START: 1

WELDING TRAINING RULES AND PRECAUTION

1.Course will start exactly as scheduled,and sign the attendance sheet before training
begin.

2.Always wear correct personal protective equipment (PPE) like protective clothing,
Safety shoes, boots, and eye protection while training is on process.

3.Always check welding equipment, like welding machine, grinder, oxy/acetylene

cutting,power circular cutter, electrode oven are in good condition.

4.Electrodes are expensive, maintain at least 2” long electrodes bts before each
disposal, and place it in proper trashcan.

5.Welding cubicles are made of light materials do not lean or hold unto it.

6.Do not make unnecessary weld on each stand, use extra materials as striker of elec-
trodes and for amperages adjustment.

7.Switch off all welding machine, grinder, oxy acetylene tank, regulator before leaving
each respective area especially during break time.

8.Always check welding area free from any flammable materials and safe for work.

9.Observe good house keeping: clean your respective area before you leave.

10.Use toilet and washing basin properly consider it as your own, and avoid lettering
on wall.

11.Be aware of unconscious act of your fellow student and co-workers, call attention of
your trainor or officer on duty.

12.Horseplay is strickly prohibited inside training premises.

 2.

OUTLINE OF LECTURE
IN SHIELDED METAL ARC WELDING (SMAW NC1—SMAW NCII)

1. FUNDAMENTALS OF WELDING

1.1 What is welding

2.2 How does welding differ from soldering and brazing
3.3 Safety in welding
4.4 Hand tools
5.5 Common kinds of welding

1.5 ARC WELDING:

1.5 A1- SMAW (Shielded metal arc welding)
1.5 A2- GMAW (Gas metal arc welding)
1.5 A3- GTAW ( Gas tungsten arc welding)

1.5 GAS CUTTING:

1.5-B1- Oxy/accetylene gas welding
1.5-B2- Brazing
1.5-B3- Soldering

1.6 TPES OF WEDING MACHINE:

1.6-1 Arc welding machine
1.6-2 Dc welding machine
1.6-3 Ac/Dc welding machine
1.6-4 Diesel or gasoline Engine driven Ac/Dc welding machine.

1.7 Basic electricity

1.8 Welding position
1.9 Types of welds
1.10 Types of joint and their parts
1.11 Types of groove and their parts
1.12 Different shape and types of base metals
 3.
WHAT IS SMAW?

SMAW (Shielded Metal Arc Welding)

OBJECTIVES:

1.Identify and explain shielded metal arc welding (SMAW) safety?

a.)Always wear suitable protective clothing and eye protection.

b.)Always keep a safe and clean work area.
c.)Always keep welding machine and good condition.
d.)Always check welding area to make sure they’re safe to work in.
e.)Always respect gas cylinder as dangerous and potentially lethal.
f.)Always make sure vintallation provides three to four charges of air per hour.
g.)Always look out for fellow students and workers.

2.Identify and explain welding electrical current?(welding machine and their characte
ristic)

a.)Basic circuit— current must travel in a complete loop from the power supply to
the arc and back to the power supply and circuit must be grounded.
b.)Polarity— this is the direction that current flows through a basic welding circuit
and is express as negative or positive in a relation to direct current.
c.)Direct current – (DC) this is current that flow only in one direction.

d.)Alternating current— (AC) this is current that alternate from one direction to
another 60 times per seconds and is express as 60 hertz.
e.)Direct current electrode negative—this is provide by a negative electrode to work
piece, positive work piece that courses the current flow from the electrode to
work piece.

Note: (DC—EN/DC—SP) Direct current straight polarity.

(DC—EP/DC—RP) Direct current reverse polarity.

3.Identify and explain welding machine?

a.)AC-DC welding machine — another type of welding machine that use both alternative current and
direct current as power supply.
b.)DC- welding machine -- the type that use direct current as power supply, direct current is a kind
that flows in one direction.
c.)AC- welding machine— a machine that use alternate current as power supply, alternating current
is a kind of electricity which reverse its direction periodically.
d.)Diesel or gasoline engine driven—DC or AC welding machine a machine driven by diesel or gaso
line through generator use where there are no power line especially in remote area.
 4.

Benefits of learning smaw/beginners.

a.)smaw introduces a beginner to the basic of another arc welding processes.

b.)smaw acquaints the beginner with the welding machine and electrical used in
other arc welding process.
c.)smaw introduces the beginners to the world of electrodes and their relationship to the metal thick-
ness,welding speed, and amperage requirements.
d.)smaw acquaints the beginner with the basic concepts of shielding and how shielding improves and
protects a weld.

Welding processes in their applications.

1. Terms and definitions.

a.)Base metal— the metal or alloy tha is welded, brazed , soldered or cut.
b.)coalescence— the growing together or growth into one body of the materials being welded.
c.)fusion welding— the melting together of filler metal and base metal or of base metal only to
produce a weld.
d.)welding— a joining process that produces coalescence of materials by heating to a melting point
with or without the application of pressure and with or without the uses ot filler metal.

(a) shielded metal arc welding (smaw) an arc welding process that produces coalescence of material by
heating them with an arc between a covered electrode and a work piece.shielding is obtained from
the composition of electrode covered electrode and a work piece,shielding from de- composition of
electrode cover pressure is not use, and filler is obtained from the electrode.

images:
 (b)Gas tungsten arc welding—an arc welding process that produces coalesence of materials by heating
them with an arc between a non consumable tungsten electrode and a work piece, shielding is
obtaining from gas and filler metal may or may not be used.

Images.

(c)Gas metal arc welding (gmaw)—an arc welding process that produces a coalescence of metal
by heating them with an arc between continuous filler metal electrode and work piece, shielding is
obtained entirely from an externally supplied gas.

Images.

(d)Submerge arc welding (saw)—an arc welding process that produces coalescence of metals by
heating them with an arc or arcs between a bare metal electrode or electrodes and a work piece,
the arc and the molten metal are shielded by a blanket of granular,fusible material on the work
piece, pressure is not used and filler metal is obtained from the electrode or sometimes from
a supplemental source.

images.
(c)Arc length.

Besides the current,the arc length is an essential factor in producing a sound weld.Too long an arc
dissipates the arc force resulting in less concentration of heat in the work. The arc tends to be
woobly and is difficult to maintain ith consequently excessive spattering. The danger of porosity
becomes greater,as the longer arc permits longer exposure of the droplets of molten metal to the
harmful effects the nitrogen and oxygen in the air.

In the arc is too short, a high uneven bead results with poor fusion and the possibility of entrap-
ping slag and formation of surface gas holes becomes greater.

In general oerlikon electrodes require a short arc—an arc length about equal to the diameter of the
diameter of the core wire,using the recommended current the arc is so stable that the electrode
can be held as close as possible to the work and in come types can dragged without sticking.The
coating however should not be allowed to dip into the molten pool,especially in the case of cellu-
losic electrodes..CELLOCORD and CELLCORD.

(d)Travel speed.

Assuming that one maintain the correct arc length and uses the correct current,the speed at which
one moves the electrodes will now determine the soundness and appearance of the weld bead.Too
high speed will result incomplete fusion (not enough time is provided to melt the base metal) with
slag inclusions and gas holes,especially and fillet welds as there is not enough “pudding time” to
allow this impurities to scape to the surface. The slag may be left behind and slag coverage will be
incomplete. Too slow a speed is a waste of time and electrode—the metal piles up—and the slag
may crowd the arc and smother it.

In general the rate of travel is correct if the length of the deposited bead is ¾ or about to that
of consumed electrode.

(e) Size of electrode.

For economical reasons,it is best to use the largest size electrode applicable. The use of small
electrodes requires more passes and is of no advantage except in welding special alloy or
casting (cast iron, stainless steel where low heat input is desirable.

However small size electrodes may be necessary for the first pass or stringer bead to assure
complete fusion at the root of jonts.

In over head or horizontal welding, electrodes smaller by one size than those used for flat posi-
tion are recommended to minimized metal run down, electrodes more than 3/16” in diameter are
not recommended for overhead welding.
 5.

Properly dressed welder for personal protection

Here are some useful tips to help ensure safety in the work place.

1. keep pipe extinguishers available forall types of fire.

2 .welding areas should have adequate and functioning ventilation system,airlines and and fans

should be installed to eliminate fumes and toxic gases.

3. flammable gas should be stored in separate safe area.

4. welding machine should not be operated in wet areas,cable and other connection should be fre-

Quently chech for leaks, cracks, and other damage.

5. remove from used containers or tanks the residues of chemicals,which may cause explo
 6.

Hand tools:

A welder must be equipped with the necessary tools to help him in his work. Listed below are some
hand tools with their corresponding uses:

√ Blacksmith tongs- to hold a piece of metal

√ Adjustable pliers- to hold a hot work piece

.
√ Chipping hammer- to remove slag.

√ Wire brush- to clean the surface of a work piece.

√ Steel scriber with tungsten carbide (hard material) to mark lay-out

√ Try square- to check the squareness of welded components.

√ Drill (high speed)b to make holes into the work piece

√ Portable power drill- to drive the drill bit to produce holes.

√ Tape rule (steel tape) – to gauge line measurement

√ C- clamp – to hold two or more pieces together for rigidity and stability in welding

√ Bence vise – to clamp a work piece

√ Portable power grinder- to clean out slag ‘s, spatters and the rough surfaces of a work piece.
 7.

Common kinds of welding

a. Arc welding.

1. Shielded metal arc welding (Smaw)—an arc welding process wherein coalescence is produced

electrodes arc between a covered metal electrode and the work, shielding is developed by the
evaporation and chemical breakdown of the electrode covering.

2. Mig-mag welding gas metal arc welding (Gmaw)—an arc welding process wherein coalescence is
produced by heating an electrode between a filler metal electrode and the work, shielding is
obtained from a gas or a mixture of gases and fluxes.

3. Tig welding, gas tungsten arc welding (Gtaw)-- an arc welding process wherein coalescence
is produced by heating with an arc between a single tungsten (non consumbles) electrode and
the work shielded is obtained from an inert gas.

4. Stud welding—an arc welding process wherein coalescence is produced by establishing on arc be-
tween a metal stud and the work piece until sufficient temperature is produced and then pressing
the stud against the work with enough pressure to complete joining of the stud to the work.
 8.

b. Gas welding.

1. Oxy-acetylene gas welding—a gas welding is done by burning gases. Oxygen and acetylene mixed
together in a carburetor-mixing chamber.Using oxy-acetylene flame,welding is possible with or
without a filler metal or welding rod.

2. Brazing—is a welding process wherein coalescence is produced by heating to suitable temperature

above 800˚F and using a none ferrous filler metal which has a melting temperature below that of
base metal .Carburizing flame is used in this process.

3. Soldering—is also welding process wherein coalescence is produced by heating at 570˚F to 595˚F
maximum temperature coalescence is the same as brazing,it only differ in tensile strength of the
welding process, its not adhesion based on the author’s conclusion and experience. It can only be
called soldering when you will be using soldering rod and soldering iron on a particular
 9.

Types of welding machine

1.Alternating current (AC) welding machine.

A welding machine that uses alternating current as power supply. Alternating cu-
rrent is a kind of electricity, which reverses its direction periodically. For 60˚ cycle current, the cu
goes in one direction and then in the other direction 60 times in the same second, so that the
current changes its direction120 times in one second.

2.Direct current (DC) welding machine

The type that uses direct current as power supply.Direct current is electricity that flows in one di-
rection.

3.AC-DC Arc welding machine.

Another thype of welding machine that uses both alternating current (AC) and dorect current as
power supply.

4.Diesel or gasoline engine driven DC OR AC Welding machine

A welding machine driven by diesel or gasoline through a generator used where there no power
lines especially in remote areas.
 10.

Electrical welding circuit

1. Power source
2. Welding machine
a. current adjuster
b. gauge
3. Electrode cable
4. Ground cable
5. Electrode clamp handle
6. Electrode holder
7. Welding electrode
8 Base metal
 11.
Welding positions
(Figure shows ASME and EN STANDARDS)

IMAGES.
Welding positions

Fillet welding

Groove welding

As per illustration above,in plate and pipe showed and all positions te exact zigzag manipulation and dis-
tribution of the molten metal using counting method.

When discussing groove welds, a “G” is used to signify groove weld,and the number is assigned to sig-
nify welding position.

Plate weld designation are as:

1G- flat position,groove weld

2G- horizontal position, groove weld
3G- vertical position, groove weld
4G-overhead position, groove weld

Pipe weld as:

1G- flat position,groove weld pipe rotated

2G- horizontal groove weld, pipe axis is vertical
5G- multiple position (overhead, vertical,and flat) groove weld,pipe axis is horizontal and is not rotated.
6G- & 6GR- multiple positions groove weld, pipe axis is 45˚ from horizontal and is n
Continue#11.b.

Pipe welding situations that requires special attention.

a.When field welding pipe in a grassy area,be especially careful of fire, and doubly careful in the pre-
presence of light to moderate winds.
b. When pipe welding in situations where oil and gaslines are present ,check with a supervisor to make
sure the area is safe to weld in.
c.Before pipe welding or cutting on an oil or gas drilling rig, check with the drilled or tool pusher to
make sure the area is to safe to weld in.
d.Use shielding screens in all instances where sparks from cutting or arc welding could pose a danger
to nearby workers or equipment.

Special precautions for pipe welding hotlines

a. Never cut into or weld on a line without knowing for certain that it is safe.
b. Never cut into or weld on a hotline without going through the proper procedure for obtaining a
“ hot work “ or entry permit from a supervisor authorized to grant such permission.

Aws position for groove pipe welding.

a. Position 1G. images.

I. horizontal rolled, weld flat (± 15˚)

image.
2.rotate pipe and deposit weld at or near the top.

b. Position 2G. images.

1.Pipe vertical weld horizontal (± 15˚)

2.Pipe shall not be rotated during welding

c.Position 5G. images.

1.Pipe horizontal fixed (± 15˚) weld flat,

vertical. Overhead Image.

2.Pipe shall not be rotated during welding.

d. Position. 6G. images.

Continue #11.c.

Aws position for fillet pipe welding.

a. Position 1F. images.

I. Pipe rotated at 45˚

2. Fillet weld flat at or near the top.

b. Position 2F. images.

1. Pipe vertical fixed (± 15˚)

2. fillet weld horizontal

c. Position 4F. images

1. Pipe vertical fixed (± 15˚)

2. Fillet weld overhead

d. Position 5G. images.

1. Pipe horizontal fixed

2. Fillet weld horizontal vertical and overhead
 12.

Types of welds
Common terms applied to a weld
Fillet Plug or slot Groove

Arc seam or spot slotted weld surfacing

Types of groove and their parts. 14.

Square groove

double bevel
Single bevel

Single- u Double-u
 13.

Types of joint and and their parts

Butt joint

Images:

Applicable welds
Square groove, V-groove, Bevel groove, U- groove J- groove, Flare v-groove, Flare bevel groove,
Edge flange, Braze.

Corner joint:

Images:

Applicable welds
Fillet, Square groove, V-groove, Bevel groove, U- groove, J-groove, Flare v- groove, Flare bevel
Groove, Edge flange, Corner joint, Spot, Projection, seam, Braze.

T- joint

Images:
Applicable welds:
Fillet, Plug, Slot, Square groove, Bevel groove, Flare bevel groove, Spot, Projection, seam,
Braze.
 14.

Lap- joint
Applicable weld
Plug, Slot Bevel groove, J- groove, Flare bevel groove, Spot, Projection, Seam, Braze.

Edge joint:

Images:

Applicable welds

Square groove, Bevel groove, V- groove, U- groove, J- groove, Edge flange, Corner flange
Seam, Edge.
 15

Different shapes of materials that the student must know. It may be made of Stainless steel, Mild steel,
Brass, Bronze, copper,aluminum.

Images:

a. b. c. d. e. f. g. h. i j.

a.Flat bar

b.Metal sheet

c. Square bar

d. Rectangular bar

e. Round bar

f. B I. pipe

g. Hexagonal bar

h. Angle bar

i. I- beam

j. C- clamp
 16.

Welding techniques

1.Zig zag
2.Crescent
3.Oscillation
4.Circular
-Scratching methods of striking an arc
-Position to counter arc blow 10˚/15˚/90˚
-Electrode angle for overlapping beads
-Arc length x the diameter of electrodes
-Travel angle 10˚/15˚ trave angle drag 10˚/15˚
-Bead running techniques
-technique for electrode take off, to avoid craterfill.
-Basic steps in preparation joint.

Weaving motion of electrode—the weaving motion depends to tally on the skillness of the welders.
Weaving motion—is very essential to fill-up the crater while welding goes on various types weaves
motion arc to practice.
Weaving motion—is the most important control to produce a sound and durable weld .

There are some effects of good weaving.

1. Improves penetration and fusion.

2. Help maintain desired weld size and bead profile.
3. Eliminates undercuts and overlaps
4. Prevents slag inclusion porosity and other defects

Welding parameters.

The welding procedure is a set of written instruction which list all parameters required to produce a
sound weld to some specific code specification.

The specific parameters.

The weld procedure is a set of written instruction which list all parameters required to produce a sound
weld to some specific code specification.
 17.
Smaw starting technique

a. The technique most basic to all arc welding is to start and maintain an arc so that current is forced
across the gap between the electrode tip and the base metal . and beginners should develop the
skill of starting and maintaining an arc with a proper gap or arc length.

b. The “scratch method” for starting an arc is the simplest method for most beginners, and the
scratch method works according to the following.

1. Move the electrode across the base metal at an angle like you would use to strike a match.
2. As the electrode scratches the base metal, an arc starts.
3. When the arc starts, raise the electrode slightly to make a long arc,and then return to normal
Arc length.

c. The top method for starting an arc is accomplished by moving the electrode downward in a ver-
tical direction until iot just tap sthe base metal,then raising the electrodes up slightly to form a
long arc, then returning to normal arc length again.
 18.

Padding—used with all types of electrodes to build up metal surfaces with one or more layers of
weld
beads and can be used on either flat or curved surfaces as overlapping straight beads or overlapping
weave beads .

Technique for stopping and restarting an arc.

a. anticipate the point where the rod is going to be used up or where welding will stop
b. stop the forward motion of the electrode
c. gradually withdraw the electrode to break the arc.
d. chip the slag off the end of the weld about ¼ to ½ “ back.
e. restart the arc about ½ “ in front of the forward end of the crater.
i. move the electrode quickly back to the back crown of the crater and immediately resume welding in
the direction.
 19.

The specific parameters are:

1. Welding process
2. Welding technique
3. Joint geometry
4.Filler material
5. Current
6. Voltage
7. Post heat
8. Preheat

The welding should carry out the welding exactly to this instruction . The welder joint
so produced are to be satisfied,besides all these general procedure and system spe-
cific care and attention must be given to the following areas of welding.

1. Multipass welding
2.Long continuous groove or fillet joint
3.structure consisting of a number of welds
4.Thin sheet of welding

In this area of welding ,in addition of the above control on welding parameters a definite sequence
of welding should be followed to make quality joint particularly to prevent distortion.

In fusion welding process, prior to welding the following physical parameters must be checked to pro-
duce a defect free weld.

1.Parent metal,base metal, check up for weld ability.

2.Clean the edges of joints from dust,grease,or any other foreign element.
3.Prepare the edge joint geometry.
4.Selection of matching electrodes
5.Selection of desired current and voltage
6.Weld speed and weld feed they help to deposit metal uniformly and develop proper weld size.
7.Welding technique sequence
8.Electrode movement / motion or uniformity of molten metal or bead.
 20.

A. What are the basic responsibilities of a welder during in production?

1.To weld by the process he is qualified.

2.To weld as per the instruction of the welding supervisor and in the line with the applicable welding
procedure.
3.To use the welding consumable economically.
4.To identified the weld performed by him, by making working weld area.
5.To keep his area clean.

While performing his basic job,welder shall also observe the following rules.

1.Welding consumables shall be received and returned in portable electrode oven.

2.Shall received electrodes only after a proper authorization from the supervisor
3.Shall perform grinding or arc gouging and grinding whenever required

B.Production welding requirements are:

1.Welding procedure list. (WPL)

2.Welding procedure specification. (WPS)
3.Welding qualification test. (WQT)
4.Suitable welding consumable.(SWC)

C.What is welding procedure specification?(wps)

Welding procedure specification is a working instruction to perform a given production weld.

The information in this sheet relevant to welder are.

1.Process used—gtaw + smaw

2.Type of materials used in thickness
3.Joint preparation
4.Preheating requirements
5.Gas if use gtaw
6.Welding consumables types in its size
7.Welding parameter such as current,voltage,and speed.
8.Position of welding
9.Technique such as weaving,back gouging.
10.Electrical characteristics such as type of current,polarity.

D.What is welding procedure list? (WPL)

Welding procedure is a document which identifies the weld joint in the item,it is also identifies the type
of weld preparation and the weld procedure (WPS) to employed against each joint
 21.

E. What does a client inspector check in the production welding?

1.Joint fit-up
2.Preheat and interpass temperature
3.Weld consumable used
4.Welding position
5.Welding qualification

AWS guideline for G- position qualification.

a. Qualification in the 1G position qualifies for welding only in the 1G position.

b. Qualification in the 2G position qualifies for welding in the 1G and 2G position.
c. Qualification in the 2G and 5G Positions qualifies for welding in the 1G and 5G position
d. Qualification in the 6G position qualifies for welding in any position because it includes elements
of all positions.

AWS guidelines for F-position qualification.

a.Qualification in the 1F position qualifies for fillet welding only in the 1F position.
b.Qualification in the 2F position qualifies for fillet welding in the 1F and 2F position only.
c.Qualification in the 4F position qualifies for fillet welding in the 1F,2F, and 4F position only.
d.Qualification in the 5F position qualifies for fillet welding in any position because it includes elements
of all positions.
e.Qualification in any of the fixed G position qualifies for the fillet welding of any fillet welding in pipe.

Guidelines for pipe welding safety.

a.Wear proper protective clothing for both oxy-acetylene cutting and arc welding.
b.Wear protective leader sleeves to protect from sparks in confined space and out of position welding.
c.Unroll and roll-up lead cables with care.
d.Handle beveling machine with care because they are easy to damage if dropped.
e.Handle free ends of pipe being beveled with or pliers to keep them from dropping on your feet.
i. Keep flammable materials away from the welding area and make sure thre is proper vintellation.
g.Keep a correct types of fire extinguisher nearby when pipe welding in a shop and have one at a
convenient location when welding in the field.
h.Use windshields when they are practical, but do not pipe weld in rain or in high winds or blowing
sand.
symbol of welding

22.
 23.

Welding current for carbon electrode types.

Electrode Size Amperes Volts

E-6010 3.32mm/ 2.5” 45-- 75 22/28

E-6010 3.2mm/ 1/8” 80- 140 22/28
E-6011 3.32mm/ 2.5” 45-75 22/28
E-6011 3.2mm 1/8” 80- 140 22/28
E-6012 3.32mm 2.5” 40- 75 22/28
E-6012 3.2 mm/1/8” 75- 140 22/28
 24.
WELDING TIPS AND TRICKS

Theres is an ACRONYM used in shielded metal ar welding (called)CLAMS.

It is way to cover the basis when you teaching some one to weld

CLAMS stands for,

CURRENT-is not only for amperage but also hot start polarity, arc control(also called dig
on some machine)
I really like the hot start teaching,its not on all machines but what is does is strike the
arc at a hotter amperage than what is set on te machine and it make perfect sense the
have a few more aps to prevent the rod from sticking,some machine allow you to set
the hot start for the percentage of amps over 100% o the setting and also for a time
like one second or 2 seconds.and control is a great features too,although not always
desired with arc control feature the machine sense in voltage and is ale to bump-up the
amperage when the arc get too tight so it can prevent sticking the down side of that is
it takes away the control the welder has of cooling or heating up the puddle with arc
length.

LENGHT.-of arc for welding of E-7018 out of positions,its important to maintain a very
tight arc length,I mean that you should be able to feel the rod rub a bit,iam not talking
about forcefully cramming the rod in the puddle but rather just gently holding it very
close and steady .If you hold a long arc its difficult to make the weld look good.

ANGLE- of electrode should be a slight push without even trying,but I am a push angle
sometimes my angles gets to steep.

MANIPULATION-of electrode is very slight to the root pass with E7018 in fac some
welders prefer to usea straight drag with no side ways moment (and some procedure
are written for bidding any side to side moment)for the second pass I used two weave
motion holding the toes for a count to prevent undercuts,and spesking of undercut
cleaning the mill scale off pior to welding helps to prevent undercut too.Yes the stick
electrode will burn right thru the mill scale and its possible to not have undercut even
mill scale intact,its just best practiceto remove mill scale.

SPEED-of travel is just slow enough for the ripples to be tight with no undercut.If travel
speed is excessively slow,then heat will buld up and the weld might be too convex or
piled-up,in the flat position its pretty hand to travel too slow but for vertical uphill welds
and overhead welds,travelling too slow will cause the weld to sag due to the forces of
gravity,surface tention of the puddle etc.
Prepared by:
Jaime A. Sumangil. Trainer/Assessor
 16.

Welding techniques

1.Zig zag
2.Crescent
3.Oscillation
4.Circular
-Scratching methods of striking an arc
-Position to counter arc blow 10˚/15˚/90˚
-Electrode angle for overlapping beads
-Arc length x the diameter of electrodes
-Travel angle 10˚/15˚ trave angle drag 10˚/15˚
-Bead running techniques
-technique for electrode take off, to avoid craterfill.
-Basic steps in preparation joint.

Weaving motion of electrode—the weaving motion depends to tally on the skillness of the welders.
Weaving motion—is very essential to fill-up the crater while welding goes on various types weaves
motion arc to practice.
Weaving motion—is the most important control to produce a sound and durable weld .

There are some effects of good weaving.

1. Improves penetration and fusion.

2. Help maintain desired weld size and bead profile.
3. Eliminates undercuts and overlaps
4. Prevents slag inclusion porosity and other defects
Welding parameters.

The welding procedure is a set of written instruction which list all parameters required to produce a
sound weld to some specific code specification.

The specific parameters.

The weld procedure is a set of written instruction which list all parameters required to produce a sound
weld to some specific code specification.

19.

The specific parameters are:

1. Welding process
2. Welding technique
3. Joint geometry
4.Filler material
5. Current
6. Voltage
7. Post heat
8. Preheat

The welding should carry out the welding exactly to this instruction . The welder joint
so produced are to be satisfied,besides all these general procedure and system spe-
cific care and attention must be given to the following areas of welding.

1. Multipass welding
2.Long continuous groove or fillet joint
3.structure consisting of a number of welds
4.Thin sheet of welding

In this area of welding ,in addition of the above control on welding parameters a definite sequence
of welding should be followed to make quality joint particularly to prevent distortion.

In fusion welding process, prior to welding the following physical parameters must be checked to pro-
duce a defect free weld.
1.Parent metal,base metal, check up for weld ability.
2.Clean the edges of joints from dust,grease,or any other foreign element.
3.Prepare the edge joint geometry.
4.Selection of matching electrodes
5.Selection of desired current and voltage
6.Weld speed and weld feed they help to deposit metal uniformly and develop proper weld size.
7.Welding technique sequence
8.Electrode movement / motion or uniformity of molten metal or bead.

17.
Smaw starting technique

a. The technique most basic to all arc welding is to start and maintain an arc so that current is forced
across the gap between the electrode tip and the base metal . and beginners should develop the
skill of starting and maintaining an arc with a proper gap or arc length.

b. The “scratch method” for starting an arc is the simplest method for most beginners, and the
scratch method works according to the following.

1. Move the electrode across the base metal at an angle like you would use to strike a match.
2. As the electrode scratches the base metal, an arc starts.
3. When the arc starts, raise the electrode slightly to make a long arc,and then return to normal
Arc length.

c. The top method for starting an arc is accomplished by moving the electrode downward in a ver-
tical direction until iot just tap sthe base metal,then raising the electrodes up slightly to form a
long arc, then returning to normal arc length again.
 18.

Padding—used with all types of electrodes to build up metal surfaces with one or more layers of
weld
beads and can be used on either flat or curved surfaces as overlapping straight beads or overlapping
weave beads .

Technique for stopping and restarting an arc.

a. anticipate the point where the rod is going to be used up or where welding will stop
b. stop the forward motion of the electrode
c. gradually withdraw the electrode to break the arc.
d. chip the slag off the end of the weld about ¼ to ½ “ back.
e. restart the arc about ½ “ in front of the forward end of the crater.
i. move the electrode quickly back to the back crown of the crater and immediately resume welding in
 the direction.

trode, and speed of travel really makes you think about the fundamentals of welding
…sometimes we can all benefit from whether we are just learning,or have years of
experience.
WELDING TIPS AND TRICKS

Theres is an ACRONYM used in shielded metal ar welding (called)CLAMS.

It is way to cover the basis when you teaching some one to weld

CLAMS stands for,

CURRENT-is not only for amperage but also hot start polarity, arc control(also called dig
on some machine)

I really like the hot start teaching,its not on all machines but what is does is strike the
arc at a hotter amperage than what is set on te machine and it make perfect sense the
have a few more aps to prevent the rod from sticking,some machine allow you to set
the hot start for the percentage of amps over 100% o the setting and also for a time
like one second or 2 seconds.and control is a great features too,although not always
desired with arc control feature the machine sense in voltage and is ale to bump-up the
amperage when the arc get too tight so it can prevent sticking the down side of that is
that,it takes away the control the welder has of cooling or heating up the puddle with
arc length.

LENGTH-of arc for welding of E-7018 out of positions,its important to maintain a very
tight arc length,I mean that you should be able to feel the rod rub a bit,iam not talking
about forcefully cramming the rod in the puddle but rather just gently holding it very
close and steady .If you hold a long arc its difficult to make the weld look good.

ANGLE- of electrode should be a slight push without even trying,but I am a push angle
sometimes my angles gets to steep.

MANIPULATION-of electrode is very slight to the root pass with E7018 in fac some
welders prefer to usea straight drag with no side ways moment (and some procedure
are written for bidding any side to side moment)for the second pass I used two weave
motion holding the toes for a count to prevent undercuts,and spesking of undercut
cleaning the mill scale off pior to welding helps to prevent undercut too.Yes the stick
electrode will burn right thru the mill scale and its possible to not have undercut even
mill scale intact,its just best practiceto remove mill scale.

SPEED-of travel is just slow enough for the ripples to be tight with no undercut.If travel
speed is excessively slow,then heat will buld up and the weld might be too convex or
piled-up,in the flat position its pretty hand to travel too slow but for vertical uphill welds
and overhead welds,travelling too slow will cause the weld to sag due to the forces of
gravity,surface tention of the puddle etc.

Thinking about current, length of arc,angle of electrode,manipulation of elec

Common kinds of welding

a. Arc welding.

1. Shielded metal arc welding (Smaw)—an arc welding process wherein coalescence is produced

electrodes arc between a covered metal electrode and the work, shielding is developed by the
evaporation and chemical breakdown of the electrode covering.

2. Mig-mag welding gas metal arc welding (Gmaw)—an arc welding process wherein coalescence is
produced by heating an electrode between a filler metal electrode and the work, shielding is
obtained from a gas or a mixture of gases and fluxes.

3. Tig welding, gas tungsten arc welding (Gtaw)-- an arc welding process wherein coalescence
 is produced by heating with an arc between a single tungsten (non consumbles) electrode and
the work shielded is obtained from an inert gas.

4. Stud welding—an arc welding process wherein coalescence is produced by establishing on arc be-
tween a metal stud and the work piece until sufficient temperature is produced and then pressing
the stud against the work with enough pressure to complete joining of the stud to the work.

9.

Types of welding machine

1.Alternating current (AC) welding machine.

A welding machine that uses alternating current as power supply. Alternating cu-
rrent is a kind of electricity, which reverses its direction periodically. For 60˚ cycle current, the cu
goes in one direction and then in the other direction 60 times in the same second, so that the
current changes its direction120 times in one second.

2.Direct current (DC) welding machine

The type that uses direct current as power supply.Direct current is electricity that flows in one di-
rection.

3.AC-DC Arc welding machine.

 Another thype of welding machine that uses both alternating current (AC) and dorect current as
power supply.

4.Diesel or gasoline engine driven DC OR AC Welding machine

A welding machine driven by diesel or gasoline through a generator used where there no power
lines especially in remote areas.

11.
Welding positions
(Figure shows ASME and EN STANDARDS)

IMAGES.
Welding positions

Fillet welding

Groove welding

As per illustration above,in plate and pipe showed and all positions te exact zigzag manipulation and dis-
tribution of the molten metal using counting method.
 When discussing groove welds, a “G” is used to signify groove weld,and the number is assigned to sig-
nify welding position.

Plate weld designation are as:

1G- flat position,groove weld

2G- horizontal position, groove weld
3G- vertical position, groove weld
4G-overhead position, groove weld

Pipe weld as:

1G- flat position,groove weld pipe rotated

2G- horizontal groove weld, pipe axis is vertical
5G- multiple position (overhead, vertical,and flat) groove weld,pipe axis is horizontal and is not rotated.
6G- & 6GR- multiple positions groove weld, pipe axis is 45˚ from horizontal and is not rotated.

Continue #11a.

When discussing fillet welds an “F” is used to signify a fillet weld, a numbered is assigned to signify
the welding position.

Plate weld designation are as:

1F- flat position, fillet weld.

2F- horizontzal position, fillet weld.
3F- vertical position, fillet weld.
4F- overhead position, fillet weld.

Pipe weld as:

1F- flat position, fillet weld, pipe axis is 45˚ from the horizontal & the pipe is rotated
2F- horizontal fillet weld, pipe axis is vertical
2FR- horizontal position,fillet weld pipe axis is horizontal and the pipe is rotated
5F- multiple position (overhead ,vertical and flat ) fillet weld pipe axis is horizontal and is not rotated
6F- multiple position, fillet weld, pipe axis is 45˚ from horizontal and is not rotated.

Welding position and types of weld

Images:

12.

Types of welds
Common terms applied to a weld
Fillet Plug or slot Groove

Arc seam or spot slotted weld surfacing

Types of groove and their parts. 14.

 Square groove

double bevel
Single bevel

Single- u Double-u

13.

Types of joint and and their parts

Butt joint

Images:

Applicable welds
Square groove, V-groove, Bevel groove, U- groove J- groove, Flare v-groove, Flare bevel groove,
Edge flange, Braze.

Corner joint:

Images:

Applicable welds
Fillet, Square groove, V-groove, Bevel groove, U- groove, J-groove, Flare v- groove, Flare bevel
Groove, Edge flange, Corner joint, Spot, Projection, seam, Braze.
 T- joint

Images:
Applicable welds:
Fillet, Plug, Slot, Square groove, Bevel groove, Flare bevel groove, Spot, Projection, seam,
Braze.

Continue #14.

Lap- joint
Applicable weld
Plug, Slot Bevel groove, J- groove, Flare bevel groove, Spot, Projection, Seam, Braze.

Edge joint:

Images:
Applicable welds

Square groove, Bevel groove, V- groove, U- groove, J- groove, Edge flange, Corner flange
Seam, Edge.

15.

Different shapes of materials that the student must know. It may be made of Stainless steel, Mild steel,
Brass, Bronze, copper,aluminum.

Images:

a. b. c. d. e. f. g. h. i j.

a.Flat bar

b.Metal sheet

c. Square bar

d. Rectangular bar

e. Round bar

f. B I. pipe

g. Hexagonal bar

h. Angle bar
 i. I- beam

j. C- clamp

2.

OUTLINE OF LECTURE
IN SHIELDED METAL ARC WELDING (SMAW NC1—SMAW NCII)

1. FUNDAMENTALS OF WELDING

1.1 What is welding

2.2 How does welding differ from soldering and brazing
3.3 Safety in welding
4.4 Hand tools
5.5 Common kinds of welding

1.5 ARC WELDING:

1.5 A1- SMAW (Shielded metal arc welding)
1.5 A2- GMAW (Gas metal arc welding)
1.5 A3- GTAW ( Gas tungsten arc welding)

1.5 GAS CUTTING:

1.5-B1- Oxy/accetylene gas welding
1.5-B2- Brazing
1.5-B3- Soldering
1.6 TPES OF WEDING MACHINE:
1.6-1 Arc welding machine
1.6-2 Dc welding machine
1.6-3 Ac/Dc welding machine
1.6-4 Diesel or gasoline Engine driven Ac/Dc welding machine.

1.7 Basic electricity

1.8 Welding position
1.9 Types of welds
1.10 Types of joint and their parts
1.11 Types of groove and their parts
1.12 Different shape and types of base metals

3.
What is welding?

Welding is the process of joining metal pieces by heating th to suitable temperature that would cause
them to melt and fuse together into a single piece. This may be done with or without the ues of a filler
material composition and welting point of the base metals being joint.

How does welding differ from brazing and soldering? In brazing, metal pieces are joined by
heating them to suitable temperature about 800˚F but below their melting points and adding non ferrous
filler metal with a melting point below those of the base metals. On the other hand, soldering is the
process that uses alloys with low melting p[oints (under 800˚F) to join the metal parts. The molten solder
usually a tin lead alloy coalescence to the metal surfaces and fills the space between the parts to be
joined. A soldered joint is not as strong as a welded or braze joint. Not all metals can be soldered.

WHAT IS SMAW?

SMAW (Shielded Metal Arc Welding)

OBJECTIVES:

1.Identify and explain shielded metal arc welding (SMAW) safety?

a.)Always wear suitable protective clothing and eye protection.

b.)Always keep a safe and clean work area.
c.)Always keep welding machine and good condition.
d.)Always check welding area to make sure they’re safe to work in.
 e.)Always respect gas cylinder as dangerous and potentially lethal.
f.)Always make sure vintallation provides three to four charges of air per hour.
g.)Always look out for fellow students and workers.

2.Identify and explain welding electrical current?(welding machine and their characte
ristic)

a.)Basic circuit— current must travel in a complete loop from the power supply to
the arc and back to the power supply and circuit must be grounded.
b.)Polarity— this is the direction that current flows through a basic welding circuit
and is express as negative or positive in a relation to direct current.
c.)Direct current – (DC) this is current that flow only in one direction.

d.)Alternating current— (AC) this is current that alternate from one direction to
another 60 times per seconds and is express as 60 hertz.
e.)Direct current electrode negative—this is provide by a negative electrode to work
piece, positive work piece that courses the current flow from the electrode to
work piece.

Continue # 3

Note: (DC—EN/DC—SP) Direct current straight polarity.

(DC—EP/DC—RP) Direct current reverse polarity.

3.Identify and explain welding machine?

a.)AC-DC welding machine — another type of welding machine that use both alternative current and
direct current as power supply.
b.)DC- welding machine -- the type that use direct current as power supply, direct current is a kind
that flows in one direction.
c.)AC- welding machine— a machine that use alternate current as power supply, alternating current
is a kind of electricity which reverse its direction periodically.
d.)Diesel or gasoline engine driven—DC or AC welding machine a machine driven by diesel or gaso
line through generator use where there are no power line especially in remote area.

4.
Safety in welding.

The safety of welders in work place of paramount importance. An accident is avoided if the necessary
precaution are taken.

For personal protection, the welder must be properly dressed, clothing should not be made flammable
material and must not have oil or grease on it, attached material may be made of denims, wool,
tanned leather or asbestos, depending on the type of the job to be done. Pants should not have cuffs or
horizontal pockets because molten metal could get caught in them and burn,spark can also lodge in shirt
pockets and rolled –up sleeves.
 A head shield (Helmet) should be worn to protect the head,eyes, face, and neck from harmful rays of
electric arc and spatters or molten metal. Rubber ear plugs prevent eardrum damage from sparks and
slag during overhead welding when metal is pulled down by gravity, under certain welding conditions a
hard hat fastened to the helmet is advisable.

Suitable goggles protect the eyes from harmful rays and sparks and from flying particles during welding
chipping or grinding. If a welder needs glasses for close work, there are special goggles to fit over
reading glasses. Goggles for oxy/acetylene welding may have a flip front which allows the welder to flip
up the dark lens to see the weld after the torch is switched off.

Gloves made of leather or asbestos protect the hands and act as insulator against electricity and heat,
jacket, apron or sleeves provide added protect the feet from flying sparks, molten metals and falling
object.

It is strongly suggested the ( 5 S ) policy work practice must be adopted, as follows, SORT, SWEEP,
SYSTEMATIZE, STANDARDIZE,and SELF DECIPLINE.

5.

Properly dressed welder for personal protection

 Here are some useful tips to help ensure safety in the work place.

1. keep pipe extinguishers available forall types of fire.

2 .welding areas should have adequate and functioning ventilation system,airlines and and fans

should be installed to eliminate fumes and toxic gases.

3. flammable gas should be stored in separate safe area.

4. welding machine should not be operated in wet areas,cable and other connection should be fre-

Quently chech for leaks, cracks, and other damage.

5. remove from used containers or tanks the residues of chemicals,which may cause explo

8.

b. Gas welding.

1. Oxy-acetylene gas welding—a gas welding is done by burning gases. Oxygen and acetylene mixed
together in a carburetor-mixing chamber.Using oxy-acetylene flame,welding is possible with or
without a filler metal or welding rod.

2. Brazing—is a welding process wherein coalescence is produced by heating to suitable temperature

above 800˚F and using a none ferrous filler metal which has a melting temperature below that of
base metal .Carburizing flame is used in this process.

3. Soldering—is also welding process wherein coalescence is produced by heating at 570˚F to 595˚F
maximum temperature coalescence is the same as brazing,it only differ in tensile strength of the
welding process, its not adhesion based on the author’s conclusion and experience. It can only be
called soldering when you will be using soldering rod and soldering iron on a particular
 6.

Hand tools:

A welder must be equipped with the necessary tools to help him in his work. Listed below are some
hand tools with their corresponding uses:

√ Blacksmith tongs- to hold a piece of metal

√ Adjustable pliers- to hold a hot work piece

.
√ Chipping hammer- to remove slag.

√ Wire brush- to clean the surface of a work piece.

√ Steel scriber with tungsten carbide (hard material) to mark lay-out

√ Try square- to check the squareness of welded components.

√ Drill (high speed)b to make holes into the work piece

√ Portable power drill- to drive the drill bit to produce holes.

√ Tape rule (steel tape) – to gauge line measurement

 √ C- clamp – to hold two or more pieces together for rigidity and stability in welding

√ Bence vise – to clamp a work piece

√ Portable power grinder- to clean out slag ‘s, spatters and the rough surfaces of a work piece.

10.

Electrical welding circuit

1. Power source
2. Welding machine
a. current adjuster
b. gauge
3. Electrode cable
4. Ground cable
5. Electrode clamp handle
6. Electrode
holder
7. Welding
electrode
8 Base metal
.
 21.

What does a client inspector check in the production welding?

1.Joint fit-up
2.Preheat and interpass temperature
3.Weld consumable used
4.Welding position
5.Welding qualification

AWS guideline for G- position qualification.

a. Qualification in the 1G position qualifies for welding only in the 1G position.

b. Qualification in the 2G position qualifies for welding in the 1G and 2G position.
c. Qualification in the 2G and 5G Positions qualifies for welding in the 1G and 5G position
d. Qualification in the 6G position qualifies for welding in any
AWS guidelines for F-position qualification

a.Qualification in the 1F position qualifies for fillet welding only in the 1F position.
b.Qualification in the 2F position qualifies for fillet welding in the 1F and 2F position only.
c.Qualification in the 4F position qualifies for fillet welding in the 1F,2F, and 4F position only.
d.Qualification in the 5F position qualifies for fillet welding in any position because it includes elements
of all positions.
e.Qualification in any of the fixed G position qualifies for the fillet welding of any fillet welding in pipe.

Guidelines for pipe welding safety.

a.Wear proper protective clothing for both oxy-acetylene cutting and arc welding.
b.Wear protective leader sleeves to protect from sparks in confined space and out of position welding.
c.Unroll and roll-up lead cables with care.
d.Handle beveling machine with care because they are easy to damage if dropped.
e.Handle free ends of pipe being beveled with or pliers to keep them from dropping on your feet.
i. Keep flammable materials away from the welding area and make sure thre is proper vintellation.
g.Keep a correct types of fire extinguisher nearby when pipe welding in a shop and have one at a
convenient location when welding in the field.
h.Use windshields when they are practical, but do not pipe weld in rain or in high winds or blowing
sand

Basic symbol of welding

22.

23.
 Welding current for carbon electrode types.

Electrode Size Amperes Volts

E-6010 3.32mm/ 2.5” 45-- 75 22/28

E-6010 3.2mm/ 1/8” 80- 140 22/28
E-6011 3.32mm/ 2.5” 45-75 22/28
E-6011 3.2mm 1/8” 80- 140 22/28
E-6012 3.32mm 2.5” 40- 75 22/28
E-6012 3.2 mm/1/8” 75- 140 22/28
E-6012 4.0mm/ 5/32” 115-220 22/28
E-6013 3.32mm/ 2.5” 40- 75 22/28
E-6013 3.2mm/ 1/8 75- 140 22/28
E-6013 4.0mm/ 5/32” 115-220 22/28
E-7018 3.32mm/ 2.5” 55- 75 22/28
E-7018 3.2mm/ 1/8” 80- 140 22/28
E-7018 4.0mm/ 5/32” 110 200 22/28