Republic of the Philippines

Department of Education
Region X, Misamis Occidental
School Division Misamis Occidental

Detailed Lesson Plan in

SMAW NC-II
Annex 2B.1 to DepEd Order No. 42, s. 2016
School ALORAN TRADE Grade GRADE 10
HIGH SCHOOL Level
Teacher TRECITA P. BACO Learning TVE- SMAW NC-II
Area
Time & 8:00 – 9:00 Quarter 4
Date May 17, 2023

I. OBJECTIVES
A. Content Standards The learner demonstrates an understanding of the
concepts and underlying principles in Shielded
Metal .Arc Welding (SMAW).
B. Performance Standards The learner independently performs Shielded Metal
Arc Welding (SMAW) processes based on market
standards.
C. Learning TLE_IAAW912FW-IIIa-IVj-4
Competencies/
Identify the different welding defects, causes and
Objectives.
remedies;
Mark weld defects for repair in accordance with job
requirements
Appreciate the importance of identifying the
welding defects.
II. CONTENT Weld defects causes and remedies
III.LEARNING
RESOURCES
A. References
1. Teacher’s Guide pages Curriculum Guide/Training Regulation
2. Learner’s Materials SHIELDED METAL ARC WELDING Learner’s
pages Material: Module 1 Page 125-131
3. Textbook pages
4. Additional Materials
from Learning Resource
(LR) portal

B. Other Learning www.goggle.com/ realia

Resources
V. PROCEDURES
Introductory Activity a. Prayer.
Ask somebody to lead a prayer.
b. Greetings
Good morning class!

c. Classroom management.
Tell the students to pick-up pieces of papers
under their chair and arrange their table
also. Remind the students to maintain one
(1) meter physical distance.
d. Checking of Attendance.
Ask the students” Who are absent?”

e. Review of the previous activity.

Yesterday we took up on perform stringer
beads in horizontal position (2F). What is the
first thing to do in performing 2f horizontal
position?
How many beads to be welded in horizontal
position (2F)?
f. Motivation.

(see the
picture thru power point presentation and observe
what happen)

This picture represents the defects of a welded

metal.

1. What happen to the welded metal?

2. Why does the base metal have a defects?
What are some causes of that defect?
3. Do you want it to happen to your output or
your work as a welder? Why?
 Yes, that’s right!

4A’s/Lecture-Demonstration/ Collaborative
Learning
Activity
Activity:
(Group the students into two group groups. Provide
each group with the welded metal and let them
identify the defects.)
From the welded metal you are holding identify
what are the defects of that particular metal.
(The teacher tests the learning of the student if they
know how to identify the defects of the welded
metal.)
The students will report what they have observed.
Analysis Ask questions:
1. Why is it, that there is a defect in the weld
bead?
2. What would you do to avoid weld defects
(Show a picture to the students through power
point welding defects)

Ask questions:
1. What did you see in the picture?
2. Do you think that this output follow the
correct welding techniques?
3. How did that welder weld that metal?

Abstraction
Welding defects are generated in a welding job due
to the faulty or poor technique.
Welding defects are broadly classified into two
categories, and these are :

1. External Welding Defects

- Occur on the upper surface of the welded
work.
2. Internal welding defects
 - Occur under the surface of welded work.

1. EXTERNAL DEFECTS

1. WELD CRACK
This is the most unwanted defect of all the
other welding defects.

Crack can also appear at different

temperatures:

a. Hot crack- it may happen during welding

and includes cracking during the
solidification of weld metal
b. Cold crack- type of crack occurs at the end
of the welding process where the
temperature is quite low. Sometimes cold
crack Is visible in several hours after welding
or even after few days.
Causes of weld cracks
1. Poor ductility of the given base metal
2. The presence of residual stress can cause
crack on weld metal.

Remedies for weld crack:

1. Using appropriate materials may decrease
the chances of crack.
2. Preheating the weld and reducing the cooling
speed helps in reducing crack
3. Reduce the gap between the weld joints by
using reasonable weld joints.
2. UNDERCUT
When the base metal melts away from the weld
zone, then a groove is formed in the shape of a
notch, then his type of defect is known as
undercut.

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 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 of 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.

3. SPATTER
When some metal drops are expelled from
the weld 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.

4. POROSITY
Refers to small cavities or holes resulting
from gas pockets in weld metal

Causes of porosity:
1. It occurs when the electrode is not coated
properly.
2. Using a longer arc may also increase its
chances.
3. Increase welding current
4. Rust or oil on 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 the rust or oil from the surface and
use a proper technique.
5. 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. Using large electrodes this defect may occur
3. High welding current.
REMEDIES FOR OVERLAP:
1. Use a proper technique for welding.
2. Use small electrode
3. Less welding current
6. DISTORTION
Means contraction of weld metal during
welding that forces base metal to move.

CAUSES OF DISTORION
1. A great number passes with small diameter
electrodes
2. Slow arc travel
3. High residual stresses in plate to be welded.
4. Using improper welding sequences.
7. BURN-THROUGH
Refers to weld metal melting completely
through base metal resulting in holes where
no metal remains.

CAUSE OF BURN-THROUGH
1. Excessive heat input
REMEDIES OF BURN-THROUGH
1. Select lower amperage. Use smaller electrode
2. Increase and/ or maintain steady travel
speed.
 INTERNAL WELDING DEFECTS
1. SLAG INCLUSION
If there is any slag in the weld, then it
affects the toughness and weldability of the
material. This decreases the structural
performance of the weld material. Slag is formed
on the surface of the weld or between the
welding turns.

CAUSES OF SLAG
1. Slag is formed if the welding current density
is very small.
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 they also slag may form.
4. Improper welding angle and travel rate of
welding electrode.

REMEDIES OF SLAG
1. Increase the current density. Adjust the
welding speed so that the slag and weld pool
do not mix with each other.
2. Clean the weld edges and remove the slags
or previous weld layers.
3. Have a proper electrode angle and travel
rate.

2. 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.

CAUSE OF INCOMPLETE FUSION

1. It occurs because of the heat input.
2. When the weld pool is very large and runs
ahead of the arc.
3. When the angle of the joint is too low
4. Incorrect electrode and torch angle may also
lead to incomplete fusion.
5. Improper bead position.
REMEDIES FOR INCOMPLETE FUSION
 1. Increasing the welding current and
decreasing the travel speed helps in
removing the chances of incomplete fusion.
2. Reducing the deposition rate.
3. Increasing the joint angle.
4. Try to position the electrode and torch angle
properly so that the edges of the plate melt
away.
3. 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 INCOMPLETE FILLED

GROOVE
1. Less deposition of the weld metal.
2. Use of improper size of the electrode.
3. Improper welding technique.

REMEDIES OF INCOMPLETE FILLED GROOVE

1. More deposition of the weld metal
2. Us a proper size of the electrode.
3. By using a proper welding technique.

Application “You can do it”

(Group the students into two groups
(The students will be given a welded steel
plates they will going to locate and mark the
defects on that plates. They will be using chalk
stone to mark defect)
Generalization From choosing the proper welding technique to
ensuring adequate implementation of the process,
welding can be a complex craft. Welding
defects can affect your product’s quality and,
ultimately, your business performance. Therefore,
it is vital to understand the various types of
welding defects, their causes, and how you can
prevent them.

Assessment Multiple choice

Direction: choose the letter that corresponds to the
correct answer.
1. Which of the following defects occur when
weld metal layer fails to fuse together?
a. Inclusion of slag
b. Inadequate penetration
c. Incomplete fusion
d. Porosity
Answer: c
2. Which of the following defects occur due to
scattering of metal around the vicinity of
weld?
a. Undercut
b. Spatter
c. Cracking in weld metal
d. Cold cracking
Answer: b
3. Which of the following defects occur due to
incorrect welding techniques?
a. Undercut
b. Hot cracking
c. Cracking in weld metal
d. Cold cracking
Answer: c.
4. Which of the following defects is influenced
by Sulphur and carbon content of weld
metals?
a. Under cut
b. Hot cracking
c. Cracking in weld metal
d. Cold cracking
Answer: b
5. Which of the following defects occur at a
lower temperature?
a. Undercut
b. Hot cracking
c. Cracking in weld metal
d. Cold cracking
Answer: d
6. Which of the following defects occur only in
the butt welds where the groove of the metal
is not filled completely.
a. Undercut
b. Hot cracking
c. cold cracking
d. Incomplete penetration
Answer: d
7. Refers to weld metal melting completely
through base metal resulting in holes where
 nometal remains.
a.Burn-through
b.Hot cracking
c.Cold cracking
d.Incomplete fusion
Answer: a
8. Which of the following defect occurs on the
surface of the weld or between the welding
turns.
a. Slag inclusion
b. Hot cracking
c. Incomplete fusion
d. Burn-through
Answer: a
9. Which of the following defects occurs when
contraction of weld metal during welding
that forces base metal to move.
a. Incomplete fusion
b. Porosity
c. Spatter
d. Distortion
Answer: d
10. Which of the following defects occurs when
the electrode is not coated properly.
a. Spatter
b. Distortion
c. Porosity
d. Incomplete penetration
Answer: c
Assignment/Agreement Bring extra t-shirt tomorrow for your actual
performance in repair welds on close butt-joint
horizontal position.

Prepared by:

TRECITA P. BACO
STUDENT TEACHER

Checked by:

ANTONIO S. SANTOS
TEACHER 1

Approved:

ANTONIO S. SANTOS
TEACHER 1