA welding in NOT for human
consumption. It contains contaminants that could be unhealthy if taken in large
quantities.

Lighting the flame

1) Open the main valve on the acetylene tank ~1/2 turn. This charges the
pressure regulator at the top of the tank.

2) Open the pressure regulator valve on the acetylene tank (turn clockwise to
open) and adjust the pressure in the acetylene line to 5 psi. DO NOT
pressurize the acetylene over 15 psi - it will explode.

3) Open the acetylene pin valve on the handle of the welding tool, letting
acetylene escape. Tweak the pressure regulator valve until the regulator
pressure is constant at 5 psi. Close the acetylene pin valve.

12
 4) Open the main valve on the oxygen tank. Turn the valve until it is fully open
(until it stops turning).

5) Open the pressure regulator valve on the oxygen tank (turn clockwise to
open) and adjust the pressure in the oxygen line to 10 psi.

6) Open the oxygen pin valve on the handle of the welding tool, letting oxygen
escape. Tweak the pressure regulator valve until the regulator pressure is
constant at 10 psi. Close the oxygen pin valve.

7) Slightly open the acetylene valve (~1/8), until you can just barely hear
acetylene escaping.

8) Make sure there is no person or anything flammable in the path of the nozzle.
Use the striker to ignite the acetylene. The flame should be yellow and will
give off a lot of soot.

Adjusting the flame

The blue flame will be divided into 3 different color regions - a long yellowish tip, a blue
middle section, and a whitish-blue intense inner section. There are three types of
flames as described below:

· Neutral - This type of flame is the one you will use most often in the metalwork
room. It is called “neutral” because it has no chemical effect upon the metal during
welding. It is achieved by mixing equal parts oxygen and acetylene and is witnessed in
the flame by adjusting the oxygen flow until the middle blue section and inner whitish-
blue parts merge into a single region.

· Reducing / carburizing flame - If there is excess acetylene, the whitish-blue flame

will be larger than the blue flame. This flame contains white hot-carbon particles, which
may be dissolved during welding. This “reducing” flame will remove oxygen from iron
oxides in steel.

· Oxidizing flame - If there is excess oxygen, the whitish-blue flame will be smaller
than the blue flame. This flame burns hotter. A slightly oxidizing flame is used in
brazing, and a more strongly oxidizing flame is used in welding certain brasses and
bronzes.

13
1) Open the acetylene valve further and watch the flame near the nozzle tip. Add
more acetylene until the flame is just about to separate from the tip. (The
flame will separate from the tip of the nozzle if you add too much acetylene.)
If so, reduce the flow until the flame reattaches to the tip, and then open the
valve again to the near-separation point.

2) Slightly open the oxygen pin valve. If the flame goes out, turn off the gases
and try again. DO NOT try and ignite the flame with both oxygen and
acetylene pin valves open. As the oxygen is added the flame will turn bluish in
color.

3) The blue flame will be divided into 3 different color regions - a long yellowish
tip, a blue middle section, and a whitish-blue intense inner section.

WELDING:

1) Put on a dark face shield to protect your eyes from the light of the flame.
Make sure you have on long sleeves and all natural fibers. You can wear a
leather welding jacket and/or gloves if it makes you feel more comfortable.

2) Apply the flame to the parts to begin heating. Use the region of the flame
near the tip of the bluish inner region.

3) The metal will begin to glow. Continue heating both parts being welded until a
small pool of welded metal appears near the edge of each of the parts. You
must get molten pools on BOTH parts simultaneously to create the weld.
They may require adding more heat to one side than the other, and takes
some practice.

14
4) After the molten pools have formed on both sides of the weld, use the flame
to gently stir the two pools together to form the weld. This also takes a little
practice.

5) After the two pools have joined, slowly move the flame along the weld line,
lengthening the pool using metal from both parts.
A gentle, circular, swirling motion will help mix the molten metal from both sides
as the puddle is lengthened. This process is highly dependent on the materials
and part geometries being welded. Practice, practice, practice to get better
control. Welding sample parts is a good idea.

5) Continue this process until the entire weld line is complete.

7) Once you're done, turn off the flame. Close the oxygen pin valve first, and
then the acetylene valve. Note: Welded parts can remain hot for a LONG time.

Backfiring:

Improper operation of the torch may cause the flame to go out with a loud snap
or pop. This is called backfire. It is caused by one of a few things.
The first thing to do is turn the gas in the torch off, check all the connections and
try relighting the torch. Backfiring can be caused by touching the tip against your
work piece, overheating the tip, operating the torch at other than recommended
gas pressures, by a loose tip or head or by dirt on the seat.

Shutting Down and Cleaning Up:

1) With the flame extinguished and the pin valves closed, close the main valve
on the oxygen tank. It should be firmly seated at the bottom.

2) Open the oxygen pin valve to bleed off all of the oxygen in the regulator and
feed line. Close the pin valve once the feed line pressure has gone to zero.

3) Fully back out the oxygen regulator valve so there is no pressure in the line.
DO NOT close the valve, as this will pressurize the line once the tank is open
again. In the case of the acetylene, if it is pressurized over 15 psi, it may
explode!

4) Repeat steps 1 through 3 for the acetylene line.

15
5) Return all of the tools to their proper storage places and coil the feed lines
around the handle on the gas cylinder cart.
Note: Do not remove the nozzle from the feed line. The feed lines should always
have a nozzle attached to prevent accidental damage to the threads used to
attach the nozzle.

6) Don’t forget to ask for a shop job!

CYLINDERS:

Oxygen and Acetylene are stored under pressure in steel cylinders. They
are sized by the cu ft. of either Oxygen or Acetylene that they hold. Cylinders
should be tested regularly with the date of the last test stamped on the top of the
cylinder. Cylinders should always be secured and used in the upright position.
When a cylinder is not being used, the valve cap should always be in place.

OXYGEN CYLINDERS

These cylinders are made of steel and are usually painted green. They
range in size from less than 20 cu ft. To over 300 cu ft. and contain compressed
Oxygen at pressures that can be as high as 2200 psig. All cylinders have valves
and ( except the small "R" tank ) are fitted with a screw on steel cap that protects
the cylinder valve when the cylinder is not in use. If Oxygen comes into contact
with oil or grease, it will burst into flame. Never use oil or grease on Oxygen
cylinder valves or regulators. Make sure hands and gloves are free of oil and
grease before handling cylinders. Crack open the cylinder valve then close it
before installing the regulator to clear the valve of any dirt. With the regulator
installed, always crack the cylinder valve open first, then open it fully. This will
lessen the chance of recompression which is caused by high cylinder pressure
entering the regulator, heating up and damaging the regulator.

ACETYLENE CYLINDERS:

These cylinders contain Acetylene under pressure, are painted black, (

small "B" and "MC" tanks can be gray, silver or red ) made of steel and have
cylinder valves. They range in size from 10 to almost 400 cu ft capacity. The
cylinders contain a porous filler material which is wetted with acetone that allows
the Acetylene to safely be contained in the cylinder at 250 psig.

16
 Always use an Acetylene cylinder in the upright position so you don't draw
any of the acetone out of the tank. Only open the cylinder valve 1 to 1 1/2 turns,
leaving the valve wrench on the valve in the event it has to be shut off quickly.
Acetylene should never be used at a pressure that exceeds 15 psig as it
becomes highly unstable which, depending on the condition, could cause it to
decompose and explode. As with the Oxygen cylinder, make sure the cylinder
valve is clean before installing the regulator.

With the pressure in a full Acetylene cylinder at 250 psig and a full Oxygen
cylinder at 2200 psig, a way is needed to lower these cylinder pressures to
desired working pressures for use in the torch. This is accomplished by using an
adjustable pressure reducing regulator. The regulator will also maintain a steady
working pressure as the cylinder pressure drops from use.
Basically, regulators work by admitting the high cylinder pressure through a valve
which is operated by a flexible diaphragm. By turning the regulator adjusting
knob or screw in or out causes a spring in the regulator to operate the diaphragm
which opens or closes a valve in the regulator. This in turn regulates the outlet
pressure and flow. By turning the adjusting knob in you increase the flow and
pressure, out decreases the flow and pressure. Most regulators have two
gauges. One shows the inlet pressure from the cylinder (the high pressure
gauge) and the other (low pressure gauge) shows the working pressure being
supplied from the regulator.
There are regulators that are made for heavy duty or rough service that are not
equipped with gauges, (referred to as gauge less) and have a scale in the
regulator body that is used to make pressure adjustments.
There are two general types of regulators, single stage and two stage. Both
perform the same function but the two stage regulator will supply a more
constant pressure as the cylinder pressure falls by compensating for any drop in
cylinder pressure better than will the single stage unit.

17
 Two stage regulators can be identified by their second pressure chamber
where single stage units have only one. Oxygen and Acetylene regulators
connect differently to their cylinders so they cannot be mixed up. Oxygen
regulators have right hand threads and regulators for Acetylene and other fuel
gases have left hand threads. You will notice a groove around fuel connections
which indicate a left handed thread. Finally all outlet (low pressure ) gauges on
Acetylene regulators have their gauge scales marked in red starting at 15 psig.
This is to act as a reminder not to use Acetylene at pressures over 15 psig as
explained in the section on Acetylene cylinders.

WELDING HOSES

The cylinder regulators and torch are usually connected together by

double line rubber hoses. Double line hose is know as type VD. The Oxygen line
is green, the fuel line red. Hoses are available in four sizes, 3/16, 1/4, 3/8 and 1/2
inch I.D. There are different grades of double line hose used for Acetylene. They
are: Non-oil resisting rubber cover

RM- carries both a non-oil and flame and oil resisting cover

(For use with all fuel gases & Acetylene) flame and oil resisting cover.
Grades R & RM should be marked for Acetylene only. Grade T should be marked
fuel gas. All hoses should be marked as to their service level (light, standard or
heavy).

Date of manufacture, maximum working pressure, (200 psig ) nominal I.D

size and if it meets RMA/CGA IP-90 (Rubber Manufactures Association,
Compressed Gas Association ) specifications for rubber welding hose. The
fittings on the hoses are marked as to right and left handed threads. Single line
hose come in three grades, L, light duty, S, standard duty and H, heavy duty.
And are also limited to a working pressure of 200 psig.

18
 For combustion to occur, fuel and Oxygen have to mix. This should only
happen in the torch mixer or the torch tip. Sometimes, due to improper operation,
fuel and Oxygen could feed back into the hoses and cause combustion in the
hoses or regulators. (Not good!) Check valves when installed between the hoses
and torch prevent this back flow as they close if a reverse flow starts. Check
valves should be used with all torches.

FLASH BACK ARRESTORS

 A flashback, which is a rapid high pressure flame in the hose, can occur if there
aren't any check valves or the check valves fail to operate due to improper
installation. Once a flashback starts, check valves cannot stop it, but a flashback
arrestor will!
The arrestor connects the same as the check valves, in the hose at the torch or
regulator and contains a trap that is spring loaded that cuts off the gas flow in the
event of a flashback. Both check valves and flashback arrestors are like they say,
cheap insurance and should be included on every Oxy-Acetylene outfit!

TORCHES

 The torch assembly consists of the handle, oxygen and fuel gas valves and
mixing chamber. Welding tips or a cutting attachment can be used with the
handle allowing it to be used for welding, heating and cutting operations. Oxygen
and fuel gas flow through tubes inside the handle which blend in the mixing
chamber or tip. It is at the tip that the mixed gases are ignited. There are two
basic mixer types, the equal or medium pressure type (also known as balance or
positive pressure type) and the injector type. The equal pressure type is the most
common and is used with fuel gas pressures that are above 1 psi.
Oxygen and fuel gas enter the torch at almost equal pressures. The injector type
is used when fuel gas pressures are less than 1 psi. In this type, Oxygen at high
pressure pulls the fuel gas into the mixing chamber.

19
 WELDING AND CUTTING TIPS

The welding tip is mounted on the end of the torch handle and through it the
oxygen and fuel gas mixture feed the flame. Tips are available in a variety of
shapes and sizes to fit most any welding job and are identified by number.
The larger the number, the larger the hole in the tip and the thicker the metal that
can be welded or cut. Welding tips have one hole and cutting tips have a
centrally located hole with a number of smaller holes located around it in a
circular pattern. The cutting Oxygen comes from the center hole with the preheat
flame coming from the holes around it. Many factors determine the size tip to
use, but mainly the thickness of the metal to be welded or cut determines which
tip size to use. The attachments at the end of this article will serve as a guide to
tip selection .

Safety features incorporated into oxy-acetylene equipment:

The Acetylene tank contains an absorbent substance called Acetone. Acetone can
absorb 25 times its own volume of Acetylene.
Color coding: oxygen cylinder is black and acetylene is maroon, hoses and regulators
are color coded with oxygen as blue and acetylene as red.

The acetylene connection on the torch has a left hand thread and the oxygen
connection has a right hand thread to prevent interchange.

Flashback arrestors are placed on the acetylene and oxygen lines to prevent feedback
of gases.

Regulators are designed to fit only on acetylene or high pressure oxygen cylinders and
cannot be changed.

20
ACTIVITY 1
Direction: Read and answer the given questions. Write your answer on your notebook.

1. Enumerate the disadvantages in using oxyacetylene welding?

2. What are the three types of flame in oxyacetylene welding? How are they
differentiated?
3. What are the two basic torch mixer types?

REMEMBER:
· Oxidizing flame - If there is excess oxygen, the whitish-blue flame will be smaller
than the blue flame. This flame burns hotter. A slightly oxidizing flame is used in brazing,
and a more strongly oxidizing flame is used in welding certain brasses and bronzes.
· Reducing / carburizing flame - If there is excess acetylene, the whitish-blue flame
will be larger than the blue flame. This flame contains white hot-carbon particles, which
may be dissolved during welding. This “reducing” flame will remove oxygen from iron
oxides in steel.
. Neutral - This type of flame is the one you will use most often in the metalwork room.
It is called “neutral” because it has no chemical effect upon the metal during welding. It is
achieved by mixing equal parts oxygen and acetylene and is witnessed in the flame by
adjusting the oxygen flow until the middle blue section and inner whitish-blue parts merge
into a single region.

21
 CHECK YOUR UNDERSTANDING

DIRECTION. True or False

1. Acetylene should never be used at a pressure that exceeds 15 psig as it

becomes highly unstable which, depending on the condition, could cause
it to decompose and explode.

2. The Acetylene tank contains an absorbent substance called Acetone.

Acetone can absorb 25 times its own volume of Acetylene.

3. Regulators are designed to fit only on acetylene or high pressure oxygen

cylinders and cannot be changed.

4. The welding tip is mounted on the end of the torch handle and through it
the oxygen and fuel gas mixture feed the flame. Tips are available in a
variety of shapes and sizes to fit most any welding job and are unidentified
by number.

5. Welding tips have one hole and cutting tips have a centrally located hole
with a number of smaller holes located around it in a circular pattern.

6. Cylinders should always be secured and used in the upright position.

When a cylinder is not being used, the valve cap should always be in
place.

7. Clean the parts to be welded to remove any oil, rust, or other

contaminants. Use a paint brush if needed to remove any rust.

8. Return all of the tools to their proper storage places and coil the feed lines
around the handle on the gas cylinder cart.

9. Oxygen and Acetylene regulators connect differently to their cylinders so

they cannot be mixed up.

10. After welding operations are completed, the welder will mark the hot
metal or provide some other means of warning other workers.

22
 POST TEST

Test I. Multiple Choices: Write the letter only:

1. What are the advantages of Oxy-Acetylene Welding:

a. It's easy to learn.

b. equipment is cheaper than most other types of welding rigs
c. equipment is more portable than most other types of welding rigs
d. equipment can also be used to "flame-cut" large pieces of material.
e. All of the above

2. This type of flame is the one you will use most often in the metalwork room
because it has no chemical effect upon the metal during welding.

a. neutral flame
b. oxidizing flame
c. carburizing flame
d. none of the above

3. The blue flame is divided into three different color regions in oxyacetylene
welding.

a. long yellowish tip

b. blue middle section
c. whitish-blue intense inner section
d. none of the above

4. This is called as the improper operation of the torch that causes the flame to
go out with a loud snap or pop.

a. backfiring
b. test firing
c. open firing
d. none of the above

23
5. These cylinders are made of steel and are usually painted green ranging in
size from less than 20 cu ft. to over 300 cu ft.

a. acetylene cylinder
b. oxygen cylinder
c. gas cylinder
d. none of the above

6. Acetylene should never be used at a pressure that exceeds _________ as it

becomes highly unstable which, depending on the condition, could cause it to
decompose and explode.

a. 11 psi
b. 12 psi
c. 13 psi
d. 15 psi

7. Backfiring in oxyacetylene welding can be caused by touching the,

a. tip against your work piece

b. overheating the tip
c. operating the torch at other than recommended gas pressures
d. a loose tip or head or by dirt on the seat.
e. None of the above

8. When opening an Acetylene bottle, open the valve slowly, no more than
_____ turns.

a. 1
b. 1 1/3
c. 1 1/2
d. 2

24
 9. Oxygen is a _____________ gas.
a. combustible
b. non-combustible
c. flammable
d. explosive
10. In regards to regulators, you should do all of the following EXCEPT:
a. Use for line checks
b. Use to control output pressure
c. Keep petroleum products away
d. Avoid cleaning

DIRECTION. True or False

1. Acetylene should never be used at a pressure that exceeds 15 psig as it becomes

highly unstable which, depending on the condition, could cause it to decompose and
explode.

2. The Acetylene tank contains an absorbent substance called Acetone. Acetone can
absorb 25 times its own volume of Acetylene.

3. Regulators are designed to fit only on acetylene or high pressure oxygen cylinders
and cannot be changed.

4. The welding tip is mounted on the end of the torch handle and through it the oxygen
and fuel gas mixture feed the flame. Tips are available in a variety of shapes and sizes
to fit most any welding job and are unidentified by number.

5. Welding tips have one hole and cutting tips have a centrally located hole with a
number of smaller holes located around it in a circular pattern.

6. Cylinders should always be secured and used in the upright position. When a cylinder
is not being used, the valve cap should always be in place.

7. Clean the parts to be welded to remove any oil, rust, or other contaminants. Use a
paint brush if needed to remove any rust.

25
8. Return all of the tools to their proper storage places and coil the feed lines around the
handle on the gas cylinder cart.

9. Oxygen and Acetylene regulators connect differently to their cylinders so they cannot
be mixed up.

10. After welding operations are completed, the welder will mark the hot metal or
provide some other means of warning other workers.

FILL IN THE BLANKS:

1. The Acetylene tank contains an absorbent substance called ____________.

2. Carbon deposits can build up on the nozzles which interfere with flame quality
and cause ________________________.
3. The oxygen used in OA welding is NOT for ___________________. It contains
contaminants that could be unhealthy if taken in large quantities.
4. Acetylene should never be used at a pressure that exceeds 15 psig as it
becomes highly unstable which, depending on the condition, could cause it to
____________________ and _______________.
5. ___________________________ are placed on the acetylene and oxygen lines
to prevent feedback of gases.
6. _______________________ are designed to fit only on acetylene or high
pressure oxygen cylinders and cannot be changed.
7. If the metal you will be welding is very rusty and is not suitable to be sanded or
removed with a grinder another option to prep the metal is to
___________________ it.
8. _________________________________ is a process that uses a wire
consumable with a wire spool feeding the wire into the weld joint.
9. These cylinders are made of steel and are usually painted _______________.

10. Make sure there is no person or anything flammable in the path of the nozzle.
Use the ______________________ to ignite the acetylene. The flame should be
yellow and will give off a lot of soot.

STRIKER; GREEN; GAS METAL ARC WELDING; BLAST; REGULATORS;

FLASHBACK ARRESTORS; DECOMPOSE AND EXPLODE; HUMAN
CONSUMPTION; BACKFIRING; ACETONE; WELDING; OXY
ACETYLENE WELDING; CYLINDERS; GASES; METALS.

26
References:

Shielded Metal Arc Welding Process (Wikipedia)

American National Standards Institute (ANSI). Safety in Welding, Cutting, and Allied
Processes, Z49.1, available from American Welding Society, 550 N.W. LeJeune Road,
Miami, FL 33126 (phone: 800–443–9353, website: www.aws.org).

American National Standards Institute (ANSI). Practice for Occupational and

Educational Eye and Face Protection, Z87.1, available from ANSI, 11 West 42nd Street,
New York, NY 10036-8002.

Occupational Safety and Health Administration (OSHA). Code of Federal Regulations,

Title 29 Labor, Parts 1910 and 1915, available from U.S. Government Printing Office,
Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250–7954 (phone:
800–321– 6742,website: www.osha.gov).

National Fire Protection Association (NFPA). Standard for Fire Prevention during
Welding, Cutting, and Other Hot Work, 51B, available from National Fire Protection
Association, 1 Batterymarch Park, Quincy, MA 02269–9101 (phone: 800–344–3555,
website: www.nfpa.org).

American Welding Society (AWS). Safety and Health Fact Sheet No. 31, Eye and Face
Protection for Welding and Cutting Operations, available from American Welding
Society, 550 N.W. LeJeune Road, Miami, FL 33126 (phone: 800–443–9353, website:
www.aws.org).

References:

1. ^ "What Is 5S? - Sort, Set In Order, Shine, Standardize, Sustain".

27
2. ^ Gapp, R., Fisher, R., Kobayashi, K. 2008. Implementing 5S within a
Japanese Context: An Integrated Management System, Management Decision.
46(4): 565-579.
3. ^ Ortiz, Chris A. and Park, Murry. 2010. Visual Controls: Applying Visual
Management to the Factory. New York: Productivity Press.
4. ^ Galsworth, Gwendolyn D. 2005. Visual Workplace: Visual Thinking.
Portland, Ore: Visual-Lean Enterprise Press.
5. ^ Greif, Michel. 1989. The Visual Factory: Building Participation through
Shared Information. Cambridge, Massachusetts: Productivity Press.
6. ^ Hirano, Hiroyuki, ed. 1988. JIT Factory Revolution: A Pictorial Guide to
Factory Design of the Future. Cambridge, Massachusetts: Productivity Press.
7. ^ Schonberger, Richard J. 1986. World Class Manufacturing: The Lessons
of Simplicity Applied. New York: Free Press, p. 27.
8. ^ Hirano, Hiroyuki. 1988. JIT Factory Revolution: A Pictorial Guide to
Factory Design of the Future.
9. ^ Hirano, Hiroyuki (1995). 5 Pillars of the Visual Workplace. Cambridge,
Massachusetts: Productivity Press. ISBN 978-1-56327-047-5.
10. ^ Osada, Takashi (1995). The 5S's: Five keys to a Total Quality
Environment. US: Asian Productivity Organization. ISBN 978-9-28331-115-7.
Retrieved July 26, 2017.
11. ^ Bicheno, John (2004). New Lean Toolbox: Towards Fast, Flexible Flow.
Buckingham: PICSIE. ISBN 978-0-9541244-1-0.
12. ^ Managing «modernity»: work, community, and authority in late-
industrializing Japan and Russia, Rudra Sil, Publisher: Ann Arbor, Mich. :
University of Michigan Press, 2002
13. ^ Graban, Mark. 2012. Lean Hospitals: Improving Quality, Patient Safety,
and Employee Engagement. Boca Raton, Fl: CRC Press.
14. ^ "What Is 5S?".
15. ^ Ward, Allen (March 2014). Lean Product and Process
Development (2nd ed.). Cambridge, Massachusetts: Lean Enterprise Institute.
p. 215. ISBN 978-1-934109-43-4.

ACKNOWLEDGEMENT

28
This module was outlined based on the Most Essential Learning Competencies (MELC) for
S.Y. 2020-2021, the K to 12 Basic Education Curriculum Guide, Learning Continuity Plan
(LCP) for Shielded Metal Arc Welding (SMAW) and Training Regulation of TESDA for
Shielded Metal Arc Welding (SMAW) NC I.

DEVELOPMENT TEAM OF THE MODULE

Writer: Elesio P. Tabacon Jr. Head Teacher VI

Raja Soliman Science and Technology High School

Editor: Dr. Ariel D. Tosio, EPS-TLE-TE/VOC

Reviewer/Validator: Dr. Ariel D. Tosio, EPS-TLE-TE/VOC

Illustrator: Elesio P. Tabacon Jr. Head Teacher VI

Raja Soliman Science and Technology High School

Layout Artist: Elesio P. Tabacon Jr. Head Teacher VI

Raja Soliman Science and Technology High School

Management Team: Malcolm S. Gamma, Regional Director

Genia V. Santos, CLMD Chief

Dennis M. Mendoza, Regional EPS in charge of LMS and Regional

ADM Coordinator

Maria Magdalena M. Lim, CESO V, SDS

Aida H. Rondilla, Chief-CID

Lucky S. Carpio, Division EPS In-charge of LRMS and Division ADM

Coordinator

29