9.

These patterns can also be used if there is a large gap to be filled when both piecesof metal
are nearly the same size and thickness.
A. Cover C. J-patternB. Crescent pattern D. Hazard sign
ame: __________________________________Grade & Section:
__________________________ TVL 11 – SHIELDED METAL ARC WELDING (SMAW)
Quarter: 4Module: 1Week: 1-2
Learning Competency:
LO 2. WELD CARBON STEEL PLATES IN OVERHEAD POSITION (4F)
At the end of the lesson, you should be able to:
-
K– Identfy he dieren weaving moton-
S –Deermine he weaving moton o be used -
A - Appreciae he purpose of each weaving moton-
V -Deermine he imporance of performing he weaving moton

Welding techniques were developed over time in order to avoid problematic welds and
defects and improve your skills. For example, heat input is the biggest factor when it comes to
creating a good weld. If there is too little heat input there is poor penetration. If there is too
much heat input you get burn through. Weave bead welding is exactly as it sounds; you will
make a weaving pattern in order to cover a larger area. You use this motion to make cover welds
over stringer beads (multipass welding). In other words you use this when you are layering
welds. It's used when you make two or more welds on the same seam.
The potential problems that can occur from poor weaving techniques is that you can undercut
the weld bead edge as well as have bad fusion.
WEAVING
Weaving is a method or technique used to increase the width and volume of bead. Many weave
patterns are available for the welder to use. Table below shows ten different patterns that can
be used for most welding conditions
WEAVING PATTERN
CIRCULAR PATTERN –Often used in flat position weld on butt, tee, and outside
corner joints for build-up and surfacing application. The circle can be made wider or longer toch
ange the bead width or penetration.
CRESCENT WEAVE -
The “C” and square patterns are both good for most 1G (flat) welds
SAN PEDRO NATIONAL HIGH SCHOOL
Grade 12 – SMAW
1st Semester2
nd
Grading Examination
Name: ___________________________________Score:_______________ Instruction:Incircle
the that corresponds the correct answer.
1. SMAW stand for:
a)Smart Mammals Always Weld c) Stick Metal Arc Welding
b)Shielded Material Arc Welding d) Shielded Metal Arc Welding
/2. Fumes from stick electrode arc welding should always be
:a)Inhaled c)Vented /b)Ignored d)Accepted
3. The proper shade lens for SMAW is:
a)4 to 6 c)10 to 12 / b)5 to 9 d)14 to 17
4. Necessary protection includes all except:
a)Gloves, safety glasses c) Leather, exhaust b)Shorts, sunglasses/
d) Welding helmet, safety shoes
5. Attention must also be placed on the surroundings prior to welding, such as:
a)Shielding Gas Tanks c)Hot metal b)Combustibles d)All the above /
6. Two methods of striking an arc are:
a)Scratch & Sniff c)Strike & Scrap b)Scrap & Strike d)Scratch & Tap/
7. The electrode travel angle from perpendicular to the plate in the direction of travel
should be:
a)15 to 20/ c)45 to 90 b)25 to 45 d)180 to 3608.
When SMAW welding as the arc length increasea)Amps slight increase and
volts decreasec)amps slightly decrease and volts increase /b)amps greatly increase and
volts increased)amps greatly decrease and volts decrease
9. TheShielded MetalArc Weldingpower is:
a)Constant Voltage/c)Constant Currentb)Variable Voltaged)Variable Current
10. The polarity that generally provides the deepest penetration is:
a)ACc)DCENb)DCEP/d)AC/DC11. A characteristic of an E6011
electrode is:a)High Depositionc)Requires Close Arcb)Deep Penetration/d)Heavy Slag12. A
characteristic of a E7018
electrode is:a)Flat, Horizontal Welding only c)Low Depositionb)Deep Penetration d)DCEP or AC /
13. Which of the following will make a weld
bead flattera)Increase Electrode Diameterc)Increase Travel Speedb)Decrease Current/d)Increase
Arc Length14. The last digit, for example in E7018, represents all
except:a)Coating contentc)Position preference /b)Polarity preferenced)Arc characteristic15. The
general rule for amperage setting for an 1/8" diameter
electrode:a)80 ampsc)125 amps /b)110 ampsd)140 amps16. As discussed in class the amperage
setting for an 1/8" E7018 electrode isa)80 ampsc)125 ampsb)110 ampsd)140 amps /17. As
discussed in class the amperage setting for an 1/8" E6011 electrode
is:a)80 amps /c)125 ampsb)110 ampsd)140 amps18. What does the "E: represent, for the
electrode E7018?a)Electrode characteristicsc)Electrode /b)Tensile strengthd)Welding position19
. What does the "70" represent, for the electrode
E7018a)Electrode characteristicsc)Electrodeb)Tensile strength/d)Welding position20. What
does the "1" represent, for the electrode E7018?
a)Electrode characteristicsc)Electrodeb)Tensile strengthd)Welding position /21. What does the
"8" represent, for the electrode E7018?a)Electrode characteristicsc)Electrode
22. The primary weld parameter that controls penetration
isa)amperagec)travel speedb)arc lengthd)voltage23. A function of the coating on a shielded
electrode is that ita)provides easy startingc)permits better penetrationb)protects the weld from
atmospheric contaminationd)all the [Link] metal deposited should have approximately
the same mechanical properties as
the_____ a)Flux coatingc)Base metalb)Slagd)shielding [Link] of the following should be
considered when selecting an
electrodea)Electrode diameterc)Weld positionb)Welding current and polarityd)All of the above2
6. With this method of GMAW the filler metal is deposited when the wire touches the work;
approximately 20to 200 times per
seconda)Short Circuit Transferc)Spray Transferb)Globular Transferd)None of the [Link]
this method of GMAW the filler metal is deposited when small molten droplets are transferred
acrossan open gap between the filler metal and the base
metala)Short Circuit Transferc)Spray Transferb)Globular Transferd)None of the above28. With
this method of GMAW the filler metal is deposited when large molten droplets, larger than
theelectrode diameter, are transferred across an open gap between the filler metal and the
base
metala)Short Circuit Transferc)Spray Transferb)Globular Transferd)None of the above29. This
method of GMAW requires high percentages, greater than 80%, of argon shielding
gasa)Short Circuit Transferc)Spray Transferb)Globular Transferd)None of the above30. This
shielding gas provides better
penetration characteristicsa)CO2c)Heliumb)75% Argon 25% CO2d)Oxygen31. This shielding gas
provides better weld bead appearancea)CO2c)Heliumb)75% Argon 25% CO2d)Oxygen32. Which
shielding gas is preferred for welding aluminuma)Argonc)Hydrogenb)CO2d)[Link]
process uses which type of power
sourcea)Constant Currentc)Constant Powerb)Constant Voltaged)None of the [Link]
most commonly uses which type of current for steela)Direct Current Electrode
Negativeb)Alternating Current Electrode Negativec)Direct Current Electrode
Positived)Alternating [Link] mode of metal transfer is undesirable due to large
quantities of
spattera)Short Circuit Transferc)Spray Transferb)Globular Transferd)None of the [Link]
d drive rolls are used
for:a)Hard wiresc)Flux/Metal cored wiresb)Soft wiresd)None of the above37. U-grooved drive
rolls are used for:a)Carbon steelc)Flux-Cored wiresb)Aluminumd)None of the above38.V-
grooved drive rolls are used
fora)hard wiresc)flux cored wiresb)soft wiresd)none of the above39. When GMAW welding
to increase amperage the welder
will:a)increase voltagec)increase wire feed speedb)decrease voltaged)decrease wire feed speed
40. Voltage controlsa)Penetrationc)Wire feed speedb)Arc l
Welding Defects – Types, Causes, Prevention

Welding defects are imperfections that occur during different welding processes. There are
various reasons why welding defects occur during an operation.
Welding services are mainly used in the manufacturing industry for joining metals in
constructing buildings, bridges, automobiles, aircraft, pipes, and many other objects. However,
welding is not a perfect process as numerous types of welding defects can occur internally or
externally in the welded metal.
Let’s explore some of the more common weld defects, their causes, and remedies.
Table of Contents hide
I What Is a Weld Defect?
II External Welding Defects
III Internal Welding Defects
IV Other Welding Defects
V How to Detect Welding Defects
VI Final Thoughts
What Is a Weld Defect?
A weld defect results from a poor weld, weakening the joint. It is defined as the point beyond
the acceptable tolerance in the welding process.
Imperfections may arise dimensionally, wherein the result is not up to standard. They may also
take place in the form of discontinuity or in material properties. Common causes of welding
defects come from incorrect welding patterns, material selection, skill, or machine settings,
including welding speed, current, and voltage.
When a welded metal has a welding defect present, there are multiple options for resolving the
issue. In some cases, the metal can be repaired, but at other times the metal itself has melted
and the welding procedure needs to be restarted.
Weld irregularities occur for a variety of reasons and it results in different welding defects. They
can be classified into two major categories: internal welding defects and external welding
defects.
External Welding Defects
External welding defects refer to discontinuities in the weld metal that are noticeable to the
naked eye.
Cracks

Cracks are the worst welding defect since they can rapidly progress to larger ones, which
inevitably leads to failure. Weld cracks are mainly classified depending on how they form in the
weld bead.
Longitudinal cracks form parallel to the weld bead while transverse cracks form across the
width. Crater cracks form at the end of the bead, where the arc concludes.
Welding cracks can also appear at varying temperatures:
  Hot cracks form when weld joints crystallise as the parent and base metals are heated
above 10000°C. The primary reasons for hot cracks is when an incorrect filler metal is
used and when the workpieces undergo high heating and cooling rates in processes such
as laser welding.
 Cold cracks form after the cooling process of the weld metal. The weld crack may form
hours or days after the metal’s cooling process.
Causes
1. Using hydrogen shielding gas in welding ferrous metals.
2. Ductile base metal and the application of residual stress.
3. Rigid joints that constrain the expansion and contraction of the metal.
4. Use of high levels of sulphur and carbon.
Prevention
1. Preheating the metals and gradually cooling the weld joints.
2. Maintaining acceptable weld joint gaps.
3. Selection of the correct welding materials.
Porosity

Porosity is the formation of holes in the weld pool resulting from gas bubbles that cannot
escape. It is usually one of the common welding defects when using shielding gas, which is
present in welding techniques such as TIG and stick welding. Absence, lack, or too much
shielding gas may lead to metal contamination, which reduces the strength of the weld.
On the other hand, severe versions of porosity come in the form of blow holes or pits when
large gas bubbles get trapped in the weld pool. Additionally, smaller gas molecules can blend
with the weld metal, forming an impure compound.
Causes
1. Unclean welding surface.
2. Wrong electrode selection.
3. Lack or absence of shielding gas.
4. Mishandled or damaged shielding gas cylinder.
5. Either too low or too high welding current.
6. Fast travel speed.
Prevention
1. Cleaning the weld surface.
2. Using the correct welding electrode.
3. Preheating the metals before welding.
4. Proper gas flow rate setting to achieve the right amount of shielding.
5. Regularly checking for moisture contamination in the shielding gas cylinder.
6. Adjustment of welding current and travel speed settings.
Scale Your Manufacturing from Prototyping to Series
 Personal account manager
 Quality assurance
 Payment terms for companies
 On-time delivery by Fractory
Get a quote
Undercut
An undercut can be formed in various ways but mainly it is tied to two reasons. The first is using
excessive current – the edges of the joint melt and drain into the weld. The second reason is not
that enough filler metal is deposited into the weld. This results in a reduced cross-section
meaning that there are notches or grooves along the weld, which increase stress when the
material is subjected to fatigue loading. This defect occurs at the toe of the weld or in the case
of multi-run welds, in the fusion face. An undercut may come from continuous, intermediate,
and inter-run.
Additionally, water and dirt are prone to get stuck into the groove and this can accelerate
corrosion in the already weakened area.
Causes
1. High arc voltage.
2. Incorrect electrode selection or wrong electrode angle.
3. High travel speed.
Prevention
1. Smaller arc length, voltage, and travel speed.
2. 30 to 45-degree electrode angle.
3. Reducing the electrode diameter.
Overlap
Overlap is the excess metal that spreads out around the bead. The spread-out filler metal is not
properly mixed with the base metals. Typically, it comes in a round shape over the weld joint.
Causes
1. Incorrect welding procedure.
2. Wrong selection of welding materials.
3. Improper preparation of base metals.
Prevention
1. Smaller welding current.
2. Use of proper welding techniques.
3. Shorter welding electrode.
Burn-Through
An open hole is exposed when the welding process accidentally penetrates the whole thickness
of the base metal, creating a burn-through or melt-through. This is one of the common weld
defects when welding thin metals.
Causes
1. High welding current.
2. Extreme gap to the root.
3. Not enough root face metal.
Prevention
1. Maintaining a proper root gap.
2. Control in the application of welding current.
3. It can be repaired in some cases wherein the hole is removed and re-welded.
Spatter
Spatter is a welding defect that occurs when metal droplets are discharged on the metal
surface. It solidifies and becomes stuck on the metal surface once it cools down. In most cases,
spatter does not alter the structural integrity of the weld but generally, it has to be removed,
adding to the total costs.
Causes
1. High arc length.
2. High welding current.
3. Improper shielding of the heat-affected zone.
4. Using the wrong polarity may create excessive spatter.
Prevention
1. Choosing the correct weld polarity.
2. Selecting a better shielding gas and better shielding technique.
3. Reducing the welding current and arc length to optimal condition.
Under Filled
Underfill occurs when too little weld metal is deposited into the joint. As a result, some of the
parent material remains unfused and the joint is under filled. These unfused sections, even
when small, act as potential stress raisers.
Causes
1. Low welding current.
2. Too high travel speeds.
3. Incorrect weld bead placement.
4. Laying weld beads too thinly in multi-pass welds.
Prevention
1. Proper electrode size selection.
2. Selecting the right current setting.
3. Avoid moving too fast.
Excess Reinforcement
Excess reinforcement (overfilled) describes a weld that has too much build-up. It is the opposite
of underfilled welds as excessive amounts of filler metal is deposited into the joint. With this
defect, high levels of stress concentration build up in the toes of the welds.
Causes
1. Low travel speeds.
2. Incorrect procedures.
3. Excess flux on the feed wire.
Prevention
1. Maintaining an optimal pace with the torch.
2. Avoiding excess heat by making sure to use the correct voltage and amperage.
3. Aligning the workpieces properly to ensure that the gap between the parts is not too
large.
Mechanical Damage
Mechanical damage is indentations present in the weld due to damage from preparation,
handling, welding, equipment usage, and other factors.
Causes
1. Unnecessary application of external force before, during, or after an operation.
2. Incorrect handling of welding equipment
3. Not engaging the arc before the welding procedure
Prevention
 1. Safe and correct handling of welding equipment.
2. Consistently engaging the arc in the metal parts before starting welding.
Distortion
Distortion or warping is an accidental change in the shape of the surrounding metal of the weld.
Excessive heating around the weld joint is the main reason for distortion around its area.
Warpage or distortion mostly occurs in thin metals and is classified into four types: angular,
longitudinal, fillet, and neutral axis.
Causes
1. Thin weld metal.
2. Incompatible base metal and weld metal.
3. High amount of weld passes.
Prevention
1. Using suitable weld metals.
2. Optimising the number of weld passes.
3. Selection of better welding methods for the metal type.
Misalignment
Improper positioning of metals before or during a welding operation may result in
misalignment. Poor metal alignment is susceptible to fatigue conditions especially if it is used in
pipe welding.
Causes
1. Rapid welding process.
2. Incorrect metal alignment or metals aren’t secured properly.
3. Lack of welder skills.
Prevention
1. Employing a slower and more stable welding procedure.
2. Securing the metals firmly before and during operation.
3. Using the correct welding techniques and conducting checks regularly.
Internal Welding Defects
Welding processes that create weld defects invisible to the naked eye are categorised as internal
welding defects.
Slag Inclusion

A weld bead that contains slag in its composition compromises the toughness and structure of
the metal. Slag inclusion may occur either on just the surface of the weld metal or in between
welding cycles. This weld defect is common to processes that use flux, such as stick, flux-
cored, submerged arc welding, and brazing.
Causes
1. Incorrect welding angle and travel speed of the welding torch.
2. Poor pre-cleaning of the edge of the weld surface.
3. Low welding current density resulting in inadequate heating of the metals.
Prevention
1. Higher welding current density.
2. Optimal welding angle and travel speed to avoid slag inclusion in the weld pool.
3. Consistent weld edge cleaning and slag removal of each layer.
Incomplete Fusion
Incomplete fusion results from poor welding wherein the metals pre-solidify, forming gaps in
the weld zone. When the welder cannot properly melt the parent metal with the base metal, it
results in a lack of fusion.
Causes
1. Low heat input resulting in metals not melting.
2. Wrong joint angle, torch angle, and bead position.
3. Extremely large weld pool.
Prevention
1. Higher welding current and slower travel rate to ensure the melting process of the
metals.
2. Improving welding positions such as joint angle, torch angle, and bead position.
3. Lower deposition rate.
Incomplete Penetration
Incomplete penetration generally occurs during butt welding, wherein the gap between the
metals isn’t filled completely through the joint thickness. This means that one side of the joint is
not fused in the root.
1. Incorrect use of the welding technique.
2. Wrong electrode size.
3. Low deposition rate.
Prevention
1. Using the correct welding technique and procedure.
2. Higher deposition rate.
3. Proper electrode size selection.
Other Welding Defects
Whiskers
Whiskers are a specific weld defect in the MIG welding process. This occurs when the root side
of a weld joint has remnants of the wire electrode.
Causes
1. The electrode is positioned ahead of the leading edge of the weld puddles.
2. Fast wire feed speed of the electrode wire to the MIG torch.
3. High travel speed while welding
Prevention
 1. Snipping off the small blob of the electrode before welding
2. Reducing the wire feed speed in the machine settings.
3. Slowing down the travel speed or using welding techniques as countermeasures, such as
whipping the electrode.
Necklace Cracking
Necklace cracking is a welding defect associated with electron beam welding. This defect occurs
when the molten metal can’t sufficiently flow into the cavity, resulting in incomplete
penetration.
Causes
1. Using metals such as stainless steel, carbon steel, tin, and nickel-based alloys.
2. Improper welding technique application.
3. High operation speed in electron beam welding.
Prevention
1. Better material selection for electron beam welding.
2. Using constant speed to achieve uniformity.
3. Applying proper welding technique and procedure.
How to Detect Welding Defects
Testing methods are a great way to check if the welding patterns meet specific criteria. It allows
us to find the causes and remedies for why welding defects occur. While it takes some time, it
ensures that the welds are safe and risk-free.
There are two standard procedures for finding defects in a weld metal:
Non-Destructive Testing
Non-destructive testing allows us to observe discontinuities in the weld incurring no damage.
This testing method is essential in high-speed production wherein a sample is tested from a
batch.
Non-destructive testing and evaluation is usually done by utilising visual inspection, liquid
penetrants, magnetic particles, eddy currents, ultrasonics, acoustics, emissions or radiography.
Destructive Testing
Destructive testing acquires information by subjecting the finished projects to strenuous
methods until it reaches their limits. Some cases require destructive testing in addition to non-
destructive tests in order to reduce weld defects in production significantly.
Some destructive methods used to identify the limits of the weld metal are acid etch, guided
bend, free bend, back bend, nick break, and tensile strength.
Final Thoughts
Welding defects pose serious risks that can lead to dangerous issues if not addressed. They can
be expensive and time-consuming to correct but are always worth it in exchange for quality. This
is why welders need to understand the fundamentals of welding.
Modern technology allows us to perform welding techniques more efficiently. Along with
numerous testing methods facilitating the discovery of different types of welding defects, the
execution and correction of these imperfections is constantly getting better. Focusing on
improving both the machinery and technical skill make up a difference when it comes to limiting
weld defects. This leads many industries to manufacture products of higher quality than ever
before.
Matching Type
Directions:
Match the pictures of Column A with the words or group of words incolumn B. Write only the
letter of your choice in your separate answersheet.
[Link] A
Pretest
Let us determine your prior knowledge on the topic/task inPerforming Groove Weld on Carbon
Steel Plates and Pipes by taking thispretest.
I. Multiple Choice:
Directions
: Read and analyze the statements carefully. Choose the correct answerand write the letter only
on your separate answer sheet.1. ______________________ are generated
in a welding job due to the faulty orpoor technique used by the inexperienced or unskilled
welder or due tofundamental difficulties in the welding
operation.a. Spatter c. Penetrationb. Welding defects d. Porosity2. ____________________
occurs when the depth of the welded joint
isinsufficient.a. Incomplete penetration c. Spatterb. Porosity d. Welding defects3. ____________
_______ cracking is due to tearing of the grain boundaries ofweld metal before complete
hardening has taken place and metal is still in theplastic
state.a. Hot tear c. Distortionb. Solidification d. Undercut4. ________________ is also known
as solidification cracking state.a. Hot tear c. Grooveb. Distortion d. Undercut5. ______________
______ is defined as the distance from the base plate topsurface to the maximum extent of the
weld nugget.a. Porosity c. Undercutb. Distortion d. Penetration6. It refers to organization of
necessary items in good order
and easy access.a. Seiri (Sort) c. Seiton (Systematize)b. Seiso (Sweep) d. Shitsuke (Self Descipline
)7. It means taking out and disposing unnecessary
items.a. Seiri (Sort) c. Seiketsu (Sanitize/Standardize)b. Seiso (Sweep) d. Seiton (Systematize)
Pretest
Let us determine your prior knowledge on the topic/task inPerforming Groove Weld on Carbon
Steel Plates and Pipes by taking thispretest.
I. Multiple Choice:
Directions
: Read and analyze the statements carefully. Choose the correct answerand write the letter only
on your separate answer sheet.1. ______________________ are generated
in a welding job due to the faulty orpoor technique used by the inexperienced or unskilled
welder or due tofundamental difficulties in the welding
operation.a. Spatter c. Penetrationb. Welding defects d. Porosity2. ____________________
occurs when the depth of the welded joint
isinsufficient.a. Incomplete penetration c. Spatterb. Porosity d. Welding defects3. ____________
_______ cracking is due to tearing of the grain boundaries ofweld metal before complete
hardening has taken place and metal is still in theplastic
state.a. Hot tear c. Distortionb. Solidification d. Undercut4. ________________ is also known
as solidification cracking state.a. Hot tear c. Grooveb. Distortion d. Undercut5. ______________
______ is defined as the distance from the base plate topsurface to the maximum extent of the
weld nugget.a. Porosity c. Undercutb. Distortion d. Penetration6. It refers to organization of
necessary items in good order
and easy access.a. Seiri (Sort) c. Seiton (Systematize)b. Seiso (Sweep) d. Shitsuke (Self Descipline
)7. It means taking out and disposing unnecessary
items.a. Seiri (Sort) c. Seiketsu (Sanitize/Standardize)b. Seiso (Sweep) d. Seiton (Systematize)
9. It is a working suit that is used in workplace as whole body protection fromsparkling of
equipment.a. Full body harness c. Safety shoesb. Cover all d. Safety apron10. They protect feet
from hot sparks or falling
objects.a. Welding sleeves c. Safety glassb. Safety shoes d. Welding gloves11. A shallow fusion
between weld metal and based
metal.a. Spatter c. Penetrationb. Porosity d. Incomplete penetration12. It is due to excessive
heat input and creates hole.a. Burn-through c. Penetrationb. Porosity d. Incomplete penetr
3. ____________________ is a group of small voids and blowholes that arecomparatively bigger
isolated holes or cavities.a. Spatter c. Penetrationb. Porosity d. Welding defects14.
_________________ is a kind of weld defect which forms a groove in theparent metal along
with the sides of the weld bead.a. Groove c. Distortionb. Hot tear d. Undercut15. It is cause of
not following the welding principle or procedures and lack of skillof a
welder.a. Spatter c. Penetrationb. Porosity d. Welding defects
Definition of Terms
Alternate Current -
it is

when electrical current alternates or reverses the directionof electron flow.

Amperage -
is a measure of electrical current flowing through a circuit and is anindication of the heat being
produced.
Arc Welding -
uses electricity to heat and melt the metal.
Direct Current -
electron flow in one direction.
Electricity -
is the flow of tiny particles called electrons through a conductor.
Electrode -
is a bare metal rod which is usually coated with chemical compoundscalled flux.
Fumes -
are produced when cutting metal containing zinc and are injurious wheninhaled.
Hazard -
is any source of potential damage, harm or adverse health effects onsomething or someone.
Penetration -
is the distance that the fusion line extends below the surface of thematerial being welded.
Polarity -
is the direction the current is flowing.
Rays -
are given off by the arc are the same as those transmitted by sunlight andcan cause severe
burn.
Reverse Polarity-
it is when the electrons flow from work piece to the electrode.
Risk -
the combination of the likelihood of the occurrence of a harm and severity ofthat harm.
Straight Polarity -
it is when the electrons flow from the electrode to the workpiece.
Welding -
is the melting, flowing together and freezing of metals under controlledconditions.
Voltage -
is a measure of electrical pressure.

adDownload to read ad-free

11
Lesson 1 Weld Carbon Steel Plate in Flat Position (1G)

Lesson Information 1.1

Fundamentals of Welding
After reading the Information Sheet, the trainee must be able to determine
thefundamentals of [Link] quality and consistency can only be maintained with respect
to the fivefundamentals. The five fundamentals of welding include the use of
correct electrodesize, current, arc length or voltage, travel speed and electrode angles. All five
mustbe collectively and consistently maintained to successfully control the puddle andproduce
a weld that is uniform in appearance, has consistent ripples, smooth facecontour, and no
noticeable defect. Once the welder masters the ability to consistentlymaintain the five
fundamentals, the ability to control the puddle will follow.
Current Setting
The correct current setting is vital for maintaining consistency in weld [Link] the current is
too high, the electrode melts too fast, and the molten pool is largerand irregular. If the
current is too high when welding single vee groove, it may blowholes through the joint and
cause large molten metal droplets to fall out of thegroove. If the current is too low, there is not
enough heat to melt the base [Link] molten pool appears too small, piles up, and looks
irregular. It can result topoor penetrat ion and incomplete fusion in the joint.
Length of an Arc
Is very important for weld puddle control. Correct arc length will cause thedeposit to be neat of
even ripple and of good penetration. Too long arc length willcause the deposit to coarse ripple
and flatter than normal with an increase in [Link] welding a root pass in an open root
vee groove, the keyhole can grow too largeand loose of weld control can [Link] short an arc
will cause deposited to be narrow, uneven and irregularlyrippled and with poor fusion. The arc
length reduces the voltage and increases theamperage slightly but the electrode may stick to
the work. When welding root passes,too short an arc length often results in loss of the keyhole.
What is it?

adDownload to read ad-free

12
Angle of Electrode
One of the fundamentals is the use of the correct electrode angles. Forfillet and groove welds,
correct electrode angles are vital for pre venting undercutand inadequate fill. When depositing
a fillet weld, the electrode should be held sothat it bisects the angle between the plates and is
perpendicular to the line of theweld. On groove weld, the technique is much the same;
although varying slightly withmultiple pass welding. There are two teams to specify electrode
angles. These aretravel angle and work [Link] travel angle applies to the position the
electrode makes with a referenceperpendicular to the axis of the weld in plane of the weld axis.
It can be either adrag angle or a push angle. A drag angle is when the electrode
is pointingbackward, which means, the welder
’
s hand and electrode holder precede the puddle. A push angle is when electrode is pointing just
the opposite of the [Link] work angle is the position the electrode makes with reference to
thesurface of the plate on a plane perpendicular to the weld axis. On butt joints, the workangle
is usually 90 degrees to the surface of the [Link] some degree, you can correct for an
improper condition by varying theessential variables. It is better though to have all conditions as
correct as possible.
Manipulation of Electrode
Choosing the correct electrode size involves many factors. If a smallerrecommended electrode is
used, welding time and heat to the joint will increase. Itcan result in increased costs, heat
affected zone, cracking or [Link] electrode can cause melt through and can be
difficult to control in outof position [Link] appearance and possible defects can result. The
welding proceduredesignates the correct electrode size, generally based on metal type and
[Link], if no procedure or instruction is available, the welder will have to choosethe
correct electrode size.
Speed of Travel
Incorrect travel is a common mistake. Sometimes travel speed is the onlycondition a welder may
need to change. Travelling fast causes the puddle to freezetoo quickly. Because of this,
impurities and gases can be entrapped, making the beadface narrow with pointing ripple.
Incomplete penetration due to loss of the keyhole inroot pass is [Link] too slow will
cause the puddle to be large, with pile up, and astraight ripple pattern. For out of position
welding, slow travel speed can cause thepuddle to drip out the joint.

adDownload to read ad-free

13
Self-Check 1.1I. TRUE OR FALSE
Directions
: Read each statement below carefully. Write
TRUE
if the statement iscorrect and
FALSE
if the statement is not correct on your separateanswer sheet.1. Using a larger electrode
diameter can cause melt through/ burn through.2. Travelling too fast will make the bead face
narrow with pointing ripple.3. If the current is too low, the electrode melts too fast.4. Quality or
sound weld is the result of correct current, constant voltage, travelspeed, electrode angle and
correct electrode size.5. In fillet weld, electrode angle is not necessary for preventing undercut
andunder fill.6. Welding is the process of joining together two pieces of metal so that
bondingtakes place at their original boundary surfaces.7. Electrode circumference is based on
the thickness of the base metal, thewelding position, and the type of joint to be weld.8. Each
type of electrode has recommended amperage ranges for optimumperformance.9. High
amperage could also cause the electrode coating to overheat and breakdown.10. Arc length is
the distance from the tip of the electrode core wire to theelectrode handle.
Assessment

adDownload to read ad-free

14
Lesson Information 1.2
Safe
Welding Practices
What are the safety practices that should be observed when doing shieldedmetal arc welding?
The following are suggested practices and tips that will help to eliminate shopaccidents when
arc welding.1. Wear a welding mask. Wear leather or welding gloves at all times when arc
weldingto protect against hot electrodes, particles of spatter and slag, or the metal
beingwelded.
Welding Mask Welding Gloves Safety Helmet
Source: [Link]
2. Wear safety shoes to protect your feet and ankles from burns caused by weldspatter.
Safety Shoes
Source: [Link]
What is it?
What is it?
adDownload to read ad-free

15
3. Do not wear clothing with turned up cuffs. Keep your collar and pockets [Link] not
wear ragged, oily or greasy clothing. Never weld when your body is exposed,as when not
wearing a shirt, or wearing a short-sleeved shirt or shorts. If welding

apronis not available, wear cover all clothing rather than cotton. Cover all does not ignite
asreadily and provides better protection from heat.
Leather Jacket Full Body Harness

Source: [Link]
4. Inspect welding cables for broken insulation and frayed conductors. Checkelectrode holder
and ground clamps for positive connections before beginning to [Link] connections and
grounds may prove dangerous. Provide a dry wooden platformto stand on or wear rubber soled
shoes where there are damp floors.
Source: [Link]
adDownload to read ad-free

16
5. Clear all flammable materials away from the welding area before beginning to [Link]
sparks from the spatter may ignite flammable material several feet from thewelding operation.
Clear the welding area of rags, straw, paper, shavings, and otherflammable items before starting
to weld.
Flammable Sparks
Source: [Link]
6. Keep matches, lighters, papers, and cellophane wrappers out of pockets as theseitems ignite
quickly and/or may explode.
Explode
Source: [Link]
7. Turn on an exhaust system or industrial fan before beginning to weld. Weldingfumes soon
spread to all parts of the shop and may be injurious when inhaled. Takespecial measures to
avoid noxious fumes that occur when welding or cutting metalscontaining zinc. Inhaling zinc
fumes will cause you to feel ill for several hours afterwelding.
Injured Fumes Cut Hands
Source: [Link]
8. Do not strike an arc before covering face and eyes with the protective welding [Link]
ultraviolet light rays given off by the arc are the same as those transmitted bysunlight, except
that they are more intense and concentrated. Exposure to these rayswill cause a severe burn.
Eye irritation and burn will result if your eyes are not shielded.
Protective Equipment
Source: [Link]

adDownload to read ad-free

17
9. Protect other workers by using a welding screen to enclose your area. Warn persons
standing nearby, by saying “cover”, to cover their eyes when you are ready to strike
 an arc.10. Never look directly at the arc without protecting your eyes. The rays can
penetratethrough closed eyelids if you are welding at close range. Do not wear contact
lenseswhile welding or around a welder.11. Do not weld barrels, tanks or other containers
which may have held combustiblematerial. These operations are best performed by professional
welders.12. Do not chip slag from a weld unless your eyes and those of others near you
areprotected by safety glass.
Safety Glass Respirator
Source: [Link]
13. Be
alert for fires at all times because when the operator’s welding mask is lowered,
clothing may catch fire without being noticed. Use your senses of touch, smell, andhearing to
indicate that something is wrong. In case of a clothing fire, strip off theclothing if possible. Do
not run, as running fans the flames, instead, wrap yourself in afire blanket, or improvise with a
coat or a piece of canvas. If there is nothing at handto wrap in, drop to the floor and roll slowly.
Ear Muff
Source: [Link]
14. Handle all hot metals with tongs or pliers to prevent burning your hands or [Link] all
hot metals where no one will come in contact with. Develop the habit of feelingall metals
cautiously before picking them up. Do not leave hot metals where anyonemay pick them up or
step on them.15. Guard against saturation of clothing by perspiration or moisture. This
increasesthe shock hazard.16. Disconnect the welding machine when repairing or adjusting
it.17. Always unplug the welding machine and put all equipment away when you havefinished
for the day.18. In case of eye or skin burns, get first-aid treatment. Report immediately to
theinstructor all burns and injuries.19. Protect fuel tanks and fuel lines with wet sheet asbestos
when welding near motorsor power units. The paint on machinery also may start to burn from
the heat of welding.

adDownload to read ad-free

18
Self-Check 1.2I. TRUE or FALSE
Directions:
In the following suggested welding practices and tips listed below,answer
T
if the statement is
TRUE
and
F
if it is
FALSE
. Write youranswers on your separate answer sheet.1. Wear a welding helmet.2. Wear leather
or special fabric gloves at all times when arc welding to protectfrom hot electrodes, particles of
spatter and slag, or the metal being welded.3. Wear high-top shoes to protect your feet and
ankles from burns caused byweld
spatter.4. Wear clothing with turned up cuffs.5. Keep your collar and pockets unbuttoned.6. Do
not wear ragged, oily or greasy clothing.7. Never weld when your body is exposed, as when not
wearing a shirt, orwearing a short-sleeved shirt or shorts.8. Wool does not ignite as readily and
provides better protection from heat.9. Inspect welding cables for broken bones and
frayed conductors.10. Check electrode holder and ground clamps for positive connections
beforebeginning to weld.
II. Multiple Choice:

Determine the appropriate Personal Protective Equipment (PPE) to be [Link] your answers
on your separate answer sheet.1. They protect feet from hot sparks or falling
objects.a. Welding sleeves c. Safety glassb. Safety shoes d. Welding gloves2. It protects the body
from hot sparks.a. Leather Jacket c. Cover allb. Safety glass d. Respirator3. It is a Personal
Protective Equipment (PPE) that is used in working
heights.a. Leggings c. Full body harnessb. Welding Mask d. Safety glass4. It is used to protect
arms from falling flux or hot
sparks.a. Welding mask c. Welding sleeveb. Leggings d. Safety apron5. It is a working suit that is
used in workplace as whole body protection fromsparkling of
equipment.a. Full body harness c. Safety shoesb. Cover all d. Safety apron
Assessment
adDownload to read ad-free

19
Lesson Information 1.3

5S of Good Housekeeping
What is the 5S system?1.
SEIRI - SORT

•
Taking out and disposing unnecessary items.
•
Unneeded items are thrown away or disposed.
Source: [Link]
2.
SEITON
–
SYSTEMATIZE
•
Organizing of necessary items in good order and easy access.
•
Items in the workplace are arranged for ease of access and repeated use.
Source: [Link]
What is it?
adDownload to read ad-free

20
3.
SEISO- SWEEP

•
Cleaning of the workplace after usage or even if things are not dirty.
Source: [Link]
4.
SEIKETSU- SANITIZE/STANDARDIZE
•
Maintaining the workplace in high standard of housekeeping and sanitation.
•
Disinfection prevents the spread of microorganismthat cannot be seen with your naked eyes.
Source: [Link]
5.
SHITSUKE
–
SELF DISCIPLINE

•
Doing things spontaneously without being told.
•
Even if you have the knowledge and skillsbut you do not practice self-discipline,they are still co
nsidered as useless.
Source: [Link]
adDownload to read ad-free

21
Self-Check 1.3

Directions:
Give an idea of the following based on your own understanding. Writeyour answers on your
separate answer sheet.1.
Sort _________________________________________________________________ _________
________________________________________________________ _____________________
____________________________________________2.
Systematize _________________________________________________________________ __
_______________________________________________________________ ______________
___________________________________________________3.
Sweep _________________________________________________________________ _______
__________________________________________________________ ___________________
______________________________________________4.
Standardize _________________________________________________________________ __
_______________________________________________________________ ______________
___________________________________________________5. Self-Discipline
________________________________________________________________________ ____
____________________________________________________________________ _________
_______________________________________________________________
Assessment

adDownload to read ad-free

22
Lesson Information 1.4Acceptable (and Unacceptable) Weld Profiles
Source: [Link]

What is it?

adDownload to read ad-free

23
Self-Check 1.4Matching Type
Directions:
Match the pictures of Column A with the words or group of words incolumn B. Write only the
letter of your choice on your separate answersheet.
[Link] A Letter Column B
1 a Desirable fillet weldprofiles2 b Acceptable filletweld
profiles3 c Insufficient throat4 d Excessiveconvexity5 e Excessive undercut
Assessment

adDownload to read ad-free

adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
adDownload to read ad-free
Reward Your Curiosity
Everything you want to read.
Anytime. Anywhere. Any device.
Read free for 30 days
No Commitment. Cancel anytime.
Share this document
Share or Embed Document
Sharing Options
 Share on Facebook, opens a new window
 Share on Twitter, opens a new window
 Share on LinkedIn, opens a new window
 Share with Email, opens mail client
 Copy link
You might also like
 12 - SMAW W 3 - Essentials of Welding

Document10 pages
12 - SMAW W 3 - Essentials of Welding
NelPalalon
100% (1)
  Smaw 11 LP Mar. 7 2019

Document2 pages
Smaw 11 LP Mar. 7 2019
ronald curayag
100% (2)
 TVL-SMAW 12 - Week 5 - Lesson 1 - Acceptable Weld Profiles

Document11 pages
TVL-SMAW 12 - Week 5 - Lesson 1 - Acceptable Weld Profiles
NelPalalon
100% (3)
 SMAW 11 - Q1-Module-1-Lesson4

Document11 pages
SMAW 11 - Q1-Module-1-Lesson4
Jerome A. Gomez
100% (3)
 SMAW 11 Modue

Document39 pages
SMAW 11 Modue
Francis Rico Mutia Rufon
100% (9)
 TVL-SMAW 12 - Week 4 - Lesson 2 - International Welding Codes and Standards
Document12 pages
TVL-SMAW 12 - Week 4 - Lesson 2 - International Welding Codes and Standards
NelPalalon
100% (2)
 Smaw 12 Module 1 Grade 12

Document39 pages
Smaw 12 Module 1 Grade 12
Francis Rico Mutia Rufon
100% (15)
 Safe Welding Practices: Smaw Quarter 1 Week 5 Module 5

Document22 pages
Safe Welding Practices: Smaw Quarter 1 Week 5 Module 5
Jessel Mejia Onza
100% (1)
 Lesson Plan in SMAW

Document2 pages
Lesson Plan in SMAW
miguel
95% (79)
 Summative Test
Document2 pages
Summative Test
Arnelson Derecho
100% (6)
 11 SMAW Q4 Module 4

Document13 pages
11 SMAW Q4 Module 4
Mark Johnson Villaron
No ratings yet
 Quarter4 M 1 SMAW 10 Final

Document25 pages
Quarter4 M 1 SMAW 10 Final
Titser Ramca
100% (1)
Show more
Related titles