MATSW301 Perform SMAW on mild steel

Competence

RQF Level: 3 Learning Hours

120
Credits: 12

Sector: MANUFACTURING AND MINING

Trade: MANUFACTURING TECHNOLOGY

Module Type: Specific

Curriculum: MAMMT3001- TVET Certificate 3 in Manufacturing Technology

Copyright: © Rwanda TVET Board, 2022

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Elements of Performance criteria
competency

1. Prepare for 1.1. Safety ,Health , Environment and security measures are effectively applied at
SMAW work place
operation
1.2. SMAW Equipment, tools and materials are properly selected according to
the work to be performed

1.3. Pre-operation checking of SMAW equipment is correctly conducted refer to

the manual guide

2. Apply SMAW 2.1. Technical drawing is correctly interpreted according to the product
on mild steel

2.2. Work pieces are properly prepared according to the product specifications

2.3. SMAW machine is accurately set based on the work to be done

2.4. Work pieces are correctly welded according to the drawing and SMAW
welding positions

2.5. Final product is correctly finished according to the SMAW welding

procedures

3. Perform post- 3.1. SMAW equipment are properly cleaned and stored according to the
operation machine operational manual
activities
3.2. Workplace is correctly cleaned according to the hygiene and safety
conditions

3.3. Performed work is correctly handed over as per reporting procedures

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LO.1: Prepare for SMAW operation
1.1. Introduction to SMAW
Description of SMAW
Welding is a process for joining two similar or dissimilar metals by fusion, with or without the
application of pressure and with or without the use of filler metal. The fusion of metal takes place by
means of heat. The heat may be generated either from electric arc, electric resistance, combustion of gases
or by chemical reaction.
Shielded Metal Arc Welding (SMAW) is an arc welding process in which the fusing of metals is
produced by heat from an electric arc that is maintained between the tip of a consumable covered
electrode and the surface of the base metal in the joint being welded.
Shielded Metal Arc welding is one of the most widely used welding processes, particularly for short
welds in production, maintenance, and repair work and for field construction.
Some metals are easier to weld than others. To compare this ease in welding, term ‘weldability’ is often
used. The weldability may be defined as property of a metal which indicates the ease with which it can be
welded with other similar or dissimilar metals.
Other joining methods
Bolting: it is the temporally metal joining process in which two or more pieces may be fixed together by
means of bolts and nuts.
Seaming: is a metal working process that uses a similar process of rolling sheet metal over and onto
itself, except it uses a seam to join two layers. With seaming, the edge of sheet metal is folded but doesn’t
sit flush. Rather, the two layers of the folded sheet are joined using a seam.
Riveting: is a forging process that may be used to join parts together by way of a metal part called a rivet.
The rivet acts to join the parts through adjacent surfaces. A straight metal piece is connected through the
parts. Then both ends are formed over the connection, joining the parts securely. Rivet is used to connect
two or more plates inserted through the hole in plates and pressed on the other side.
Soldering: This joint is made on thin metals using solder as a joining medium. The melting point of
solder is less than the metals to be joined. The joint can be opened by heating up to the solder melting
temperature (below 400°C).
Brazing: The joint is similar to soldering but has more strength. The joining medium used is brass, which
has a higher melting temperature than solder. The joint can also be opened by heating up to the melting
point of brass (850-950°C).

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Welding principles
The shielded metal arc welding process is basically a manually operated process. The electrode is
clamped in an electrode holder and the welder manipulates the tip of the electrode in relation to the metal
being welded.
The welder strikes, maintains, and stops the arc manually. The welding begins when the welder initiates
the arc by momentarily touching the electrode to the base metal, which completes the electrical circuit.
The welder guides the electrode manually, controlling both the travel speed and the direction of travel.
The welder maintains the arc by controlling the distance between the work material and the tip of the
electrode (length of the arc).
Some types of electrodes can be dragged along the surface of the work so that the coating thickness
controls the arc length, which controls the voltage. The heat of the arc melts the surface of the base metal
and forms a molten weld puddle. The melted electrode metal is transferred across the arc and becomes the
deposited weld metal. The deposit is covered by a slag produced by components in the electrode coating.
The arc is enveloped in a gas shield provided by the disintegration of some of the ingredients of the
electrode coating. Most of the electrode core wire is transferred across the arc, but small particles escape
from the weld area as spatter, and a very small portion leaves the welding area as smoke.
Advantages and disadvantages of SMAW Process

Advantages
1. Shielded metal arc welding is widely used
because of its versatility, portability, and
comparatively simple and inexpensive equipment.
In addition, it does not require
auxiliary gas shielding or granular flux.
2. Shielded Metal Arc Welding (SMAW) can be
carried out in any position with highest weld
quality.
3. SMAW is the simplest of all the arc welding
processes.
4. This welding process finds innumerable
applications, because of the availability of a
wide variety of electrodes.
5. Big range of metals and their alloys can be
welded easily.
6. The process can be very well employed for
hard facing and metal resistance etc.
7. Joints (e.g., between nozzles and shell in a
pressure vessel) which because of their positions
are difficult to be welded by automatic welding
machines can be easily accomplished by
shielded metal arc welding process.
8. The SMAW welding equipment is portable and
the cost is fairly low
Disadvantages
1. Due to flux coated electrodes, the chances of
slag entrapment and other related defects are more
as compared to MIG and TIG welding.
2. Due to fumes and particles of slag, the arc and
metal transfer is not very clear and thus welding
control in this process is a bit difficult as
compared to MIG welding.
3. Due to limited length of each electrode and
brittle flux coating on it, mechanization is
difficult.
4. In welding long joints (e.g., in pressure
vessels), as one electrode finishes, the weld is to
be progressed with the next electrode. Unless
properly cared, a defect (like slag inclusion or
insufficient penetration) may occur at the place
where welding is restarted with the new
electrode
5. The process uses stick electrodes and thus it is
slower as compared to MIG welding.

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Application of SMAW
1) Today, almost all the commonly employed metals and their alloys can be welded by this process.
2) Shielded metal arc welding is used both as a fabrication process and for maintenance and repair jobs.
3) The process finds applications in:

➢ Building and Bridge construction

➢ Automotive and aircraft industry, etc.

➢ Air receiver, tank, boiler and pressure vessel fabrication

➢ Ship building, Pipes and Penstock joining

1.2. Identification of safety and security measures

Hazards: A Hazard is a potential source of harm or adverse health effect on a person or persons.
During arc welding the welder is exposed to hazards such injury due to harmful rays (ultra violet and
infrared rays) of the arc, burns due to excessive heat from the arc and contact with hot jobs, electric
shock, toxic fumes, flying hot spatters and slag particles and objects falling on the feet.
Types of hazards in working place
i. Physical: A physical hazard is an agent, factor or circumstance that can cause harm with or without
contact. They can be classified as type of occupational hazard or environmental hazard. Physical hazards
include ergonomic hazards, radiation, heat and cold stress, vibration hazards, and noise hazards.
ii. Chemical: A chemical hazard is a type of occupational hazard caused by exposure to chemicals in the
workplace. Exposure to chemicals in the workplace can cause acute or long-term detrimental health
effects.
iii. Biological: Biological hazards, also known as biohazards, refer to biological substances that pose a
threat to the health of living organisms, primarily that of humans. This can include samples of a
microorganism, virus or toxin that can affect human health. It can also include substances harmful to
other animals.
iv. Electrical: An electrical hazard is a dangerous condition where a worker can or does make electrical
contact with energized equipment or a conductor.
The following safety apparels and accessories are used to protect the welder and other persons working
near the welding area from the above-mentioned hazards.
1. Safety apparels
a. Leather apron
b. Leather gloves
c. Leather cape with sleeves
d. Industrial safety shoes.

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they are used to protect the body, hands, arms, neck and chest of the welder from the heat radiation and
hot spatters from the arc and also from the hot slag particles flying from the weld joint during chipping
off the solidified slag.
2. Hand screen
a. Adjustable helmet: These are used to protect the eyes and face of a welder from arc radiation
and sparks during arc welding. A hand screen is designed to hold in hand A helmet screen is designed to
wear on the head. It provides better protection and allows the welder to use his both hands freely.
b. Portable fire proof canvas screens: are used to protect the persons who work near the welding
area from arc flashes.
Recommendation of filter glasses for manual metal arc welding

Shade No. of colored glass Range of welding current in amperes

8-9 Up to 100
10-11 100 to 300
12-14 Above 300

3. Chipping/ grinding goggles

4. Respirator and exhaust ducting
1.3. Selection of materials, tools and equipment
Materials
Mild steel is a type of carbon steel that contains a low level of carbon. Otherwise known as low carbon
steel, mild steel contains roughly 0.05% and 0.25% of carbon weight.
Some properties of mild steel include: ductility, machinability, weldability, magnetic, affordable.
uses of mild steel include structural steel, gates and fencing, machinery parts, pipelines.

i. Sheet metals: are metals formed by an industrial process into thin, flat pieces. Sheet metal is one of the
fundamental forms used in metalworking and it can be cut and bent into a variety of shapes.

The sizes are available in 1225mmx244mmx1mm, 1200mmx2400mmx1.25mm and

1200mmx2400mmx2mm length x width x thickness respectively.

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ii. Steel Tubes: those are the steel tubes available in variety of shapes and sizes. There exist square steel
Tubes having (20x20x6000x2), (30x30x6000x2), (40x40x6000x2), (40x60x6000x2) mm side x side x
length x thickness respectively.

iii. Round bar: are the mild steel bar which are available in the form of round shapes.
There is mild steel round bar available in (25x6000) mm diameter x length respectively. There is also
mild steel round bar available in (30x6000) mm diameter x length respectively.

iv. Profiles: steel bottle profiles are the metal that obtained in the form of bottle, having 6000mm length.

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v. Iron Tee: are the metal obtained in the form of Tee-shape, there are also known as T bar and has
6000mm length.

vi. Angle iron: are the metal bar obtained in the form of right angle or L-shapes.
There are available with the sizes of (50x50x3x6000) mm side x side x thickness x length respectively.
And with the sizes of (100x100x8x6000) mm side x side x thickness x length respectively.

vii. Flat bar: are the bars which are obtained in the form of flat shapes with the sizes of (50x6x6000) mm
width x thickness x length respectively.

viii. Square bar: Square bar is a type of bar obtained in the form of square bar. it has 6000mm long.

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ix. Pipes: are the hollow round metals which can be used in fluid conveyance and/or used in industrial
pipelines. They may be available in (50x3x6000) mm diameter x thickness x length respectively. The
Seamless pipe are also available in 3/4’’, 2mm Thickness and 6000mm length.

Mild steel welding electrodes

Electrode sizes
The electrode size refers to the diameter of its core wire. Each electrode has a certain current range. The
welding current increases with the electrode size (diameter).

Electrode size in mm Currents range in Amps

1.6 10-50
2.0 60-80
2.6 80-90
3.2 90-120
4.0 120-160
5.0 160-220
6.3 220-250

Standard length of electrodes

The electrodes are manufactured in two different lengths, 350 or 450mm.
Functions of an electrode in shielded metal arc welding (SMAW)
There are two main functions of an electrode in shielded metal arc welding:
- The core wire conducts the electric current from the electrode holder to the base metal through the arc.
- It deposits weld metal across the arc onto the base metal.

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Factors for selecting electrodes
1. Type of metal
2. Metal thickness
3. Groove design
4. Joint alignment
5. Available welding current
6. Welder skill
7. Deposition rate
8. Welding position
9. Depth of penetration
10. Weld bead finish
11. Additional metal properties

Function of flux coating

Flux: A material applied to the workpiece(s) before or during joining or surfacing to cause interactions
that remove oxides and other contaminants, improve wetting, and affect the final surface profile
During welding with the heat of the arc, the electrode coating melts and performs the following functions:
1) It stabilizes the arc
2) It forms a gaseous shield around the arc which protects the molten weld pool from atmospheric
contamination
3) It helps in easy arc striking
4) It helps in maintaining proper arc gap
5) It helps to give good appearance and penetration to the weld
6) It makes the welding in all positions easy.
7) Improve mechanical and chemical properties of the weld by adding alloying elements to the weld metal

Identification of Electrodes
For easy identification and selection of a suitable arc welding electrode for welding mild steel plates, the
electrodes are coded by Bureau of Indian Standards (B.I.S). According to the B.I.S., the electrodes to be
used for welding mild steel for training a beginner is coded as ER4211.
The classification for the electrode ER4211 is given below for easy understanding:
E = Flux coated or covered electrode
R = Type of flux covering (Rutile)
4 = Strength of the joint (UTS = 410-510 N/nm2 and YS = 330N/nm2 min.
2 = Elongation and impact properties of the weld
(Elongation = 22% min. and impact = 47 J min. at 0°C)
1 = Welding position (all position) welding can be done in all positions
1 = Welding current and voltage conditions. This means that for DC welding, the electrode can be
connected to the + ve or – ve terminal. For AC welding, the open circuit voltage should be 50 volts.

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AWS Classifications
The prefix "E" designates an arc welding electrode. The first two digits of a 4-digit number and the first
three digits of 5-digit number indicate minimum tensile strength. For example, E6010 is a 60,000 psi
tensile strength electrode while E10018 designates a 100,000 psi tensile strength electrode.

E 60 1 10
Electrode Tensile Strength Position Type of Coating and Current
The next to last digit indicates position. The "1" designates an all position electrode, "2" is for flat and
horizontal positions only; while "4" indicates an electrode that can be used for flat, horizontal, vertical
down and overhead. The last 2 digits taken together indicate the type of coating and the correct polarity or
current to use.
E6010: DC only and designed for putting the root bead on the inside of a piece of pipe, this is the most
penetrating arc of all. It is tops to dig through rust, oil, paint or dirt. It is an all-position electrode that
beginning welders usually find extremely difficult, but is loved by pipeline welders worldwide.
E6011: This electrode is used for all-position AC welding or for welding on rusty, dirty, less than new
metal. It has a deep, penetrating arc and is often the first choice for repair or maintenance work when DC
is unavailable.
E6013: This all-position, AC electrode is used for welding clean, new sheet metal. Its soft arc has
minimal spatter, moderate penetration and an easy-to-clean slag.
E7018: A low-hydrogen, usually DC, all-position electrode used when quality is an issue or for hard-to-
weld metals. It has the capability of producing more uniform weld metal, which has better impact
properties at temperatures below zero.
E7024: Typically used to make a large weld downhand with AC in plate that is at least ¼" thick, but more
commonly used for plate that is ½" and up.

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Types of electrodes
Electric arc welding electrodes are of generally following three types:
(i) Carbon electrodes
(ii) Bare electrodes
(iii) Flux coated electrodes
Carbon electrodes are used in the carbon arc welding process. The arc is created between the carbon
electrode and the job. The arc melts a small pool in the job and filler metal is added by using a separate
rod.

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Bare electrodes are also used in some arc welding processes. An inert gas is used to shield the molten
weld metal and prevent it from absorbing oxygen and nitrogen. Filler metal is separately added through a
filler rod. Usually tungsten is used as one of the bare wire electrodes. In CO2 welding and submerged arc
welding processes the mild steel bare wire electrode is also used as a filler wire.

Flux coated electrodes are used in the manual metal arc welding process for welding ferrous and non-
ferrous metals. The composition of coating provides the flux, the protective shield around the arc and a
protective slag which forms over the deposited weld metal during cooling.

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TOOLS
1. Shears or snips: are scissor like tools for cutting metal such as wire and sheet metal. Regular snips do
all their work by the force applied by the operator. They are useful for cutting thin metal. Aviation or
compound snips have compound handles that increase leverage for cutting heavier stock.

2. Angle grinder, also known as a side grinder or disc grinder, is a handheld power tool used for grinding
(abrasive cutting) and polishing. Although developed originally as tools for rigid abrasive discs, the
availability of an interchangeable power source has encouraged their use with a wide variety of cutters
and attachments.

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There are many different kinds of discs that are used for various materials and tasks, such as cut-off discs
(diamond blade), abrasive grinding discs, grinding stones, sanding discs, wire brush wheels and polishing
pads.
3. Screw drivers: A hand tool for turning a screw, consisting of a handle attached to a long, narrow
shank, usually of metal, which tapers and flattens out to a tip that fits into the slotted head of a screw.

4. Chipping Hammer is a welding tool used to remove the slag from the weld bead.

5. Wire Brush is used for cleaning the working surface prior to welding and general cleaning of the
weldment.

6. Tongs: are a type of tool used to grip and lift objects instead of holding them directly with hands.
There are many forms of tongs adapted to their specific use. Some are merely large pincers or nippers.

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Equipment and accessories
1. Welding machines
i. DC machine: DC welding machines use a direct current (DC) power supply to produce an electric arc
for welding. DC welding machines are typically used for welding thicker materials such as pipes and
structural steel and are ideal for applications that require a deeper penetration.

This type of machine also gives the least voltage ripple and produces the smoothest arc of the static type
welding machines. It automatically monitors output voltage and makes required changes to compensate
for line voltage fluctuation.
ii. AC machine: AC welding machines use an alternating current (AC) power supply to produce an
electric arc for welding. AC welding machines are typically used for welding thinner materials such as
sheet metal and are ideal for applications that require a shallow penetration.

iii. AC/DC machine: An AC/DC welding machine can use both AC and DC power supplies to produce
an electric arc for welding. This type of machine is versatile and can be used for a variety of applications,
from welding thin materials to thick materials.

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iv. Welding generator: A welding generator is a type of welding machine that also functions as a
generator. It typically uses a gasoline or diesel engine to generate both electricity and welding power.
Welding generators are portable and can be used in remote locations where there is no access to electrical
power.

Generator welding machines can provide both AC and DC power; an alternator welding machine is an
electric generator that produces AC power. This power source has a rotating assembly. These machines
are also called rotating or revolving field machines.

Table comparing AC transformers and DC generators used in Shielded Metal Arc

Welding (SMAW) process:
Characteristics AC Transformer DC Generator

Power Supply Alternating Current (AC) Direct Current (DC)

Output Voltage Less stable, fluctuates with input More stable, constant output

Electrode Polarity Alternating Current (AC) can be used for Direct Current (DC) can be used for
both polarities either straight or reverse polarity
Welding Speed Slower compared to DC Faster compared to AC

Weld Quality AC welding produces a wider and DC welding produces a deeper and
shallower penetration compared to DC narrower penetration compared to AC
welding welding
Electrode More electrode consumption compared to Less electrode consumption compared to
Consumption DC AC

In summary, while AC transformers and DC generators can both be used for the SMAW
process, they have some distinct differences in terms of their power supply, output voltage
stability, electrode polarity, welding speed, weld quality, and electrode consumption.

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The table below also shows the difference between above welding machines:

Features AC Welding DC Welding AC/DC Welding Welding

Machine Machine Machine Generator
Power Source Alternating Current Direct Current (DC) Both AC & DC Engine-driven
(AC) AC/DC
Voltage Typically ranges from Typically ranges Can output both AC Ranges vary
Output 60-80 volts from 20-40 volts & DC, voltage ranges depending on the
vary depending on model
the model
Polarity Changes polarity at 60 Can be set to have Can switch between Can switch
times per second either a negative or positive, negative, between positive,
positive polarity, and alternating negative, and
depending on the current alternating current
electrode being used
Welding Smooth and Produces a stable Combines the Good for outdoor
Output consistent, good for arc and better suited benefits of both AC use, and can be
welding thinner for welding thicker and DC welding, used for
metals materials, deep allowing for emergency repairs
penetration welds, flexibility in welding or in remote areas
and overhead a variety of materials where power is not
welding and thicknesses available
Electrode Best used with AC Best used with DC Can use both AC and Can use both AC
Compatibility compatible electrodes compatible DC compatible and DC
electrodes electrodes compatible
electrodes
Welding Good for welding thin Ideal for welding Provides the most Provides reliable
Performance materials, but less thicker materials flexibility, with the power and can be
effective on thicker and provides deeper ability to weld a wide used in a variety of
metals penetration, but not variety of materials welding situations
as effective on and thicknesses
thinner materials
Cost Generally the most More expensive Can be more Most expensive
affordable option than AC welding expensive than AC or option, due to its
machines DC welding versatility and
machines portability
Applications Best suited for Ideal for welding Best suited for Ideal for outdoor
welding thin materials thicker materials welding a variety of use, emergency
like aluminum, and like steel, cast iron, materials, including repairs, and in
for use in low and stainless steel, aluminum, steel, and remote locations
amperage situations, and for use in cast iron, and for use where power is not
such as hobby industrial in industrial or available
welding or welding in applications commercial settings
small workshops

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2. Electrode dry oven
Electrode dry oven is a high quality welding rod heater made of stainless steel enabling it to be used in
tough environments for drying electrodes for the purpose of removing and/or preventing moistures or
wetness in electrodes coatings.
Below is the example type of electrode dry oven. This is HP6 type dry oven, it has a variable thermostat
(30–110°C) and an indicator lamp that indicates that the quiver is plugged in. The heater inside the HP6 is
located in the middle to obtain excellent heating result on all welding rods. It is insulated all around to
keep the heat inside the welding rod heater which also makes it safe and energy efficient.

3. Fume extractor
Welding fume extractor is a piece of equipment used to remove welding fume created when working with
metals used in welding applications. Metal fumes created during welding process is carcinogenic and can
have dangerous long term effects if not properly removed from breathing zone.
Fume extraction welding guns are efficient in removing harmful welding fumes directly at its source
without affecting the protective gas shield. In these types of guns, a vacuum is integrated at the front
nozzle and suctions the fumes through a hose to a filtration system to catch harmful particles.

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4. work bench
A welding table is a platform that it works like a workbench. You use it when you are working in metal
fabrication with welding. It is very useful because it gives the welder a stable place to work and also can
provide assistance with both squaring and measuring. No matter what size they are, all welding tables are
made of steel that is capable of withstanding the intense heat that comes from welding.

5. Welding cables
The welding cables and connectors connect the power source to the electrode holder and to the work.
These cables are normally made of copper or aluminum. The cable that connects the work to the power
source is called the work lead. The work leads are usually connected to the work by pincher clamps or a
bolt. The cable that connects the electrode holder to the power source is called the electrode lead.
6. Electrode holder: An electrode holder, commonly called a stinger, is a clamping device for holding
the electrode securely in any position. The welding cable attaches to the holder through the hollow
insulated handle. The design of the electrode holder permits quick and easy electrode exchange.
7. Earth clamp: A good ground clamp is essential to produce quality welds. Without proper grounding,
the circuit voltage fails to produce enough heat for proper welding, and there is the possibility of damage
to the welding machine and cables. Three basic methods are used to ground a welding machine. You can
fasten the ground cable to the workbench with a C-clamp; attach a spring-loaded clamp directly onto the
workpiece, or bolt or tack-weld the end of the ground cable to the welding bench. The third way creates a
permanent common ground.
1.4. Setting up of SMAW equipment
Power supply

 Single phase supply requires two wires (one phase and one neutral) for completing the circuit. And
the supplies voltage up to 230V. Some types of electrodes operate successfully only with direct
current power. A method of supplying direct current power to the arc without using a rotating
generator is adding a rectifier, an electrical device which changes alternating current into direct
current.
 Two phase power means that the rated voltage of the electrical appliance is 380V, and it needs to be
connected to two phase wires, that is, two live wires.

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 Three phase supply requires three wires and one neutral wire for completing circuit. And the supply
carries the voltage up to 415V. Three phase source provide DC welding current to the arc.

Open circuit voltage and arc voltage

After switching on the welding machine, when there is no arc created/ struck between the electrode tip
and the base metal then the voltage “V” shown by the voltmeter in the circuit is called “Open circuit
voltage”.
After switching on the welding machine, if the arc is struck/ created between the tip of the electrode and
the base metal then the voltage “V” shown by the voltmeter in the circuit is called “Arc voltage”.
The value of this arc voltage will vary from 18V to 55V depending on the type of machine.
Polarity in dc arc welding
Importance of polarity in welding
In DC welding 2/3 of the heat liberated from the positive end and 1/3 from the negative end. To have this
advantage of unequal heat distribution in the electrode and base metal, the polarity is an important factor
for successful welding.
In AC, the polarity cannot be utilized as the power source changes its poles frequently.
Kinds of polarity are two:
- Straight polarity or electrode negative (DCEN).
- Reverse polarity or electrode positive (DCEP).
I. Straight polarity (DCEN)
In straight polarity the electrode is connected to the negative and the work to the positive terminal of the
power source.
Straight polarity is used for:
- welding with bare light coated and medium coated electrodes
- welding the thicker sections in down hand position to obtain more base metal fusion and penetration.
ii. Reverse polarity (DCEP)
In reverse polarity the electrode is connected to the positive and the work to the negative terminal of the
power source.
Reverse polarity is used for:
- welding of non-ferrous metals
- welding of cast iron
- welding with heavy and super heavy coated electrodes
- welding in horizontal, vertical and overhead positions
- sheet metal welding.

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LO.2. Apply SMAW on mild steel
2.1. Welding symbols
Like other aspects of drafting, there’s a set of symbols for welding to simplify the communication
between designer and builder.

When the weld symbol hangs below the reference line, it indicates that the weld must be performed on the
"arrow side" of the joint.

If the weld symbol appears on top of the reference line, then the weld should be made on the opposite side
of the joint where the arrow point.

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Other base symbol

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2.2. Preparation of the work piece
Edge preparation
a. Types of edge shapes:
i. V-shape (single V butt)
The single V butt joint has a 45° weld prepared on one side of each plate the full depth of the material.

ii. X-shape (Double-V)

Both ends of each plate have a 45° bevel cut out meeting halfway through the plate to form a point. When
joined together, the points meet.

iii. K-shapes (Double sided bevel)

One plate has no weld prep, keeping its corners square. The other side has two 45° bevels finishing along
the middle to make a point.

iv. Y-shape (Square V butt broad root face)

Similar to the single V butt, this weld preparation has a 45° angle on one side of each plate from the top
of metal to no more than ¾ of the way down the plate depth, leaving a section of material below.

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v. U-shape (Single U butt)
Both plates have a corner cut out in a ¼ moon shape about ¾ of the plate gauge deep to form a U partway
through the joined sections, as the symbol shows.

vi. J-shape (single J butt)

One plate has a square end, while the other has a corner cut out in a ¼ moon shape partway through the
plate thickness, forming a mild J when joined, as you can see in the symbol.

b. Advantages of edge preparation

➢ Edge preparation makes it easier to get a stronger bond via Welding and adding filler metal.
➢ Edge preparation provides access for the Welding operation.
➢ It provides an area where some filler metal can be added.
➢ This makes the weld/joint very strong and can be subjected to greater amount of load

c. Disadvantages of edge preparation

➢ Sharped workpieces can cause accident like injuries, even death.

➢ During edge preparation it requires experiences for doing it.
➢ Poor edge preparation may cause welding defects and/or poor weldment on edges

Edge preparation are applied in industries for several applications such as:
i. welding heavy equipment manufacturing industry
ii. welding industrial piping.
iii. welding of thick plates in industries.
iv. Maintenance and bridges fabrication.

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2.3. Applying of SMAW
Groove welds: After learning to start and hold an arc, practice running beads of weld metal on flat plates
using a full electrode. Hold the electrode nearly perpendicular to the work, although tilting it ahead (in the
direction of travel) will be helpful.

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Basic welding joints
Welds are made at the junction of the various pieces that make up the weldment. The junctions of parts,
or joints, are defined as the location where two or more members are to be joined.

The basic types of welding joints are listed below:

1. Butt Joint
is the joint in which two metal pieces are joined in the same plane. It is the most common, easy and
affordable method. The most disadvantages of this type of joint is the Chances of porosity and age
preparation is required. Butt joints are used in pipes, valves, flanges and fitting.
2. Corner Joint
are the joints formed by placing corner at right angle to each other. It is the most popular technic, strong
and variety of welds are formed. It has the chances of increase wear and tear in corner joint. Use for
boxes, box frame and other similar fabrication.
3. Edge joint: is the joint formed by welding the edge of part together. No filler materials and preparation
are required for this type of joint. It is rarely used and it has the chance of causing incomplete penetration.
It is used in aerospace repairing, gas tanks and assembly housing.
4. Lap joint: is the joint in which two workpieces are placed to each other, i.e. overlapped. It is easy,
quick, less risk and have stronger weld. One sided lap joint can’t bear heavy loads. It is used in tabling,
temporally framing and timber frame structuring.
5. Tee joint: it is the joint in which two parts are intersected each other at right angle, i.e. 90°. No
preparation is required in case of plain Tee joint. It has the chances of porosity, cracking and corrosion. It
is used in structural and machine application.
Types of welding positions
Welding is often done on structures in the position in which they are found. Techniques have been
developed to allow welding in any position. Some welding processes have all position capabilities, while
others may be used in only or two positions. All welding can be classified according to the position of the
workpiece or the position of the welded joint on the plates or sections being welded.

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1. Flat or down hand welding position: in this position, the welding is performed from the upper side of
the joint, and the face of the weld is approximately horizontal.
2. Horizontal Welding Position: In this position, the axis of the axis of the weld lies in an approximately
horizontal plane and the face of the weld lies in an approximately vertical plane.
3. Vertical Welding Position: In this position, the axis of the weld is approximately vertical.
4. Overhead Welding Position: In this welding position, the welding is performed from the underside of
a joint.
The types of welding positions are represented by letter symbols and number in welding symbols:
F - stands for a filler weld joint
G - stands for a groove weld joint.
Note that welding positions are presented in numbers as:
1 - stands for the flat position (F)
2 - stands for the horizontal position (H)
3 - stands for the vertical position (V)
4 - stands for the overhead position (O)

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Types of welds
1) Bead weld
It is a weld deposit produced by a single pass with one of the welding processes. The bead welds can be
composed of one or more strings of weave beads deposited on unbroken surface to obtain desired
properties or dimensions. This type of weld is used to build up surfaces or replace metal on worn surfaces.
A bead weld may be either narrow or wide, depending on the amount of transverse oscillation (side-to-
side movement) used by the welder. When there is a great deal of oscillation, the bead is wide; when there
is little or no oscillation, the bead is narrow. A weld bead made with-out much weaving motion is often
referred to as a stringer bead. On the other hand, a weld bead made with side-to-side oscillation is called
a weave bead.
2) Groove weld:
It is simply a weld made in the groove between two members to be joined. The weld is adaptable to a
variety of butt joints.

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Definition of groove weld configuration terms
Root opening: A separation at the joint root between the two work pieces.
Root face: the portion of the groove face adjacent to the joint root.
Groove face: the surface of a joint member included in the groove.
Groove angle: the total included angle of the groove between the two work places.
Bevel angle: the angle formed between the prepared edge of a member and a plane perpendicular to the
surface of the member.
Groove weld size: the joint penetration of a groove weld.
Plate thickness: the thickness of the base metals to be welded.
Weld reinforcement: Weld metal in excess of the quantity required to fill a weld groove.
Toe of the weld: is the junction between the face of the weld and the base metal.
Multi runs for groove weld:
 Root pass: the root pass is the first pass on an open joint, usually when welding pipe and mild
steel. It is usually used as a first pass that will provide the base for subsequent filler passes.
 Hot pass: hot pass is a term used in plate welding, when the bead is complete it is given a quick
clean up with a grinder then the hot pass follows, it burns out the slag that is trapped at the
junction between the bead and the pipe wall, the slag is often called wagon tracks
 Filler runs: Weld made after root pass by filling the gap between two plates of a work piece to be
welded with filler metal.
 Cover passes: The weld pass that finishes the welded joint. The cover bead is higher than the
adjacent surface and overlaps the groove.

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3) Fillet weld
A weld of approximately triangular cross section joining two surfaces approximately at right angles to
each other in a lap joint, T-joint, or corner joint.

Fillet weld leg: The distance from the joint root to the toe of the fillet weld.
Theoretical throat: The distance from the beginning of the joint root perpendicular to the hypotenuse of
the largest right triangle that can be inscribed within the cross section of a fillet weld.
Root of the Weld: This is the point at which the bottom of the weld intersects the base metal surface, as
shown in the cross section of weld.
Actual throat: This is distance from the root of a fillet weld to the center of its face.
Multi runs for fillet weld:
 First run: is the run on an open joint, usually when welding plate and/or other mild steel. It is
usually used as a first pass that will provide the base for subsequent filler passes.
 Filler runs: it is the weld made after first run by filling the gap between two plates of a work
piece to be welded with filler metal.
 Cover passes: The weld pass that finishes the welded joint. The cover bead is higher than the
adjacent surface and overlaps the groove.

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Tack weld: A weld made to hold the parts of a weldment in proper alignment until the final welds are
made. It is made as a single point
Full weld: a weld made in a specified length.

Pipe Welding Positions

Pipe Welding Positions are referred to as the combination of the different positions of the welder and the
job or specimen. Pipe welds are made under many different requirements and in different welding
situations as per the job nature. In general, the position of the specimen is fixed, but in many cases, it can
be rolled or inclined.
There are mainly four types of pipe welding positions-
1G – Horizontal Rolled Position
2G – Vertical Position
5G – Horizontal Fixed Position
6G – Inclined Position
1G – Horizontal Rolled Position
In the 1G welding position or Horizontal rolled position, the pipe will be in the horizontal position, and it
can be rotated along the horizontal (X) axis. The welder’s position remains stationary, means a welder
performs the welding at a single plane or point, and the pipe is being rotated slowly.
If the pipes are smaller in size, it can be rotated manually otherwise, equipment is used to rotate the pipe.
Welding is performed on the top surface of the pipe. This is the most basic pipe welding position that can
be performed.

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2G – Vertical Position
In the 2G pipe welding position, the pipe will be in the vertical position and it can be fixed or can be free
to rotate along the vertical (Y) axis. The welder’s position can also remain stationary or can move around
the vertical pipe. Welding is performed on the side surface of the pipe in a horizontal direction.

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5G – Horizontal Fixed Position
In the 5G pipe welding position, the pipe will be in the horizontal position. Unlike the 1G weld position,
the pipe will always remain fixed, and it cannot be rotated. The welder moves around the pipe outer
surface in the vertical direction to perform the welding.

6G – Inclined Position
In the 6G pipe welding position, the pipe is at the slope or incline, approximately 45° from the horizontal
(X) axis or from the vertical (Y) axis. The pipeline can be in a single or double offset.
The pipe will be in a fixed position, so the welder needs to move around the pipe to perform the welding.
This is an advanced pipe welding position that requires an experienced welder and an expert consultation.

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Workpiece positioning
The metal plates are pre-set and left free to move during welding. The basic principle is that the parts are
placed in position and held under restraint to minimize any movement during welding.
Example of restraints are: clamps, jigs and fixtures to hold the parts during welding.
1. Jigs and fixtures: Jigs and fixtures are used to locate the parts and to ensure that dimensional
accuracy is maintained whilst welding.
2. Flexible clamps: A flexible clamp can be effective not only in applying restraint but also in
setting up and maintaining the joint gap (it can also be used to close a gap that is too wide).
Welding is easier if the welder can find the most comfortable angle. The welder should be in either a
seated or a standing position in front of the welding table. The welding machine should be turned off.

With an electrode in place in the electrode holder, the welder can draw a straight line along the plate to be
welded; then, by turning the plate to several different angles, the welder should be able to determine
which angle is most comfortable for welding as shown in figure above.
Plate backing methods
Backing plate is material placed at the root of a weld joint for the purpose of supporting molten weld
metal. Its function is to facilitate complete joint penetration.
1. Ceramic backing plate: is a temporary backing that may be made from copper or a ceramic
substance that do not become fused to the root and are easily removed when welding is finished.
 They are used to prevent the molten metal from running out during welding
 it supports the weld root and can be broken free when the metal cools.
2. Permanent backing plate: It is made from a base metal similar to the metal being welded and,
becomes a permanent part of the joint because it is fused to the root of the weld and is not easy to
remove.
Perform steel plate welds
Padding
A padding weld consists of successive layers of overlapping weld beads. It is used in building up broken
or worn parts, in repairing machining defects, for making local bosses on a part, and for filling in large
cavities when heavy sections are welded.
Depending upon the space to be filled up a padding weld may be of either single layer or multi-layer type.
To lay a padding weld, the surface is thoroughly cleaned with a wire brush before depositing the first run
at the edge of the surface using a narrow or slightly spreading bead.

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Weaving techniques
Weaving: is a welding technique in which the energy source is oscillated transversely as it progresses
along the weld path.
1. Zigzag: the zigzag pattern is used as cover passes in the flat and vertical positions. Do not weave more
than two-and-a-half times the width of the electrode. These patterns deposit a large width of the electrode.

These patterns deposit a large quantity of metal at one time.

2. Box weave: this is also good for most 1G (flat) welds but can also be used for vertical 3G positions.

These patterns can also be used if there is a large gap to be filled when both pieces of metal are nearly the
same size and thickness.
3. Double J: the “J” Pattern works well on flat (1F) lap joints, all vertical (3G) joints, and horizontal (2G)
butt and lap (2F) welds.

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This pattern allows the heat to be concentrated on the thicker plate. It also allows the reinforcement to be
built up on the metal deposited during the first part of the pattern. As the result, a uniform bead contour is
maintained during out-of-position welds.
4. Circles: the circular weave pattern is often used for flat position welds on butt, tee and outside corner
joints, and for buildup or surfacing applications.

The circle weave pattern can be made wider or longer to change the bead width or penetration.
5. Crescent: the crescent patten (C) is good for most 1G (flat) welds but can also be used for vertical 3G
positions.

These patterns can also be used if there is a large gap to be filled when both pieces of metal are nearly the
same size and thickness.
2.4. Inspection of the weldment
Welding defects
A welding defect is any flaw that compromises the usefulness of the finished weldment.
1. Porosity: It is a group of small holes throughout the weld metal. It is caused by the trapping of gas
during the welding process caused by chemicals in the metal; Dampness and/or Too rapid cooling of the
weld.

causes
1. Arc length too long
2. Lack of cleaning base metal.
3. Use a damp electrode.
2. Lack of Penetration: It is the failure of the filler metal to penetrate into the joint which can be caused
by Improper joint preparation; Improper weld technique; Insufficient heat input; Wrong current setting;
Wrong electrode angle; Wrong selection of electrode and Fast travel speed.

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Causes:
1. Improper joint preparation.
2. Improper weld technique.
3. Insufficient heat input.
4. Wrong current setting
5. Wrong electrode angle
6. Wrong selection of electrode
7. Fast travel speed
3. Incomplete fusion or Lack of Fusion: Lack of fusion is the failure of the filler metal to fuse with the
parent metal which is caused by too fast a travel; Incorrect welding technique; Insufficient heat.

Causes:
1. Insufficient heat input.
2. Improper welding technique.
3. Work piece dirty.
4. Undercuts: These are grooves or slots along the edges of the weld caused by too fast a travel; Bad
welding technique and/or too excessive a heat build-up.

Causes:
1) Excessive current setting
2) Slow travel speed
3) Wrong electrode angle
4) Arc gap that is too long.
5) Failure to fill up the crater completely with weld metal.

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5. Cracking (Craters): These are generally the result of longitudinal shrinkage stresses acting on weld
metal of low ductility.

Causes:
 Excessive heat input.
 Improper tack weld
 Excessive current setting
 Travel speed too slow
 Many passes on the same area without allowing them to be cooled.
 Weld metal hardness problem (longitudinal)
 The center of the weld pool becomes solid before the outside of the weld pool, pulling the center
apart during cooling (transverse)
 Transverse Stresses, probably from shrinkage. Indicates inadequate filler metal selection or
welding procedure. May be due to crater crack propagation. (crater)
6. Burn Through
Burn-Through is a weld metal melting completely through base metal resulting in holes where no
metal remains.

Causes:
1. Excessive heat input
2. Improper travel speed
3. Wrong electrode angle
4. Wrong electrode selection

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 7. Slag Inclusions
Inclusions are nonmetallic materials, such as slag and oxides that are trapped in the weld metal,
between weld beads, or between the weld and the base metal.

Causes:
1. Lack of cleaning the proceeding bead weld
2. Laziness of cleaning bead
3. Wrong electrode angle
4. Improper current setting
8. Overlap also called cold lap:
Overlap occurs in fusion welds when weld deposits are larger than the joint is conditioned to accept. The
weld metal then flows over the surface of the base metal without fusing to it, along the toe of weld bead.

Causes:
 Improper welding technique; typically, electrode angles and travel speed.
 Misdirecting the arc into the vertical leg and keeping the electrode nearly vertical will also cause
overlap.
9. Underfill
The weld surface is below the adjacent surfaces of the base metal. Underfill on groove weld is when the
weld metal deposited is inadequate to bring the weld’s face or root surfaces to a level equal to that of
original plane or plate surface.

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10. excessive penetration
It is where the weld metal protrudes through the root of the weld.
Causes:
 Incorrect edge preparation
 Too big heat concentration
 Too slow travel.
Correct defects
a) Straightening
Straightening is a process of making straight, align or adjust the workpiece for obtaining the desired shape
and size.

b) Grinding and re-welding.

Grinding and re-welding is done by using angle grinder for performing grinding operation and finally re-
weld the grinded part for correction of the occurred defects.
Verify dimensions
Types of measurement.
A. Angles: Angle can be defined as the figure formed by two rays meeting at a common end point. An
angle is represented by the symbol <. Angles are measured in degrees, using a protractor.
B. Length: Length is the measurement or extent of something from end to end; the greater of two or the
greatest of three dimensions of an object is the length. Diagonals: In geometry, a diagonal is a line
segment joining two vertices of a polygon or polyhedron, when those vertices are not on the same edge.
2.5. Finishing the product or work done
a) Grinding: Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool to
remove some amount of material on a given workpieces in order to obtain the desired sizes and shape of
the finished product.

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b) Polishing: is the process of creating a smooth and shiny surface by rubbing it or by applying a
chemical treatment, leaving a clean surface with a significant specular reflection.

c) Chipping out the slag: Chipping the slags is the process of removing away the slags from the welded
metal by using a chipping hammer.
d) Brushing: Brushing is a process of removing some amount of material on a given workpieces by using
wire brush in order to obtain the desired sizes and shape of the finished product.
e) Sanding: Sanding is the process of cleaning materials especially metals by using sand papers.
Methods of preventing corrosion or protect the metal
a. Red oxide painting
Red oxide paint is a specially formulated coating used as a base coat for ferrous metals. It gives iron and
steel surfaces a layer of protection. Red oxide paint is an anti-corrosion coating designed to stop rust
formation. It can be applied directly over a rusty surface and is most ideal for exterior use.
Red oxide paint is intended for use on interior and exterior ferrous metal and is not usually suitable for
galvanized or nonferrous metals like aluminum, copper or brass.
b. Keeping away from humidity
Absolute humidity is the measure of water vapor (moisture) in the air, regardless of temperature. It is
expressed as grams of moisture per cubic meter of air (g/m3). For instance, it is more important to keep
certain types of rods away from moisture more than others. But, it is important to keep all rods dry and
away from humidity as much as possible.

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C. Galvanizing: A galvanizing process is the process of immersing iron or steel in a bath of molten zinc
to produce a corrosion resistant, multi-layered coating of zinc-iron alloy and zinc metal. While the steel is
immersed in the zinc, a metallurgical reaction occurs between the iron in steel and the molten zinc. This
reaction is a diffusion process, so the coating forms perpendicular to all surfaces creating a uniform
thickness throughout the part.
LO. 3: Perform post-operation activities
3.1. Cleaning of tools, equipment and workplace
 Cleaning techniques
Chemical spraying: Chemicals was mostly sprayed on farms, around the home, in gardens, parks and
reserves to control pests and diseases, now it can also be used in workshops for the purpose of cleaning
most equipment and/or tools used there.
Dusting: the term “dust” is already familiar, but how dust should be removed? If any surface is wiped
with a piece of dry cloth (duster), it carries the loose dust with it and the process is known as dusting. This
should be done with a clean soft cloth.
Compressed air: air which is compressed by air compressor then perform cleaning process, an air
compressor is a pneumatic machine used for cleaning tools and even heavy machinery in the workshop.
Brush: It is used for cleaning the working surface prior to welding and general cleaning of the weldment.
Most of the brushes used for cleaning tools and equipment in workshops are wire brushes.
Powered wire brush cleaning: Power brushes are distinctly suited for removal of surface film, dirt, rust,
heat treat scale, weld slag, corrosion and paint.
Cloth rugs: these are made of soft absorbent cloth such as flannel. Dry polishing cloth helps to clean and
shine the polished surfaces by rubbing them vigorously.
Mops: a tool for cleaning floors made of a bundle of cloth or yarn or a sponge fastened to a long handle,
something that looks like a cloth or yarn mop. this process is known as mopping and is generally coarser
than a duster. Mopping is mostly done on floors.
Waste disposal
Waste disposal means removing, discarding, recycling or destroying unwanted materials called waste that
is produced from agriculture, domestic usage or industrial products.
Following the correct methods for waste disposal will ensure lesser pollution and hazards for the
environment.
Here are the methods of solid waste disposal and management:
- Solid Waste Open Burning.
- Sea dumping process.
- Solid wastes sanitary landfills.
- Incineration method.
- Composting process.
- Disposal by Ploughing into the fields.
- Disposal by hog feeding.
- Salvaging procedure.

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Waste management strategy hierarchy
1. Dispose (landfill)
2. Recover (energy from waste)
3. Recycle
4. Reuse
5. Reduce
3.2. Store Tools and Equipment
During re-arrangement of tools and equipment, some tips for re-arrange and storing tools and equipment
must be followed:
1. Re-arrange tools and equipment according to the sizes: The tools and equipment should be stored
according to the sizes, where the tools of the same sizes can be kept in a convenient area depending on
their sizes.
2. Re-arrange tools and equipment according to their types: The tools or equipment of the same types
should be kept or stored together if possible, this will help it to be easily available when needed and
provide a safe storage of them.
3. Re-arrange tools and equipment according to their use: All tools and equipment of the same use should
be stored in the same place with respect to their physical, chemical and/or mechanical properties,
sometimes it is better to store in a dry place.
Shelving: involves putting products in the system and retrieve them by hand. Shelves are for storing
items people can walk up and grab with their hands, rather than cartons or boxes.
Hanging: is the popular way to organize and keep tools or equipment in sight.
Waste disposal
Waste disposal means removing, discarding, recycling or destroying unwanted materials called waste that
is produced from agriculture, domestic usage or industrial products.
Following the correct methods for waste disposal will ensure lesser pollution and hazards for the
environment.
Here are the methods of solid waste disposal and management:
- Solid Waste Open Burning.
- Sea dumping process.
- Solid wastes sanitary landfills.
- Incineration method.
- Composting process.
- Disposal by Ploughing into the fields.
- Disposal by hog feeding.
- Salvaging procedure.

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Waste management strategy hierarchy
1. Dispose (landfill)
2. Recover (energy from waste)
3. Recycle
4. Reuse
5. Reduce
In waste disposal, we find recyclable materials and non-recyclable materials.
1. Recyclable materials
The mechanical recycling involves crushing, washing and sorting operations and it is use for all types of
plastic waste materials. This process involves the assembly of mechanical products which includes driven
electrical motor, pulley, cutter and others.
2. Non-recyclable materials

 Garbage.
 Food waste.
 Food-tainted items (such as: used paper plates or boxes, paper towels, or paper napkins)
 Ceramics
 Windows and mirrors.
 Plastic wrap.
Report
Types of reports
1. Informational Reports
2. Analytical Reports
3. Operational Reports
4. Product Reports
5. Department Reports
6. Progress Reports
Advantages of reporting

❖ Ensure enhanced control and visibility.

❖ Ensures that teams and departments remain self-driven
❖ Defines clearly where a person should report
❖ Defines levels of responsibility and authority clearly
❖ Measure and Evaluate Work Performance
❖ Determine Strengths, and Weaknesses
❖ Build Up Work Reputation

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  Technical report format
The format is very important because it is unique from other reports in that it carries technical
information.
A technical report should contain the following:
1. The title page: Must include the title of the report. Reports for assessment, where the word
length has been specified, will often also require the summary word count and the main text word
count
2. Introduction: States the objectives of the report and comments on the way the topic of the report
is to be treated. Leads straight into the report itself. Must not be a copy of the introduction in a lab
handout
3. The summary: A summary of the whole report including important features, results and
conclusions
4. The body: The sections which make up the body of the report. Divided into numbered and
headed sections. These sections separate the different main ideas in a logical order
5. Conclusions: A short, logical summing up of the theme(s) developed in the main text
6. Recommendations: In the recommendation, you are supposed to suggest solutions to the
challenges that are there in the body. This is where your opinion is welcomed.
7. Reference: Details of published sources of material referred to or quoted in the text (including
any lecture notes and URL addresses of any websites used.
8. Bibliography: Other published sources of material, including websites, not referred to in the text
but useful for background or further reading.
9. Acknowledgements: List of people who helped you research or prepare the report, including
your proofreaders
10. Appendices: Any further material which is essential for full understanding of your report (e.g.
large scale diagrams, computer code, raw data, specifications) but not required by a casual reader.
Steps which could be taken to write a professional report in the workplace:
1. Find the Appropriate Template and Follow Instructions
2. Plan the Structure of the Report
3. Construct a Summary of the Accomplished Tasks and Activities
4. Write with Conciseness and Accuracy
5. Proofread and Revise the Overall Report
6. Prepare the Final Work Report

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