CBLM For SMAW Dondon

Competency-Based Learning Material
Sector : METALS AND ENGINEERING
Qualification Title : SHIELDED METAL ARC WELDING (SMAW) NC II
Unit of Competency: Weld Carbon Steel Plates Using SMAW
Module Title : Welding Steel Plates using SMAW
JAGUPIT NATIONAL HIGH SCHOOL

Jagupit, Santiago, Agusan del Norte
Agusan del Norte Division
ACKNOWLEDGEMENTS
In the development of this CBLM, I would like to express my sincere

gratitude to my loving and understanding family for their continuous
support of my research and writing of this CBLM.
I would like to show my sincere gratitude also and appreciation to

Ms. Lilian C. Garces and Mrs. Marife Peña. For their support, help and
encourage every time I need guidance and in time I can not understand
some of my task in every module. And I would like to give my warmest
thanks to my co-trainees especially Mr. Garry G. Monteclaro, Mrs. Leoniza
L. Monoy , Hannah Faith M. Aranton and Irene joy T. Bermudez for the
sleepless nights we were working together for the assessment and thier
always give me support and advice.
Special thanks to my lovely son Romeo E. Carmona-I for their

unconditional support, emotionally and patience show me during the
training is greatly appreciated.
Date Developed: Document No.

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Metal Arc Welding NC Issued by:
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Welding carbon steel Developed by:
plates using SMAW Romeo E. Carmona
Jr.
HOW TO USE THIS COMPETENCY-BASED LEARNING MATERIAL
Welcome!
The unit of competency, “Weld Carbon Steel Plates using SMAW”, is one of
the competencies of SHIELDED MATERIAL ARC WELDING NC II, a course
which comprises the skills, knowledge, and attitudes of a Welder in
accordance with AWS and WPS standards.
The module, Welding Carbon Steel Plates, contains training materials and
activities related to planning and preparing for installation, installing
equipment/ device system and conducting test for you to complete.
In this module, you are required to go through a series of learning in order
to complete each learning outcome. In each learning outcome are
Information sheets, Self-check, Operation Sheets and Task/Job Sheet.
Follow and perform the activities on your own. If you have question, do not
hesitate to ask for assistance from your facilitator.
Remember to:
 Work through all the information and complete the activities in each
section.
 Read information sheets and complete the self-check. Suggested
references are included to supplement the materials provided in this
module.
 Most probably, your trainer will also be you supervisor or manager.
He is there to support you and show you the correct way to do things.
 You will be given plenty of opportunities to ask question and practice
on the job. Make sure you practice your new skills during regular
work shifts. This way, you will improve your speed, memory and
confidence.
 Use the self-checks, operation sheets, or Task or Job Sheets at the
end of each section to test your own progress. Use performance
criteria
 Checklist or Procedural Checklist located after the sheet to check your
own performance.
 When you feel confident that you have had sufficient practice, ask
your trainer to evaluate you. The results of your assessment will be
recorded in your Progress Chart and Accomplishment Chart.

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MODULE CONTENT
UNIT OF COMPETENCY: Weld Carbon Steel Plates Using SMAW
Module Title: Welding Carbon Teel Plates Using SMAW
MODULE DESCRIPTOR: This module covers the skills, knowledge and

attitudes required in welding carbon steel plates
using SMAW process.
LEARNING OUTCOME:
At the end of this module you will be able to:
1. Weld V groove butt joint carbon steel plates in flat position 1G

2. Weld V groove butt joint carbon steel plates in horizontal position 2G
3. Weld V groove butt joint carbon steel plates in vertical position 3G
4. Weld V groove butt joint carbon steel plates n overhead position 4G

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Learning Outcome 1:
Weld V groove butt joint carbon steel plates in flat position 1G
Assessment criteria
1. Root pass in carbon steel plate in flat position (1G) is performed in

accordance with WPS and/or client specifications.
2. Root pass in carbon steel plate in flat position (1G) is cleaned and free
from defects and discontinuities.
3. Task is performed in accordance with approved WPS standard.
4. Subsequent filling passes is performed in accordance with approved
WPS standard
5. Weld is checked visually for defects and repaired as required
6. Weld is visually acceptable in accordance with applicable codes and
standards.
7. Capping in carbon steel plate in flat position (1G) is performed in
accordance with approved WPS and / or Client specifications.
8. Weld in carbon steel plate in flat position (1G) is visually checked for
defects and repaired as required.
9. Weld in carbon steel plate in flat position (1G) is visually acceptable
in accordance with applicable codes and standards.

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CONTENTS CONDITION ASSESSMENT
METHODS
1. Welding Terms and 1. EQUIPMENT 1. written test
Definition
 Welding Machine 2. Demonstration
2. Five essentials in (AC or AC/DC) 3. oral questioning
welding  Welding table or
jig
3. International welding  Portable grinder
codes and standards  Welding booth
4. Acceptable weld Portable oven
profile
2.
5. Welding joints and TOOL/ACCESSORIES
symbols  Welding mask
6. Basic Metal and  Steel brush
Metallurgy  Clear glass
 Chipping hammer
7. Weld Defects, Causes  Dark glass
& Remedies
3.
8. Welding Procedure SUPPLIES/MATERIALS
Specification (WPS)  Electrodes
 Carbon steel
plates
9. Safety Welding  Cutting and
Practices grinding disk

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10. Welding Technique 4.PERSONAL
and Procedure PROTECTIVE
11. Procedures in EQUIPMENT
Welding Steel Plates in
 Safety shoes
Flat Position (1G)
 Apron
 Leggings
 Safety goggles
 Leather gloves
 TRAINING
MATERIALS
 Arc welding
manuals
 Welding
procedures
specification
(WPS)
 Welding
standards

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Learning Experiences
Learning Outcome No. 1
Learning Activities Special Instruction
1.Read Information sheet No.1.1-1 on If you feel you can familiarized the
welding terms and definitions you can
Welding Terms and Definitions
answer self check 1.1-1
Answer self check No. 1.1-1
Refer/ compare your answer to answer
key 1.1-1
2. Listen to your teachers If you feel you can already explain the
discussion/information No 1.1-2 on essentials in welding you can now
Essentials of Welding Answer self-check No 1.1-2
Answer Self-check No. 1.1-2
Refer/compare your answer to answer key
1.1-1
3. Read Information Sheet No 1.1-3 on If you feel you can already identify and
and differentiates the sources of
International Welding Codes
International welding codes and
Standard
standard you can answer self check
No.1.1-3
Answer self-check No. 1.1-3
key 1.1-3
4. Listen to you teacher’s discussion If you feel you can determine and
/Information Sheet No.1.1-4 on differentiates the acceptable and
unacceptable weld profile you can now
Acceptable Weld Profile
answer self check No. 1.1-4
Answer self-check No. 1.1-4
key 1.1-4
Weld V groove butt joint steel plates in flat position (1G)

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5. Read Information Sheet No. 1.1-5 on If you feel you can differentiates the types
Welding Joints and Symbols and parts of weld you can now answer self
check 1.1-5
key 1.1-5
6. Listen to your teacher’s discussion / If you feel you can differentiates the causes
Information sheet No. 1.1-6 on of residual stresses and distortion and
identify the guidelines in changing welding
Basic Metals and Metallurgy
procedure to control stresses, the
application of weld quality control you can
now answer self check 1.1-6
Answer self check no. 1.1-6
key 1.1-6
7. Listen to your teacher’s discussion / If you can feel you can identify the different
Information sheet No. 1.1-7 on weld defect, their causes and remedies you
Weld Defects, Causes, and Remedies can answer self check 1.1-7

key No. 1.1-7
8. Read information sheet 1.1-8 on If you feel you can explain the importance
Welding Procedures Specification of WPS you can now answer self check No.
(WPS) 1.1-8
key No. 1.1-8
9. Read information sheet No.1.1-9 on If you feel you can identify the hazardous
Safety Welding Practices area, identify the PPEs and its uses and
handling of tools, equipment and materials
you can now answer self check No 1.1-9
Answer self check No.1.1-9 Refer/
compare your answer to answer key
No.1.1-9

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10. Listen to your teachers If you feel you can identify the Welding
discussion /Information sheet No.1.1- process and welding principles you can
10 on Welding Technique & now answer self check No. 1.1-10
Procedure
Answer self check No. 1.1-10 Refer/
No.1.1-10
View video clip on Welding technique
No. 1.1-10
11. Listen to your teacher’s If you feel you can identify the procedures
Information Sheet1.1-11 on in welding steel plates in flat position. you
can now answer self check No 1.1-11
Procedures in Welding Steel Plates
in Flat Position (1G)
Answer self check No. 1.1-10 Refer/
No.1.1-11
View video clip on Welding Steel Plates
in Flat Position (1G) No. 1.1-11

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INFORMATION SHEET 1.1-1
WELDING TERMS AND DEFINITIONS
Learning objectives:
After reading this INFORMATION SHEET, YOU MUST be able to familiarize
the welding terminology and definitions.
Introduction:
This module covers the skills, knowledge, and attitudes
required in welding carbon steel plates using SMAW process.
You need to complete this module by learning the theories and
principles closely coupled with practical activities to master the skills
required. Desirable values and attitudes must also be taken into
consideration.
This module consists of four learning outcomes. Each outcome
contains learning activities for both knowledge and skill, supported with
information sheets, self-checks and Job/Task Sheets gathered from different
sources.
Upon completion of this module, you have to subject yourself for
institutional assessment to your instructor. You will be given a certificate of
achievement as a proof that you have met the standard requirement for this
module.
Acetylene- a highly combustible gas composed of carbon and hydrogen.

Used as a fuel gas in the oxyacetylene welding process.
Air- Carbon Arc Cutting (CAC-A)- an arc cutting process in which metals to
be cut are melted by the heat of the arc.
Alloy- a mixture with metallic properties composed of two or more elements,
off which at least one is metal.
Alternating current- an electric current that reverse its direction at
regularly reoccurring intervals.

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Annealing- a comprehensive term used to describe the heating and cooling
cycle of steel in the solid state. The term annealing usually implies relatively
slow cooling magnetic forces.
Arc brazing- a brazing process wherein the heat is obtain from an electric
arc form between the base metal and electrode, or between two electrodes.
Arc cutting- a group of cutting processes in which the heat of an arc
between the electrode and the base metal.
Arc force- also called Dig bad Arc Control. Gives power source variable
additional amperage during low voltage (short length) conditions while
welding.
Arc length- the distance between the tip of the electrode and base metal.
Arc voltage- the voltage across the welding arc.
Arc welding- a group of welding process in which fusion is obtained by
heating with an electric arc.
Arc-oxygen cutting- an oxygen cutting process used to sever metals by a
chemical reaction of oxygen with a base metal at elevated temperature.
Automatic Hydrogen Cutting- an arc welding process in which fusion is
obtained by heating with an arc maintained between two metal electrodes in
an atmosphere of hydrogen.
Axis of a weld- a line through the length of a weld, perpendicular to a cross
section at a centre of gravity.
Back gouging- the removal of weld metal, gouging or grinding from the
other side of a partially welded joint to assure complete penetration upon
subsequent welding from that side.
Back pass- a pass made to deposited back weld.
Back up- a weld deposited at the back of a single groove weld.
Bare electrode- an arc welding electrode that has no coating other than
that incidental to the drawing of the fire.
Backing strip- a piece of material used to retain molten metal at the root of
the weld and/ increase the thermal capacity of the joint so as to prevent
excessive warping of the base metal.
Backing weld- a weld bead applied to the root of a single groove joint to
assure complete root penetration.
Back step- a sequent of bead increments are deposited in a direction
opposite to the direction of progress.
Backhand welding- a welding technique in which the flame is directed
towards the completed weld.
Bare metal arc welding- an arc welding process in which fusion is obtained
by heating with an unshielded arc between a bare or light coated electrode

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and the work. Pressure is not used and filler metal is obtained from the
electrode.
Base metal- the metal to be welded or cut.
Bead weld- a type of weld composed of one or more string or weave beads
deposited on unbroken surface.
Bevel angle- the angle formed between the prepared edge of a member and
a plane perpendicular to the surface of the member.
Block brazing- a brazing process in which bonding is produced by the heat
obtained from heated blocks applied to the parts to be joined and by a
nonferrous filler metal having a melting point above 800? F (427? C), but
below that a base metal.
Block sequence-a building up sequence of continuous multi-pass welds in
which separate lengths of weld are completely or partially built up before
intervening lengths are deposited.
Braze- a group of welding process in which a groove, filler, lap, or flange
joint is bounded by using a nonferrous filler metal.
Bridging- a welding defect caused by a poor penetration. A void at the root
of the weld is spanned by weld metals.
Buckling- a distortion caused by the heat of a welding process.
Build sequence- the order in which the weld beads of a multi-pass weld are
deposited with respect to the cross section of a joint.
Butt joint- a joint between two work pieces in such a manner that the weld
joining the parts is between the surface planes of both of the pieces joined.
Butt weld- a weld in a butt joint
Carbon-arc cutting- a process of cutting metals with the heat of an arc
between a carbon electrode and the work.
Carbon-arc welding- a welding process in which fusion is produced by an
arc between a carbon electrode and the work. Pressure and/or shielding
may or may not be used.
Chain intermittent fillet weld- two lines of intermittent fillets weld I s T lap
joint in which the welds in one approximately opposite those in the other
line.
Chain intermittent weld- an intermittent weld on each side of joint
(usually fillet welds in T and Lap joints) arranged so that the welds lie
opposite to one another along the joint.
Co2 flux welding- metal-arc welding in which a bare wire electrode is used
the arc and molten pool being shielded with carbon dioxide.
Coalescence- the uniting and fusing of metals upon heating.

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Composite electrode- filler metal electrode used in arc welding, consisting
of more than one metal component combined mechanically, it may or it may
not include materials that improve the properties of the weld, or stabilize the
arc.
Composite joint- a joint in which both thermal and mechanical process are
used to unite the base metal pars.
Concave fillet weld- a fillet weld in which the welds face in concave (curved
inwards).
Concavity- the maximum perpendicular distance from the face of a
concave weld to a line joining the toes.
Concurrent heating- supplemental heat applied to a structure during the
course of welding.
Cone- the conical part of a gas flame next to the orifice of the tip.
Constant current (cc) welding machine- these welding machine have
limited maximum short circuit. They have a negative volt-amp curve and are
often referred to as droppers.
Constant voltage (CV) constant potential (cp) welding machine- potential
and voltage are basically the same in meaning. This type of welding machine
output maintains a relatively stable, consistent voltage regardless of an
amperage output.
Constant-feed wire feeder- feeder operates from 25 to 115 VAC supplied by
the welding power source.
Consumable insert- preplaced filler metal which is completely fused into
the root of the joint and become part of the weld.
Continuous weld- a weld extending along the entire length of a joint.
Convexity- the maximum perpendicular distance from the face of a convex
fillet weld to a line joining the toes.
Cover glass- a clear glass used in goggles, hand shield, and helmets to
protect the filter glass from spattering material.
Covered electrode- a metal electrode with a covering material which
stabilizes the arc and improves the properties of the welding metal. The
material may be an external wrapping of paper, asbestos, and other material
or a flux coating.
Crack- a fracture type discontinuity characterized by a sharp tip and high
ratio of length and width to opening displacement.
Crater- a depression at the termination of an Arc weld.
Current- another name of amperage. The amount of electricity flowing past
a point in a conductor every second.

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Cutting electrode- an electrode with a covering that aids the production of
such an arc that the molten metal is blown away to produced a groove or
cut in the work.
Cutting oxygen- oxygen used at a pressure suitable for cutting.
Cutting tip- a gas torch tip especially adapted or cutting.
Cutting torch- a device used in gas cutting for controlling the gases used
for preheating and thee oxygen used for cutting the metal.
De-seaming- a method of metal-arc welding in which fused particles of the
electrode wire in the contact with the molten pool are detached from the
electrode in rapid succession by the short circuit current, which develops
every time the wire touches thee molten pool.
Deposit metal- filter metal that has been added during a welding operation.
Depth of fusion- the distance from the original surface of the base metal to
that point at which fusion ceases in a welding.
Die- a resistance welding- a member usually shaped to the work contour,
used to clamp the parts being welded and conducted the welding current.
Forge welding- device used in forge welding primarily to form the work
while hot and applies the necessary pressure.
Direct current (DC)- a method of metal-arc welding in which fused particles
of the electrode wire in contact with the molten pool are detached from the
electrodes in rapid succession by the short circuit current, which develops
every time the wire touches the molten pool.
Direct Current Electrode Negative (DCEN)- the specific direction of
current flow through a welding circuit when the electrode lead is connected
to the negative terminal and the work lead is connected to the positive
terminal of a DC welding machine. Also called direct current, reverse
polarity (DCRP).
Direct Current Electrode Positive (DCEP)- the specific direction of current
flow through a welding circuit when the electrode lead is connected to a
positive terminal and the work lead is connected to a negative terminal to a
DC welding machine. Also called Direct Current Reverse Polarity (DCRP).
Ductility- the property of a metal which allows it to be permanently
deformed in tension before final rupture.
Duty cycle- the number of minutes out of a 10-minutes time period an arc
welding machine can be operated at maximum rated output.
Edge joint- a joint between the edges of two or more parallel or nearly
parallel members.
Edge preparation- the contour prepared on an edge of a joint member for
welding.
Pliers-
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Hacksaw- used to manually cut or separate metal.
Cut-off saw- used to cut heavier metal at different angles or in straight cuts.
Anvil- an iron or steel block with both flat and curved surfaces for shaping
metals that are hammered or penned against it.
Angle grinder- generally used with attachments for cleaning joints before or
after welding process.
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Welding carbon steel NTTA
Developed by:
plates using SMAW
Romeo E. Carmona
Jr.
Effective length of weld- the length weld throughout which the correctly
proportioned cross section exist.
Electrode- filler metal in the form of wire or rod, whether bare or covered.
Through which current is conducted between the electrode holder and the
arc
Electrode force- in spot, seam and projection welding, the force (pounds)
between the electrodes during the actual welding cycle.
Excess penetration bead- excessive metal protruding through the root of a
fusion weld made from one side only.
Face bend test- a bend test in which specified side of the weld normal bend
test.
Face of welds- the exposed surface of the weld, made by n arc pr gas
welding process, on the side from which welding was done.
Face reinforcement- the reinforcement of weld at the side of the joint from
which welding was done.
Filler metal- a weld of approximately triangular cross section, as used in a
lap joint, joining two surfaces at approximately right angles to each other.
Fixed automation- automated, electronically controlled welding system for
simple, straight or circular welds.
Flash- metal and oxide expelled from a joint made by a resistance welding
process.
Flash welding- a resistance welding process in which fusion is produced,
simultaneously over the entire area of abutting surfaces, by the heat
obtained from the resistance to the flow of current between two surfaces,
and by the application of pressure after heating is substantially completed.
Flashing is accompanied by expulsion of metal from the joint.
Flat position- the position in which welding is performed from the upper
side of the joint and the face of the weld is approximately horizontal.
Flexible automation- automated, robotically controlled welding system for
complex shapes and applications where welding paths require torch-angle
manipulation.

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Flow welding- a process in which fusion is produced by heating with molten
filler metal poured over the surfaces to be welded until the welding
temperature.
Flux- a cleaning agent used to dissolve oxides, release trapped gases and
slag, and to cleanse metals for welding, soldering, and brazing.
Flux Cored Arc Welding (FCAW)- an arc welding process which melts and
joins metal by heating them with an arc between a continues, consumable
electrode wire and the work. Shielding gas is obtained from a flux contained
within the electrode core.
Forehand welding- a gas welding technique in which the flare is directed
against the base metal ahead of the completed weld.
Forge welding- a group of welding processes in which fusion is produced by
heating in a forge or furnace and applying pressure or blows.
Full fillet weld- a fillet weld whose size is equal to the thickness of the
thinner member joined.
Fusion- a thorough and complete mixing between two edges of the base
metal to be joined or between the base metal and the filler metal added
during welding.
Gas carbon-arc welding- an arc welding process in which fusion is
produced by heating with an electric arc between a carbon electrode and the
work. Shielding is obtained from an inert gas such helium or argon.
Pressure and filler metal may or may not be used.
Gas metal arc welding (GMAW)- an arc welding process in which fusion is
produced by heating an electric arc between a metal electrode and the work.
Shielding is obtained from an inert gas such as helium or argon.
Gas pocket- a weld cavity caused by the trapping of gases released by the
metal when cooling.
Gas tungsten arc welding (GTAW)- an arc welding process in which fusion
is produced by heating with an electric arc between a tungsten electrode and
the work while an inert gas forms around the weld area to prevent oxidation.
No flux used.
Gas welding- a process in which the welding heat is obtained from a gas
flame.
Globular Transfer (arc welding)- a type of metal transfer in which molten
filler metal is transferred across the arc in large droplets.
Groove- the opening between two members to be joined by a groove weld.
Groove angle- the include angle of the groove between parts to be joined by
the groove weld.
Groove weld- a weld made by depositing filler metal in a groove between two
members to be joined.

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Hammer welding- forge welding process
Hand shield- a device used in arc welding to protect the face and the neck.
It is equipped with a filter glass lens and I designed to be held by hand.
Heat affected zone- the portion of the base metal whose structure or
properties have been changed by the heat of welding or cutting.
Heat time- the duration of each current impulse is impulse welding.
Heat treatment- an operation or combination of operations involving the
heating and cooling of a metal or an alloy in the solid state for the purpose
of obtaining certain desirable conditions or properties. Heating and cooling
for the sole purpose of mechanical working are excluded from the meaning
of the definition.
Lap joint- a joint between two overlapping members.
Layer- a stratum of weld metal, consisting of one or more weld beads.
Leg of fillet weld- the distance from the root of the join to the toe of the
fillet weld.
Liquidus- the lowest temperature at which a metal or an alloy is completely
liquid.
Manifold- a multiple header for connecting several cylinders to one or more
torch supply lines.
Mash seam welding- a seam weld made in a lap joint in which the
thickness at the lap is reduced to approximately the thickness of one of the
lapped joints by applying pressure while the metal is in the plastic state.
Melting point- the temperature at which the metal begins to liquefy.
Metal arc welding- an arc welding process in which a metal electrode is
held so that the heat of an arc fuses both the electrode and the work to form
a weld.
Metalizing- a member of overlay or metal bonding to repair worn parts.
MIG (GMAW or Gas Metal arc welding)- an arc metal welding process in
which joins metals by heating them with an arc. The arc is between a
continuously fed filler metal (consumable) electrode and the work piece.
Externally supplied gas or gas mixture provide shielding. Common weld
welding is also referred to as short circuit transfer. Metal is deposited only
when the wire actually touches the work. No metal is transferred across the
arc.
Multi impulse welding- the making spot, projection, and upset welds by
more than one impulse of current. When alternating current is used each
impulse may consist of a fraction of a cycle or a number of cycles.
Nonferrous- metals which contain no iron, aluminum, brass, bronze,
copper, lead, nickel, and titanium nonferrous.

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Open circuit voltage- no current is flowing in the circuit because the
circuit is open. The voltage is impressed upon the circuit is completed. The
current will flow immediately.
Overhead position- the position in which welding is performed from the
underside of a joint and the face of the weld is approximately horizontal.
Overlap- the protrusion of weld metal beyond bond at the toe of the weld.
Oxidizing flames- an oxyacetylene in which there is an excess of oxygen.
The unburned excess tends to oxidize the weld metal.
Oxy-Hydrogen welding- a gas welding process in which the required
welding temperature is attained by flames obtained from the combustion of
hydrogen with oxygen.
Peening- the mechanical working of metals by means of hammer blows.
peening tends to stretch the surface of the cold metal, thereby relieving
contraction stresses.
Percussive welding- a resistance welding process in which a discharge of
electrical energy and the application of high pressure occurs
simultaneously, or with the electrical discharge occurring slightly before the
application of pressure.
Pitch- centre to centre spacing of welds.
Plasma- the fourth state of matter following solid and gas. Plasma is an
ionized (electrified) form of gas in plasma cutting.
Plasma arc cutting- an arc cutting process which serves metal by using a
constricted arc to melt a small area of the work. This process can work cut
all materials that conduct electricity.
Plug weld- a weld is made a hole of one member of a lap joint, joining that
members to that portion of the surface of the member which is exposed
trough the hole. The walls of the holes may or may not be parallel, and the
hole may be partially or completely filled with the weld metal.
Poke welding- a spot welding process on which pressure is applied
manually to one electrode. The other electrode is clamped to any part of the
metal much in the same manner that the arc welding is grounded.
Porosity- the presence of gas pockets or inclusions in welding.
Position of welding- all welding is accomplished in one of four position: flat,
horizontal, overhead and vertical. The limiting angles of the various
positions depend somewhat as to whether the weld is a fillet or groove weld.
Post heading- the application of heat to an assembly after a welding
operation.
Post weld interval- in resistance welding, the heat time between the end of
weld time or weld interval, and the start of hold time. During this time, the
weld is subjected to mechanical and heat treatment.

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Preheating- the application of heat to a base prior to a welding or cutting
operation while welding.
Pressure controlled welding- the making of a number of spot or projection
welds in which several electrodes function progressively under the control of
a pressure sequencing device.
Pressure welding- any welding process or method in which pressure is used
to complete the weld.
Pre weld interval- in spot, projection, and upset welding, he time between
the end of squeeze time and the start of weld time or weld interval during
which the material is preheated.
Pulsation welding- a spot, projection or seam welding process in which the
welding current is interrupted one or more times without the release of
pressures or change of location of electrodes.
Pulsed MIG (MIG-P)- modified spray transfer process that produces no
spatter because the wire does not touch the weld puddle.
Pulsed TIG (TIG-P)- a modified TIG process appropriate for welding thinner
materials. Consumable tungsten electrodes, filler material, shielding gas.
Pulsing- sequencing and controlling the amount of current, the polarity,
and the duration of the welding arc.
Push welding- the making of a spot or projection weld in which the force is
spring current is interrupted one or more times without the release of
pressure or change of location of electrodes.
Quenching- the sudden cooling of heated metal with oil, water, or
compressed air.
Regulator- a device used to reduce cylinder pressure tom a suitable torch
working pressure.
Reinforce weld- the weld metal built up above the surface of the two
abutting sheets or plates in excess of that required for the size of the weld
specified.
Resistance butt welding- a group of resistance welding processes in which
the weld occurs simultaneously over the entire contact area of the parts is
being joined.
Resistance Spot Welding (RSW)- a process in which two pieces of metal are
joined by passing current between electrodes positioned on opposite sides of
the pieces to be welded. There is no arc within this process, and it is the
resistance of the metal to the current flow that causes the fusion.
Resistance welding- a group of welding processes in which fusion is
produced by heat obtained from resistance from the flow of the electric
current in a circuit of which the work piece is a part and by the application
of the pressure.

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Reverse polarity- the arrangement of direct current arc welding leads in
which the works is the negative pole and the electrode is the positive pole of
the welding arc.
Root crack- a crack in the weld or base metal which occurs at the root of a
weld.
Root edge- the edge of a part to be welded which is adjacent to the area.
Root face- the portion of the prepared edge of a member to be joined by a
groove weld which is not beveled or groove.
Root of joint- the portion of a joint to be welded where the members
approach closet to each other. In cross section, the root of a joint may be a
point, a line, or an area.
Root of weld- the points, as shown in cross section, which the bottom of the
weld intersects the base metal surfaces.
Root opening- the separation between the members to be joined at the root
of the joint.
Root penetration- the depth a groove weld extends into the root of joint
measured on the centre line of the root cross section.
Scarping- a process of removing defects and checks which develop in the
rolling of steel billets by the use of a low cross section.
Seal weld- a weld used primarily to obtained tightness and to prevent
leakage.
Seam welding- welding a lengthwise seam in sheet metal either by abutting
or overlapping joints.
Semi-automatic welding- the equipments controls only the electrode wire
feeding. The welding gun movement is controlled by hands.
Series welding- a resistance is welding process in which two or more welds
are made simultaneously by a single welding transformer with the total
current passing through its welds.
Sheet separation- in spot, seam, and projection welding the gap surrounds
the welds between faying surfaces, after the joint gas been welded.
Shielded welding- an arc welding process in which protection from the
atmosphere is obtained through use of flux, decomposition of the electrodes
covering, or an inert gas.
Shielding gas- protective gas used to prevent atmospheric contamination of
the weld pool.
Single impulse welding- the making of spot, projection and upset welds by
a single impulse of current. When alternating current is used, an impulse
may consist of a fraction of a cycle or a number of cycles.

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Size of weld- the joint penetration depth of chamfering plus the root
penetration when specified. The weld metal thickness measured at the root
of the weld.
Slug inclusion- non-metallic solid material entrapped in a weld metal or
between the metal and the base metal.
Slugging- adding a separate pieces of material in a joint before or during
welding with a resultant welded joint that does not comply with design
drawing or specification requirements.
Soldering- a group of welding processes which produce coalescence of
materials by heating them o suitable temperature.
Spacer trip- a metal strip or bar inserted in the root of a joint prepared for
groove weld to serve as a backing and to maintain the root opening during
welding.
Spatter- the metal particles expelled during arc and gas welding which do
not form a part of a weld.
Spot welding- a resistance welding process in which fusion is produced by
the heat obtained from the resistance to the flow of electric current through
the work pieces held together under pressure by the electrodes. The size and
the shape of the individually formed welds are limited by the size and
contour of the electrodes.
Staggered intermittent fillet weld- two lines of intermittent welding on a
joint, such as tee joint, wherein the fillet increments in one line are
staggered with respect to those in the other line.
Stick welding (SMAW or SHIELDED METAL ARC WELDING)-
Straight polarity- the arrangement of direct current arc welding leads in
which the work is the positive pole and the electrode is the negative pole of
the welding arc.
Stress relieving- a process of reducing internal residual stresses in a metal
object by heating to a suitable temperature and holding for a proper time at
the temperature.
String bead welding- a method of metal arc welding on pieces ¾ in (19mm)
thick heavier in which the weld metal is deposited in layers composed of
strings of beads applied directly to the face of the bevel.
Stud welding- an arc welding process in which fusion is produced by
heating with an electric arc drawn between a metal studs, or similar part,
and the other work piece, until the surfaces to be joined are properly heated.
They are brought together under pressure.
Submerge arc welding- an arc welding process in which fusion is produced
by heating with an electric arc or arcs between bare metal electrode or
electrodes and the work. The welding is shield by a blanket of granular,
fusible material on the work. Pressure is not used filler metal is obtained
from the electrode, and sometimes from a supplementary welding rod.
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Tack weld- a weld made to gold parts of a weld man in proper alignment
until final welds are made.
Temper time- in resistance welding, the part of the post weld interval
during which a current suitable for tempering or heat treatment flows.
Current can be single or multiple impulses with varying heat and cool
interval.
Tempering- reheating hardened steel to some temperature below the lower
critical temperature, followed by a desired rate of cooling.
Thermite mold- a mold formed around the parts to be welded to receive the
molten material.
Thermite welding- a group of welding processes in which fusion is
produced by heating with superheated liquid metal and slag resulting from a
chemical reaction between a metal oxide and aluminum, with a universal
head, the throat depth is measured with the machine arranged for
transverse welding.
Throat depth- in a resistance welding machine, the distance from the
centre-line of the electrodes or platens to the nearest point of the
interference for the flatwork or sheets. In a seam welding machine with a
universal head, the throat depth is measured with the machine arranged
for transverse welding.
Throat of fillet weld- the distance from the root of the fillet weld to the
centre of its face.
TIG WELDING (GTAW or Gas Tungsten Arc)- often called TIG welding
(tungsten inert gas), this process joins metals heating them with a tungsten
electrode which should not become part of the completed weld. filler metal is
sometimes used and argon inert gas mixtures are used for shielding.
Toe crack- a crack in the base metal occurring at the toe of the weld.
Touch start- a low voltage, low amperage arc starting procedure for TIG
(GTAW). The tungsten is touch to the work piece; when tungsten is lifted
from the work piece an arc is established.
Transverse seam welding- the making of the seam in a direction essentially
at right angles to the throat depth of a seam welding machine.
Tungsten- rare metallic element with extremely high point. Used in
manufacturing TIG electrodes.
Under bead crack- a crack in the heat affected zone not extending to the
surface of the base metal.
Undercutting- an undesirable crater at the edge of the weld caused by a
poor weaving technique or high current.
Upset- a localized increase in volume in the region of the weld, resulting
from the application of pressure.

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Upset welding- a resistance welding process in which fusion is produced by
simultaneously over the entire area of abutting surfaces, or progressively
along a joint, by the heat obtained from the resistance to the flow of electric
current through the area of conduct of those surfaces.
Upsetting force- the force exerted at the welding surfaces in flash or upset
welding.
Vertical position- the position of welding in which the axis of the weld is
approximately vertical.
Volt-amp curve- graph that shows the output characteristics of a welding
power source. Shows voltage and amperage capabilities of a specific
machine.
Voltage- the pressure or force that pushes the electrons through a
conductor.
Voltage-sensing wire feeder- feeder operates from the arc voltage
generated by- a block welding sequence in which successive weld blocks are
completed at random after several starting blocks have been completed.
Wandering sequence- a longitudinal sequence in which the weld bead
increments are deposited in random.
Wax pattern- wax molded around the parts to be welded by termites
welding process to the form desired for the completed weld.
Weaving- a technique of depositing a weld metal in the electrode is
oscillated. It is usually accomplished by a semi-circular motion of the arc to
the right and left of the direction of welding.
Weld- a localized fusion of metals produced by heating to suitable
temperatures. Pressure and/ or filler metal may or may not be used. The
filler make has a melting point approximately the same or below that of the
base metals.
Weld bead- a weld deposit resulting from gas
Weld gauge- a device designed for checking the shape and size of the welds.
Weld metal- the portion of the weld that has been melted during welding.
Weld ability- the capacity of a material to form a strong bond of adherence
under pressure or when solidifying from a liquid.
Welder certification- certificate in writing that a welder has produced weld
meetings prescribed standards.
Welding procedure- the detailed methods and practices all joint welding
procedures involved in the production of a weldment.
Welding rod- filler metal wire or rod form, used in gas welding and brazing
processes and in those arc welding processes in which electrode does not
provide the filler metal.

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Welding symbol- the assembled symbol consist of the following right
elements. Or such of these as are necessary: reference line, arrow, basic
weld symbol, dimension and other data, supplementary symbols, finish
symbols, tail specification process, or other references.
Welding technique- the detail of a manual, machine or semi-automatic
welding operation which within the limitations of the prescribe joint welding
procedures are controlled by the welder or welding operator.
Welding tip- the tip of a gas torch especially adapted to welding.
Welding torch- a device used in gas welding and torch brazing for mixing
and controlling the flow of gases.
Welding transformer- a device for providing current of the desired voltage.
Weldment- an assembly whose component parts are formed by welding.
Work lead- the electric conductor (cable) between the source of arc welding
current and the work piece.
Work piece connection- a means to fasten the work lead (work cable to the
work metal to be welded).
Work piece lead- the conductor cable or electrical conductor between the
arc welding machine and the work.
WPS- Welding Procedure Specification
Yield point- is the load per unit area value at which a mark increase in
deformation of the specimen occurs with little or no increase load.

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Self-check 1.1-1
1. A welding process or method in which pressure id used to complete the

weld.
a. pulsation welding b. preheating c. pressured welding
2. The junction between the face of the weld and the base metal.
a. weld metal b. tack weld c. toe Crack
3. The process of which metal and electrode that heat an arc fuses both he
electrode and work to form weld.
a. metal-arc welding b. normalizing c. plasma

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Answer Key 1.1-1
1. c
2. c
3. a

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THE ESSENTIALS OF ARC WELDING
Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to identify,
explain and apply the Five Essentials in Welding in order to produce quality
weld.
INTRODUCTION
To produce good welds you must not only know how to manipulate the
electrode, but you need to know certain weld characteristics.
Weld quality consistency only be maintained with respect to the essentials.
The Five Essentials of Welding include the use of the correct current,
correct electrode diameter, correct arc length, correct electrode angle,
correct travel speed.
Terms and Definition:

Welding- is a joining of two or more metal thru fusion.
Electrodes- metal rods which conduct a current from the tip of the electrode
to the base metal.
Arc- the flow of the electric current from the tip of the electrode to the base,
metal being welded.
Arc length- the distance from the tip of the electrode to the base metal being
welded.
Arc blow- a condition that occurs when the arc does not follow its intended
path from the electrode to the work piece. Arc blow can cause undesirable
weld beads.
Flux- a fusible material or gas used to dissolved and/ or prevent the
information of oxides, nitrides, or other undesirable inclusions formed in
welding.
Base metal- to be welded or cut.

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Crater- a depression at the termination of a weld. A recess in the weld bead.
A crater can cause cracking if not properly filled.
Weld puddle- that portion of a weld that is molten t the place.
Shielding gas- a layer of inert or slightly reactive gas provided by the
electrode. Shielding gas protects the weld puddle and arc from atmospheric
contamination.
1. CORRECT CURRENT
If the current is too high, the electrodes melt too fast and the molten pool is
large and irregular. When the current is too low, there is not enough heat to
melt the base metal and the molten pool will be too small. The result is not
only poor fusion but the beads will pile up and be irregular in shape.
AC (Alternative current) transformer welder- current alternating current
directions 20 times per second.
AC-DC- transformer rectifier provides either alternating current or direct.
Motor Generator- produces DC current
Engine Generator- produces DC current
POLARITIES

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A. Direct Current Electrode Negative ( DCEN )- The specific direction of
current flow through a welding current when the electrode lead is connected
to the negative terminal and the work lead is connected to the positive
terminal of a machine. (Current flows from the base metal to electrode). This
is also called as direct current straight polarity (DCSP).
B. Direct Current Electrode Positive (DCEP)- The specific direction of current
flows through a welding circuit when the electrode lead is connected to
positive terminal and the work lead is connected to the negative terminal to
a welding machine. (Current flows from base metal to the electrode). This is
also called direct current reverse polarity (DCRP)
Note: Welding leads must connect to correct terminals if machine has

polarity switch. Otherwise a change in polarity is made by reversing leads on
the terminals)
Factors that determine polarity:
 E6010 DC (+) reverse polarity
 E6012 DC (-) straight polarity
 E7018 AC (+) reverse polarity
 E7024 AC (+) reverse or straight polarity
2. CORRECT ELECTRODE DIAMETER
The choice of an electrode involves such items as position of the weld,

properties of the base metal, diameter of the electrode, type of joint
and current value.

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WHAT IS AN ELECTRODE
An electrode is a coated metal wire having approximately the same
composition as the metal to be welded. When the current is produced by
the generator or transformer and flows through the circuit to to electrode,
the arc is formed between the end of the electrode and the work. The arc
melts the electrode and the base metal, the melted metal of the electrode
flows into the molten crater and forms a bond between the two pieces of
metal being joined.
SELECTING CORRECT ELECTRODE

The ideal electrode is one that will provide good arc stability, smooth weld
bead, fast deposition, minimum spatter, maximum weld strength, and easy
slag removal. To achieve these characteristics five factors should be consider
in selecting an electrode, these are:
PROPERTIES OF BASE METAL

A top quality weld should be as strong as the apparent metal. This mean
that the electrode to be used must produces as weld metal with
approximately the same mechanical properties as the parent metal.
ELECTRODE DIAMETER
Some operator prefer larger electrodes because they permit faster travel
along the joint and thus speed up the welding operation.
JOINT DESIGN AND FIT-UP

Joint with insufficient beveled edges require deep penetration, fast-freeze
electrodes.
WELDING POSITION
The position of the weld joint is an important factor in the type of electrode
to be used. Some electrodes produce better results when the welding is done
in a flat position. Other is designed for vertical, horizontal, and overhead
welding.
WELDING CURRENT

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Electrodes are made for use with either AC current or DC current reverse
polarity of DC current straight polarity, although some electrodes function
as well on both AC and DC current.
TWO KINDS OF MILD STEEL ELECTRODES:
1. Bare Electrodes- were uncoated metal rods
2. Shielded-have heavy coating of various substances such cellulose
sodium, iron cellulose potassium, iron oxide, iron powder.
Core Rod (Metal Filler)

 Carries welding current
 Become part of the weld
Flux coating
 Produces a shielding gas
 Can provide additional filler metal the gap of groove between two base
metal
 Forms a slag covering to protect the weld from contaminants during
cooling.
IDENTIFYING ELECTRODES
In this classification, each types of electrodes has been assign specific

symbols, such as E-6010; E-8010, etc. The prefix E identifies the electrode
for the electric arc welding.
The first two digits designated the minimum allowable tensile strength, of
the deposited weld metal in thousands of pounds of square inch (psi).
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The third digit of the symbol indicates the possible welding position. Three
numbers are used for these purposes: 1, 2, 3. Number 1 is for an electrode
which can be used for welding in any position. Number 2 represents an
electrode restricted for welding in horizontal and flat position only. Number
3 represents electrodes to be used in the flat position only.
The fourth digit of the symbol simply shows some special characteristic of
the electrode, such as type of coating, weld quality, type of arc, an amount
of penetration.
The fourth may be 0, 1, 2, 3, 4, 5, 6, 7, or 8
AWS DESIGNATION FOR MANUAL ELECTRODE
The letter and each number used to classify electrodes have a specific
meaning.
E 60 1 1
ELECTRODE TENSILE STRENGH WELDING SPECIAL
WELDING POSITION CHARACTERISTIC
Such as power type DC

Polarity. Straight
polarity
Arc Properties
60-60,000 psi 1 Any position
70-70,000 psi 2 Horizontal or flat
80-80,000 psi 3 Flat only
110-110,000 psi 4 Flat, horizontal, overhead, downhill
CONSERVING AND STORING ELECTRODES

Most electrodes are costly; therefore, every bit of the electrode should be
consumed. Do not discard stub ends until they are down to only 1 ½ “to 2”
long.
Always store electrodes in a dry place at a normal room temperature and 50
percent maximum relative humidity. When exposed to moisture, the coating
has a tendency to disintegrate. In storing electrode, be sure they are not
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bumped, bent, or stepped on, since this will remove the coating and make
the electrodes useless.
E-6011. This electrode is similar to the E-6010 except that it is made

especially for AC machines. Although the electrode can be used on DC
machines with reversed polarity, it does not work quite as well as the E-
6010. Its amperage setting is slightly lower than for E6010.
CURRENT SETTING for E-6010 Electrodes

ELECTRODES DIA AMPERES*
(INCHES)
3/32 50-90
1/8 80-130
5/32 120-180
3/16 140-220
7/32 170-250
¼ 225-325
E-6012- This fill-freeze electrode and maybe used on either DC or AC

welders. When employed on DC welders the current must be set for straight
polarity. The electrode provides medium penetration, quiet type arc, slight
spatter, and dense slag. Although it is considered as all-position electrode, it
is used in greater quantities for flat and horizon position welds.

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CURRENT SETTING for E-6012 Electrodes
ELECTRODES DIA AMEPERES*

( INCHES)
3/32 40-90
1/8 80-120
5/32 120-190
3/16 140-240
7/32 180-315
¼ 225-350
E-6013. Electrodes of this type are very similar to E-6012 with few slight
exceptions. Slag removal is better and the arc can be maintained easier,
especially with small diameter electrodes.
Current Settings for – 6013 Electrodes

(INCHES)
1/16 20-40
5/74 25-50
3/32 30-80
1/8 80-120
5/32 120-190
3/16 120-240
7/32 225-300
¼ 250-350
CBLM on Shielded Date Developed: Document No.
II
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Welding carbon steel NTTA
Developed by:
plates using SMAW
Romeo E. Carmona
Jr.
IRON POWDERED ELECTRODE
Iron powdered electrodes are those which contain a high content of iron
powder. They are design for welding mild steels where speed and fast
deposition rate are required.
The three principal types are:
E-6027
E-7014
E-7024
All of them produce low spatter with easy slag removal.
E-6027. This electrodes produces high quality welds for high speed
disposition of ¼ “and 5/16” horizontal fillets and for on butt and fillet welds
in the flat position and for cover beads on butt welds where complete
coverage and good bead appearance are required. Current may be AC or DC
with other polarity.
Current setting for E-6027 Electrodes

(INCHES)
3/16 225-300
7/32 275-375
¼ 350-450
LOW-HYDROGEN ELECTRODES
LOW-HYDROGEN ELECTRODES are design for welding high-sulfur and
high-carbon steels. When such steels are welded they tend to develop
porosity and cracks under the weld bead because of hydrogen absorption
from the atmosphere. Low-hydrogen electrodes were developed to prevent
the induction of hydrogen in the weld.

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The basic low-hydrogen electrodes are:
E-7016
E-7028
E-7018
E-7028
Low-hydrogen electrodes with a heavy iron powder type covering and are
considered the counterpart of E-7018 but for flay and horizontal positions
only.
Current Settings for E-7028

( INCHES)
5/32 175-250
3/16 250-325
7/32 300-400
¼ 375-475
E- 7018. The E-7018 is a low-hydrogen type electrode but also contains iron
powder. It is a high-speed fast-disposition rate electrode design to pass the
most severe X-ray requirements when applied in all welding position, either
AC or DC reverse polarity current.

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Current Settings for E – 7018 Electrodes
ELECTRODES
DIA (INCHES) *AMPERS*
3/32 70-120
1/8 100-150
5/32 120-200
3/16 200-275
7/32 275-350
1/4 300-400
MILD STEEL ELECTRODE SELECTION

AWS NUMBER APPLICATION
E-6010 GENERAL PURPOSE- DEEP PENETRATION-AVERAGE
DEPOSITION-LIGHT SLAG-FAST FREEZING-ALL POSITION
E-6011
GENARAL PURPOSE-MEDIUM PENETRATION-GOOD
E-6012
DEPOSITION-EASY TO USE HEAVY SLAG-LOW QUALITIES-ALL
E6013 POSITION
E-6014
E-7024 PRODUCTION-IRON POWDER COATING-FAST DEPOSIT RATE-
E-6027 AMOOTH BEADS-DRAG TECHNIQUE;MILD PENETRATION-
HEAVY SLAG-FAST FILL-HORIZONTAL AND FLAT
E-7018
LOW HYDROGEN-CRACK RESISTANCE-RAY QUALITY-PROBLEM
E-7028 STEEL- GOOD DEPOSITION-MEDIUM PENETRATION-MEDIUM
SLAG-ALL POSITION

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3. CORRECT ARC LENGTH
It is one of the essential for good welding. The length of the arc
depends on the size of electrode used and the kind of welding done.
After striking the arc, maintain a 1/8” distance between the electrode and
the work piece.
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If the arc length becomes too short, the electrode will get stuck or freezzed to
the work piece or ‘short out’. The voltage will decrease.
If the arc length becomes too long; spatter, undercut, and porosity can
occur. The voltage will increase.
4. CORRECT ELECTRODE ANGLE

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Experienced welders vary the angle of the electrode according to the
electrode being used and the job. However, the beginner should lean the
electrode slightly in the direction of the travel. A 75 degree to 85 degree
angle, 10-15 degree from the vertical (straight up) position, is suggested.
WORK ANGLE
The work angle is the angle between the electrode and the work as depicted
on the left. Work angle can vary depending on the position the weld is being
made in.
TRAVEL ANGLE
Also commonly called lead angle. The travel (lead) angle is the angle
between the electrode and the plane perpendicular to the weld axis.
Excessively fast travel speed also decrease penetration, create a narrower

and/ or highly crowned bead, and possibly under fill or undercut , which is
when the area outside of the weld is concaved or recessed. Note towards the
end of the bead appears inconsistent as if the puddle were trying to keep up.
5. CORRECT TRAVEL SPEED

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To achieve a uniform rate of travel across the metal requires practice in arm
movement. It requires the welder to be in a comfortable position that
permits such movements. The best way to control the movement is to watch
the welded metal solidifying behind puddle. When weld material forms
evenly spaced semicircles behind the puddle.
The travel speed is the speed at which the electrode moves along the base
material while welding.
Too fast of a travel speed result in a ropey or convex weld.
Too slow of a travel speed results in a wide weld with an excessive metal
deposit.
The travel speed impacts the shape of the bead.
Self-checked 1.1-2

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MULTIPLE CHOICE:
INSTRUCTION: Read the question carefully. On your own answer sheet,

write the letter of the correct answer.
1. What is the polarity when the electrode is positive?
a. straight polarity
b. reverse polarity
c. balance polarity
d. forward polarity
2. The next to the last number in the AWS electrode classification indicates.
a. polarity
b. covering
c. position of welding
d. welding current
3. The first two numbers in the AWS electrode classification indicates?
a. polarity
b. tensile strength
c. welding current
d. welding position
4. What is the purpose of electrode coating?
a. insolate the electrode
b. add alloying elements to the weld
c. increase penetration
d. shield the weld zone atmosphere
5. It is one of the essentials of good welding
a. travel speed b. electrode
c. flux coating d. correct are length
ENUMERATION:
1. What are the 5 essentials in welding?
2. What are the two polarities in welding ?
Answer Key to 1.1-2

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MULTIPLE CHOICE:
1. A
2. D
3. C
4. B
ENUMERATION:
1.
a. correct current
b. correct electrode diameter
c. correct are length
d .correct electrode angle
e. correct travel speed
2.
a. DCEP
b. DCSP
INTERNATIONAL WELDING CODES and STANDARD

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After reading this INFORMATION SHEET, YOU MUST be able to:

1. Explain the importance of welding Codes and Standards ;
2. Define American Welding Society (AWS);
3. Identify the different welding position.
Introduction:
This Information Sheet covers the skills, knowledge, and attitudes
required in Welding Codes and Standards using SMAW process.
Welding Codes and Standards: When Are They Used, and How Are They
Developed
Many aspects of the design and fabrication of welded components are
governed by documents known as codes and standards. Other names used
for such documents include guides, recommended practices, regulations,
rules, and specifications. These documents are often specified by an end
user/purchaser as a contractual agreement in order to control the
characteristics of the welded fabrication that may affect its service
requirements. They are also used by the manufacturer to assist in the
development and implementation of their welding quality system. Many end
users of welded components have developed and issued specifications that
have been compiled by them to address their specific requirements. Such
specifications may be limited in application and related only to that
customer’s situation and requirements. National interest in areas such as
public safety and reliability has promoted the development of welding codes
and standards that command broader recognition both on a national and
industry-specific basis. Numerous committees have been developed over the
years within national engineering and technical societies that continue to
evaluate the needs of industry and develop new welding codes and
standards. Such committees are comprised of members who are technical
experts and represent all interested parties such as manufacturers, end
users, inspection authorities, and government agencies. The membership of
these committees is balanced in order to prevent any one interest group
from controlling the committee. On completion of a new or revised document
by the specific committee, it is usually then reviewed and approved by a
review committee, and if accepted, then published in the name of the
applicable engineering society.
Documents that have significant influence upon public health and

safety are sometimes adopted by legislative bodies or by federal regulating

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agencies. In those jurisdictions, such documents become law and are often
referred to as Codes or Regulations.
The welding inspector should be aware of what codes or standards are

applicable within their jurisdiction, understand the requirements of the
relevant documents and perform their inspection accordingly.
Sources Of Codes and Standards Of Interest To The Welding Industry
The following are some of the more popular sources of welding codes and
standards found in the USA.
American Welding Society (AWS) –
Probably the largest producer of welding codes and standards in the

USA. The AWS publishes many documents addressing the use and quality
control of welding. These documents include such general subjects as
Welding Definitions and Symbols, Classification of Filler Metals,
Qualification and Testing, Welding Processes, Welding Applications, and
Safety.
(AWS)- is a nonprofit organization dedicated to advancing the science,

technology, and application of welding and allied joining and cutting
processes, including brazing, soldering, and thermal spraying.Probably the
largest producer of welding codes and standards in the USA. The AWS
publishes many documents addressing the use and quality control of
welding. These documents include such general subjects as Welding
Definitions and Symbols, Classification of Filler Metals, Qualification and
Testing, Welding Processes, Welding Applications, and Safety.
AWS codes
It is important to become knowledgeable about every type of welding
position in use today for making groove and fillet welds on metal plate and
pipe. As mentioned earlier, the American Welding Society (AWS) has
developed a system to simplify this process. The system is very easy to
understand. If a “G” appears before each position this indicates that the
weld being described is a groove weld. Conversely, if an “F” appears it
indicates that the weld in question is a fillet weld.
The system has been set up to also describe the type of welding
position that is being used. In order to do this the AWS uses four digits. The
numbers one through four are used to identify the types of welding positions
possible. A “1” indicates that the weld was made in the flat position, a “2”
indicates the horizontal position, a “3” the vertical position, and a “4”
the overhead position. In addition to these four digits, a five and six are
used to describe two types of welds used when working with pipe. The “5”
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indicates a horizontal fixed pipe position and the “6” indicates an
inclined fixed pipe position. Some examples of weld names are:
1G – groove weld, in the flat position

2G – groove weld, in the horizontal position
3G – groove weld, in the overhead position
4G – groove weld, in the overhead position
1F – fillet weld, in the flat position

2F – fillet weld, in the horizontal position
3F – fillet weld, in the vertical position
4F – fillet weld, in the overhead position
1G – groove weld on pipe, in the horizontal rotated

2G – groove weld on pipe, in the vertical fixed position
5G – groove weld on pipe, in the horizontal fixed position
6G – groove weld on pipe, in the inclined fixed position
The following is an illustration that adequately shows the AWS system at

work.

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Welding testing position
Groove Weld Positions

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In most instances it will be necessary to make more than one weld pass to
properly secure a joint. There are few terms that are given to the types of
weld passes needed to adequately join two pieces of metal. Many times, the
first weld pass will be referred to as the stringer, or root pass, and requires
full penetration of the metal being welded. The second pass is referred to as
a hot pass, the third is called a filler pass and the final pass is called a cap
or cover pass. Keep in mind that not all weld joints will require all four weld
passes to be run. Each pass is meant to cover the previous one and join a
bit more of the metal to the welds.
In most instances, full penetration is not required for this type of weld. In
cases that call for full penetration, the plates should be beveled on the joint
edge and the same procedure used. There are many types of practice
methods used to complete butt welds. Acquire the knowledge needed to
master butt welds in the 1G, 2G, 3G,4G, 5G, and 6G positions. Repeated
practice is key to becoming proficient at each of these welds. Become
familiar with the types of weld tests that will be completed to determine the
strength and quality of the welds you produce. Two common tests used by
the American Welding Society (AWS) are the X-ray and Guided Bend tests.
American Welding Society (AWS) Standards
AWS DII.2 Welding (cast iron)

AWS D10.13 Tube brazing (copper)
AWS D01.8 Structural welding seismic supplement
AWS D01.9 Structural welding (titanium)
AWS D01.7 Structural welding (strengthening and repair)
AWS D01.1 Structural welding (steel)
AWS D01.6 Structural welding (stainless steel)
AWS D01.3 Structural welding (sheet steel)
AWS D01.4 Structural welding (reinforcing steel)
AWS D01.2 Structural welding (aluminum)
AWS A03.0 Standard welding terms and definitions
AWS A02.4 Standard symbols for welding, brazing, and non-destructive
examination

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AWS D18.2 Stainless steel tube discoloration guide
AWS A05.1 Specification for carbon steel electrodes for shielded metal arc
welding
AWS A05.18 Specification for carbon steel electrodes and rots for gas
shielded arc welding
AWS D09.1 Sheet metal welding
AWS D10.11 Root pass welding for pipe
American Society of Mechanical Engineers (ASME) – This society is

responsible for the development of the Boiler and Pressure Vessel Code,
which contains eleven sections and covers the design, construction, and
inspection of boilers and pressure vessels. ASME also produces the Code for
Pressure Piping, which consists of seven sections. Each section prescribes
the minimum requirements for the design, materials, fabrication, erection,
testing and inspection of a particular type of piping system. Both of these
documents are American National Standards.
American Petroleum Institute (API) – This institute publishes many

documents relating to petroleum production, a number of which include
welding requirements. The most well known is possibly API STD 1104 –
Standard for Welding Pipelines and Related Facilities.
What The Welding Code and Standard Generally Provides
The specific content and requirements of a welding code or standard can

vary in detail, however, there are a number of elements within these types of
documents which are common and which we will examine.
The Scope and General Requirements: This is found at the beginning of

the document and is important as it will normally provide a description as to
the type and extent of welding fabrication for which the document was
developed and intended to be used. It may also provide information relating
to the limitations for the use of the document. Care should be taken to use
codes and standards that are applicable for your particular application.
Design: If the document provides a section for design, it may refer the user
to a secondary source of information, or it may contain minimum
requirements for the design of specific welded connections.
Qualification: This section of the document will typically outline the

requirements for qualification testing of welding procedure specifications
(WPS) and also those requirements for qualification of welding personnel. It
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may provide the essential variables, these being the change limitations that
govern the extent of qualification. Such variables are typically the welding
process, type and thickness of base metal, filler metal type, electrical
parameters, joint design, welding position, and others.
This section of the document may also provide the qualification testing
requirements. Usually this is divided into welding procedure and welder
performance testing requirements. Typically, it will provide the types and
sizes of test samples to be welded and prepared for testing, the testing
methods to be used, and the minimum acceptance criteria to be used for the
evaluation of test samples.
Fabrication: This section, when included in the document, will typically

provide information associated with the fabrication methods and/or
workmanship standards. It may contain information and requirements on
such items as base materials, welding consumable classification
requirements, shielding gas quality, heat treatment requirements,
preparation and care of base material, and other welding fabrication
requirements.
Inspection: This section of the document will typically address the welding
inspector’s qualification requirements and responsibilities, acceptance
criteria for discontinuities, and requirements relating to procedures for
nondestructive testing.
Self-Check 1.1-3
MULTIPLE CHOICE:
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Instructions: Read the questions carefully. On your answer sheet, write
the letter of the correct answer.
1.Match the welding positions of a grooved butt joint which corresponds

to AWS code?
1.1. Flat a. 3G
1.2. Horizontal b. 4G
1.3. Vertical c. 1G
1.4. Overhead d. 2G
2. What is American Welding Society and how it helps to the process of

welding?
3. What is the two common test used by the American Welding Society?
4. What are the sources of codes and standards of welding industry?
5. What the welding codes and standard generally provides?
Answer Key to 1.1-3
1.
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1.1. C
1.2. D
1.3. A
1.4. B
2. American Welding Society is a non-profit organization dedication in

advancing the science, technology, and application of welding, setting
standard and norms in different welding processes.
3.
A. X-ray
B .Guided bend test
4. The sources of codes and standards are AWS, ASME ,and API
5. The codes and standard provides the Scope and General Requirements,
Design, Qualification, Fabrication and Inspection.

ACCEPTABLE WELD PROFILE

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1. Differentiates acceptable and unacceptable weld profile;
2. Define and Identify the parts of Fillet Welds ;
3. Define, identify and perform Groove Welds;
4. Differentiates types of welds;
5. Explain the five basic welded joints .
Introduction:
This Information Sheet covers the skills, knowledge, and attitudes required
in Acceptable Weld Profile in welding carbon steel plates using SMAW
process.
Acceptable and Unacceptable Weld Profile

The number of acceptable and unacceptable weld discontinuities for welding
inspection usually is obtained from welding codes and standards. Welding
codes and standards have been developed for many types of welding
fabrication applications. It is important to choose a welding standard
intended for use within the particular industry or application in which you
are involved.
DETERMINING THE WELD QUALITY

Weld quality acceptance criteria can originate from a number of sources.
The welding fabrication drawing or blueprint provides weld sizes and other
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welding dimensional requirements such as length and location. These
dimensional requirements are established through design calculations or
are taken from proven designs that meet the performance requirements of
the welded connection.
Fillet Welds
The fillet weld symbol is one of the most widely used symbols and the
shape placed on the reference line to indicate a fillet weld is a triangle that
resembles the side profile of a fillet weld.
The examples of the weld all around and field weld above show a fillet weld
symbol so that the weld to be applied in both cases is a fillet weld.
May consist of one or more beads deposited in the angle formed by two
plates that are at the right angles and they are used to weld a lap joints
and a Tee joints.
Parts of Fillet Weld

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KEY POINT: Fillet sounds like fill it (pronounce the T) not fillay as in
fillet a fish.
The size of a fillet weld refers to the length of the legs of the weld. The
two legs are assumed to be equal in size unless otherwise specified.
 Face of Bead – a weld of approximately triangular cross section

joining the two surfaces approximately at the right angle two each
other in a lap joint, tee joint or corner joint.
 Root – the bottom of the weld that intersects the base metal surfaces.
 The leg length -is the distance from the root of the joint to the toe of
the fillet weld.
 The throat -is the distance from the root to a point on the face of the
weld along a line perpendicular to the face of the weld. Theoretically,
the face forms a straight line between the toes.
 Toe – the junction between the face of the weld and the base metal.
 Penetration – the depth of fusion.
Groove Welds
A weld made in the groove between two members to be joined.
May consist of one or more beads deposited in a groove.
They are used in welding various forms of V ─bevel, J, and U─ groove butt
joint.
Parts of Groove Weld
 The faceof weldis the exposed surface of a weld on the side from
which the weld was made.
 The toe -is the junction between the face of the weld and the base
metal.
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 The root -of a weld includes the points at which the back of the weld
intersects the base metal surfaces.
 The throat – Shortest distance from the root to the face of bead.
TYPES OF WELDS
There are many types of welds. The most common types are the bead,
surfacing, plug, slot, fillet, and groove.
 A weld Bead is a weld deposit produced by a single pass with one of

the welding processes. A weld bead may be either narrow or wide,
depending on the amount of transverse oscillation (side-to-side
movement) used by the welder. A weld bead made without much
weaving motion is often referred to as a stringer bead. On the other
hand, a weld bead made with side-to-side oscillation is called a weave
bead.
 Several weld beads applied side-by-side are usually used in

Surfacing which is a welding process used to apply a hard, wear-
resistant layer of metal to surfaces or edges of worn-out parts.
 A Fillet weld is triangular in shape and this weld is used to join two
surfaces that are at approximately right angles to each other in a lap,
tee, or comer joint.

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 Plug and Slot welds are welds made through holes or slots in one
member of a lap joint. These welds are used to join that member to
the surface of another member that has been exposed through the
hole.
 Groove welds (also may be referred to as Butt welds) are simply welds
made in the groove between two members to be joined. The weld is
adaptable to a variety of butt joints, as seen in the figure. Groove
welds may be joined with one or more weld beads, depending on the
thickness of the metal. If two or more beads are deposited in the
groove, the weld is made with multiple-pass layers. As a rule, a
multiple-pass layer is made with stringer beads in manual operations.

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 Groove welds may be joined with one or more weld beads, depending
on the thickness of the metal. If two or more beads are deposited in
the groove, the weld is made with multiple-pass layers. As a rule, a
multiple-pass layer is made with stringer beads in manual operations.
 The build-up sequence -refers to the order in which the beads of a

multiple-pass weld are deposited in the joint. Usually, before adding
the next pass, the previous pass needs to cool down to a certain
temperature which is called the inter-pass temperature. Also, before
adding the next pass, the surface of the previous pass needs to be
cleaned from slag, especially with SMAW, using a wire brush or other
appropriate method.
 Weld reinforcement -is a term used to describe weld metal in excess

of the metal necessary to fill a joint. The reinforcement needs to be
grinded in some cases depending on the intended use of the joint.

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Some other terms which are used to describe areas or zones of welds are:
The fusion zone is the region of the base metal that is actually melted.
The depth of fusion is the distance that fusion extends into the base
metal or previous welding pass.
The heat-affected zone (HAZ) refers to that portion of the base metal
that has not been melted; however, the structural or mechanical
properties of the metal have been altered by the welding heat.
THE FIVE BASIC WELDED JOINTS

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• Butt joint • Tee joint • Lap joint • Corner joint • Edge joint
Each welding joint has several variations to provide for different needs. Two
different types of welds are used when welding these joints. The groove-type
weld (butt weld) fills in grooves that are cut on the inside of two pieces of
metal that are positioned next to each other. The fillet-type weld fills in
space on the outside of pieces of metal that are positioned at an angle to
each other.
Butt joint- a joint between two members aligned approximately in the same
plane
Corner joint - a joint between two members located at right angles to each
other
T- joint - a joint between two members located approximately at right angles

to each other in the form of a T.

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Lap Joint- a joint between two overlapping members.
Edge joint- a joint between the edges of two or more parallel or nearly
parallel members.
Proper terminology -is needed in everyday job communication
 Joint design identifies, “the shape , dimensions, and

configuration of the joint
 The individual work pieces of a joint are called members .
 Three types members non-butting member, butting member ,
and splice member
A butting-member -is “a joint member that is prevented, by the other

member from movement in one direction perpendicular to its thickness
dimension”

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A non-butting member is “a joint member that is free to move in any
direction perpendicular to its thickness dimension
A splice member -is “the work piece that spans the joint in a spliced joint
Single-spliced butt joint

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Double-spliced butt joint with joint filler
PARTS OF WELDED JOINTS

The root of a joint is that portion of the joint where the metals are closest
to each other. As shown in the figure, the root may be a point, a line,
or an area, when viewed in cross section.
 A groove - is an opening or space provided between the edges of the

metal parts to be welded.

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 The groove face -is that surface of a metal part included in the
groove
 A given joint may have a root face or a root edge
 The root face, also shown in view A, is the portion of the prepared
edge of a part to be joined by a groove weld that has not been
grooved. As you can see, the root face has relatively small
dimensions.
 The root edge -is basically a root face of zero width, as shown in view
B. As you can see in views C and D of the illustration, the groove face
and the root face are the same metal surfaces in some joints.
 The specified requirements for a particular joint are expressed in terms

such as bevel angle, groove angle, groove radius, and root opening.
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 Groove Face - is that surface of a metal part included in the
groove.
 Root Face - is the portion of the prepared edge of a part to be

joined by a groove weld that has not been grooved.
 The bevel angle -is the angle formed between the prepared edge
of a member and a plane perpendicular to the surface of the
member.
 The groove angle -is the total angle of the groove between the
parts to be joined. For example, if the edge of each of two plates
were beveled to an angle of 30 degrees, the groove angle would
be 60 degrees.
 The groove radius -is the radius used to form the shape of a J-
or U-groove weld joint. It is used only for special groove joint
designs.
 The root gap or root opening -refers to the separation between
the parts to be joined at the root of the joint.


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Root penetration -refers to the depth that a weld extends into the root of
the joint. Root penetration is measured on the canter line of the root
cross section. 1
 Joint penetration -refers to the minimum depth that a groove weld

extends from its face into a joint, exclusive of weld reinforcement.
ROOT OPENING TECHNIQUE

Use root opening to allow increase in amperage for smother welding
Whip backwards for penetration
Whip forwards to reduce penetration
Do not weave a root pass
Maintain a short arc gap
Stay slightly in front of the puddle at all times. Use key-holing technique.
-60 degrees included angle

-Root faces
-Tacking
-Feather tacks
In many cases, root penetration and joint penetration, often refer to the
same dimension.

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Self-check 1.1-4
Essay type:
1. What is the importance weld quality? And how will the quality applies in
different welding process?
Enumeration:
1. The exposed surface of the welding the side from which the weld was
made.
Throat b. root c. face of the weld d. all of the
above
2. The junction between the face of the weld and the base metal.
Groove weld b. root c. throat d.leg
3. The distance from the root of the joint to the toe of the fillet weld.
Root b. leg length c. penetration d. all of the above
4. Shortest distance from the root to the face of bead.

a. penetration b. fillet weld c. face of the weld d.
Throat
5. Refers to the portion of the base metal that has not been melted.
a. Fusion Zone b. Weld reinforcement c. HAZ - Heat affected zone

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Answer Key 1.1-4
Essay:
Weld quality acceptance criteria can originate from a member of sources.

The welding fabrication drawing or blue print provides weld sizes and other
welding dimensional requirements such as length and location. The member
of acceptable and unacceptable weld discontinuities for welding inspection
usually obtain from welding codes and standard.
Enumeration:
1. Face of the weld
2. Toe
3. Leg Length
4. Throat
5. HAZ- heat affected zone

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BASIC WELDING JOINTS and SYMBOLS
1. Differentiate the different welding symbols.
2. Identify the basic parts of welding symbols and symbols for welding in
details
3. Identify the dimensions applied to weld symbols
4. Thoroughly familiar with welding symbols and their significance
Introduction:
This Information Sheet the Welders must not only be competent in
the manipulative skills of the trade but must be equally competent in their
ability to interpret the trade drawings in symbols which describe the work
they must do.
Standards welding symbols are published by the American Welding Society.
These symbols should be used as necessary on details of attachments,
vessels, piping support, etc.
The practice of writing on drawing constructions such as ‘TO
BEWELDEDTHROUGHOUT, or TO BE COMPLETELY WELDED‘ transfer
the design responsibility are all attachments and connections from the
designer to the welder, which the society consider to be a dangerous and
economic practice.

Concave – rounded or curved inward in relation to adjoining planes.
Consumable insert – Replaced filler metal that is completely fused into the
joint root and becomes part of the weld.
Convex – rounded or curved outward in relation to adjoining planes.
Flush – forming a relatively level or continues plane o n a surface.
Fillet Weld – a weld of approximately triangular cross section joining two
surfaces approximately at right angles to each other n a lap joint, T-joint, or
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corner joint surfaces approximately at right angles to each other in a lap
joint, T- Joint, or corner joint.
Groove weld – a weld made in the groove between work pieces.
Miter – the beveled edges of thee work pieces made by cutting pieces at
angles and joining them.
Pitch – the corner to corner distance between two welds.
Welding symbol – a graphical character connected to the welding symbol
indicating the type of weld.
Work piece – the part that is welded, brazed, soldered, thermal cut. Or
thermal sprayed.
Basic Parts of a welding symbol:

Reference line
Arrow line
Basic Weld Symbols
Dimension and other Data
Supplementary Symbols
Finish Symbols
Tail
Specifications, process or Other References
Reference line - is a line straight line on a horizontal plane with all other
welding information located above, below, or the reference line.
________________
Multiple reference lines are used to indicate a sequence of welds or
associated activity with the first weld of the series closest the arrow.
3rd operation
` 2nd operation
1st operation
Arrow Line – a line extends at an angle from their end of a reference line
and is terminated with an arrowhead.
Arrow – arrow may point on any direction but it always points to the
welding joint which requires preparation and/or welding.

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Tail – the tail of the welding symbol is at the end of a reference line, opposite
the arrow and it has the horizontal V-shape of feathers at the end of an
arrow.
_______________
The Free space in the tail – is used to notes, specifications, process, and
other items, but if no instructions are required, the tail is not used.
________________ SMAW __________________
Arrow side, other side significance

A Weld symbol located above the reference line indicates the weld is
to be made on the opposite side the arrow points to.
________________
Weld symbol located above the reference line indicates the weld is to
be made on the opposite side the arrow points to.
_________________
Arrow line variations

A broken arrow line points to the work piece to be prepared, and is
used on a bevel, J- joint flare bevel, and a corner flange.
1 2
Multiple arrow lines are used to indicate that the same weld is required in
several different places.

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Weld Symbols and Welding Symbols
A weld symbol is a shape designed to represent a basic weld.
V-groove butt joint

Example: Fillet Weld
I plug or slot
A welding symbol has the weld symbol on the reference line along all other
information significant to the weld.
¼(3/8)
Example: In the graphic above, the V groove specified should be ¼” in depth

and shall be made on the other side of the joint with 3/8” weld.
Supplementary Symbols
The weld all around symbol is an open circle positioned at the

junction of the reference/arrow lines, indicating that the weld is to be
made all around the joint.
A field Weld symbol is darkened flag located at the junction of the

reference/arrow line, indicating that the weld is to be made at the site
not in the shop.

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A melt through symbol is a solid oval located on the opposite side of
the weld symbol, indicating a requirement for 100% penetration.
A consumables insert symbol is an open square box located on the

reference line indicating that an insert is consumed in the basic weld.
A backing symbol is an open rectangular box used in combination with a

groove weld symbol: the symbol is located on the reference line, indicating
that backing material is required on the opposite side of the weld to control
penetration.
The other element seen on the reference line resembles a flag and is located
where the leader line joins the reference line. This element is called a field
weld and means the weld will be done in another location. For instance, this
weld may be applied at the job site not in the shop. Sometimes clarification
will be given in the welding symbol tail or as a specification on the print.
If backing is removed after completion of the weld, there will be an R in the

backing symbol.
A spacer is an open rectangular box that intersects the reference line,

indicating that is required in the joint.

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Note: Spacer and backing size and material are normally placed in the tail of
the arrow
Contour and Finish Symbols
A flush contour symbol is located on the same side as the symbol and
indicates the weld should be on approximately a flat plane with the surface.
A convex contour symbol is located on the same side as the symbol and
indicates that the weld should have a raised or convex shape.
A concave contour symbol is located on the same side as the symbol and
indicates that the weld should have a depressed or concave shape.

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If a control requires finishing, a finishing symbol will be used conjunction
with the contour symbol, a letter G to indicates grinding, C to the indicate
chipping. M to indicate machining and U to indicate unspecified which
means the best local method should be used.
SYMBOLS FOR WELDING DETAILS

 Reference line
 Arrow
 Basic Weld symbols
 Dimensions & other Data
 Supplementary Symbols
 Finish Symbols
 Tail
 Specification, Process or other Reference
Assembling the Welding Symbols

Reference line and arrow: The symbol begins with a reference line and arrow
pointing to the joint where the weld is to make. The reference line has two
sides: Other side (above the line) and arrow side (below the line).
BASIC WELDING ARROW

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Other side other side other side other side
Arrow side Arrow side Arrow side
BASIC WELDING SYMBOLS
The weld symbol
Fillet - A weld of an approximately triangular cross section

joining two surfaces approximately at right angles to each other in a lap
joint, t-joint, or corner joint.
Back or backing weld - aback weld is distinguished from a backing weld

only by the time of application.
Plug or Slot weld - a plug is distinguished from a slot weld only by the
shape of the hole.
Spot or projection weld- a spot weld is distinguished from a projection only

by the welding process in the tail of the arrow.
Edge Flange weld - a weld used on the flange edges of light gage metal.

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Corner Flange weld- a weld used on light gage metal when only one edge of
the work piece is flange.
B. Groove Weld – A weld made in a groove between two work pieces.
V – Groove weld -a groove in a shape of V.
Bevel groove weld -When only one or two work pieces are to be groove.
J-groove weld - a groove in the shape of a J on one work piece.
U -groove weld-a groove in the shape of U.
Flare V-groove weld-a groove when both work pieces are to be flared.
Flare bevel groove weld – a groove when only one work piece to be flared.
Scarf groove weld – a slanted square groove used only for brazing.

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Surfacing weld - a weld used to build up work pieces for extended life.
Edge Flange weld- a weld used on the flange edges of light gage metal.
Corner Flange weld- a weld used on light gage metal when only one edge of
the work piece is flange.
Example of fillet weld symbol
If a continues fillet weld is needed, like this:

The fillet weld symbol is place
on the “ARROW SIDE” of the reference line, thus:
If the weld is required on the far side from the arrow, thus:
The weld symbol is shown on the
“OTHER SIDE” of the reference line, thus

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If a continues fillet weld is needed on the both sides of the joint
The fillet weld symbol is placed
BOTH SIDES” of the reference line
DIMENSIONS APPLIED TO WELD SYMBOLS

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THE FILLET WELD
The examples of the weld all around and field weld above show a fillet weld
symbol so that the weld to be applied in both cases is a fillet weld.
KEY POINT: Fillet sounds like fill it (pronounce the T) not fillay as in fillet a
fish.
The important elements added to a simple fillet weld symbol are as follows:
The size of fillet weld

The length of fillet weld
The length and pitch of intermittent weld
The contour requirements
THE SIZE OF THE WELD.
The size of the fillet weld is determined by the legs of the triangle shape
which represent the legs of the fillet.
A welded piece may have a different weld size on each side or they may be
the same size.

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Sometimes (not often) a weld of unequal legs may be required. For example:
if one member of the joint is thinner than the other.
If no size is shown on the fillet weld, a size for all fillets will be given on the
drawing as a note or specification.

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Key Point: Making the fillet welds the wrong size may lead to costly rework
if you are not sure ask for clarification.
THE LENGTH OF THE FILLETWELD
The length of the weld when it is not a continuous weld is shown by a

number on the right side of the fillet weld triangle. If it is not obvious the
location is detailed on the drawing.

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THE LENGTH AND PITCH OF INTERMITTENT WELDS
An intermittent weld is one that is not continuous across the joint, but
rather is a given length of weld separated by a given space between them.
This method of welding may be used to control heat distortion or where the
joint strength requirements allow. Intermittent welding can save time and
money if a long weld is not necessary.
Used more frequently than the length alone, the length and pitch are two
numbers located at the right of the fillet weld symbol.
The length appears first as before followed by a hyphen then the pitch is
shown.
The pitch refers to a dimension from the center of one weld to the center of
the next weld.
Key Point: The pitch is not the space between welds but a measurement
from center to center of the welds. To get the spacing for layout subtract the
length of one weld from the pitch.
The intermittent welds may be chain intermittent or staggered intermittent.
Chain intermittent the welds on both sides of the joint are opposite each
other and resemble a chain. Staggered intermittent the welds on the
opposite side are usually started in the gap between the welds on the first
side. The welds then appear staggered.

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Key Point: If the welds are staggered the fillet weld symbol will be staggered
on the reference line.

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Example of Groove Weld Symbol
If bevel groove is required, like this:

The groove symbol for a bevel is shown, with the fillet symbol
A break is made in the narrow toward the member to be beveled.
Only the bevel and ‘J’ groove symbols require a break in the arrow.
Self-check 1.1-5
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MULTIPLE CHOICE:
1. What symbols that will used to show how the face of the weld is to be
formed?
a. Element
b. Dimension
c. Supplementary symbol
d. Contour symbol
2. It is a straight on a horizontal plane with all other welding information
located above, below or on the reference line.
a. Tail
b. Arrow
c. Reference line
d. None of the above
3. The tail of weld symbol means?
a. Supplementary symbol
b. Specification of weld process
c. Contour and finish symbol Hazard sign
d. multiple reference line
4. It is an open circle positioned at the junction of the reference line and the
Arrow line, indicating that the weld is to be made all around the joint.
a. Melt through symbol
b. Field weld symbol
c. consumable inert symbol
d. Weld all around symbol
ENUMERATION:
What are the basic parts of welding symbol?
Answer Key
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Self-check 1.1-5
1. D
2. C
3. B
4. D
2. a. Reference line
b. Arrow line
c. Basic Weld Symbols
d. Dimension and other Data
e. Supplementary Symbols
f. Finish Symbols
g. Tail
h. Specifications, process or Other References

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BASIC METALS and METALLURGY
After reading this INFORMATION SHEET, YOU MUST be able to differentiate

the causes of residual stresses and distortion
1. Identify the causes of residual stresses and distortion
2. Identify the guidelines in changing welding procedure to control
stresses, the application of weld quality control
Introduction:
This Information Sheet the learners should be able to differentiate the
causes of residual stresses and distortion.
Compatibility – two or more metals that have similar properties that can
readily be joined.
Distortion - movement or warping of parts being welded, from the pre-
welding position and condition compared to the post-welding condition and
position. Distortion in a weld results from the expansion and contraction of
the weld metal and adjacent base metal during the end cooling cycle off the
welding process.
Back-step welding – a longitudinal sequence on which the weld bead
increments are deposited in the direction opposite to the progress of welding
the joint.
Inter-pass Temperature – is the temperature of the weld area between weld
passes.
Longitudinal sequence – the order in which the weld passes of a
continuous weld are made in respect to its length.
Peening – the mechanical working of metals using impact blows.
Post heating – the application of heat to an assembly after welding, brazing,
soldering, thermal spraying, or cutting
Preheat – the heat applied to the base metal or substrate to attain and
maintain preheat temperature.
Preheating – the application of heat to the base metal immediately before
welding, brazing ,soldering, thermal spraying or cutting.
Residual stress – stress present in a joint or material that is free external
forces or thermal gradients.
Stress relieving – controlled heating to an elevated temperature, followed by
controlled cooling.
Thermal conductivity – is the capacity of a metal to conduct heat.
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Thermal expansion – is the tendency of metals to expand when heated, as
expressed in terms of coefficient of expansion.
Note: Thermal expansion is extremely important in welding because a metal

such as aluminum which has a high coefficient of thermal conductivity will
readily spread heat throughout the work piece and minimized distortion at
the weld zone, but metals such as stainless steel with a low coefficient of
thermal conductivity will localized the heat in the weld zone and cause a
greater amount of distortion.
Thermal stress – stress in metal resulting from non – uniform temperature
distributions.
CHARACTERISTICS OF RESIDUAL STRESSES

 Residual stresses are the undesirable elements of distortion left in a
part or assembly after a welding operation is completed.
 The forces and counter forces of residual stress can produce

shrinkage fractures and other forms of distortion that make parts
difficult or impossible fit up.
 Residual stresses can produce in base metal structural and

metallurgical changes so severe that a welded assembly could fail in
service and damage property or injure people.
CAUSES OF RESIDUAL STRESSES AND DISTORTION
 In a welding process, filler metals and base metals expand uniformly

in a direction if they are not restricted ,but if they are restricted, they
cannot expand uniformly.
 After welding process, filter metals and base metals contract as they
cool, a will assume their original shape if unrestricted, but if
restricted, they will contract uniformly.
 The lack of uniformly in expansion and contraction means that
residual stress will vary with joint design, welding procedure, and
meal type and thickness.
 Welding thick metals promotes residual stresses, and the thicker the
metal the more problems with residual stresses.
GUIDELINES FOR CHANGING THE WELDING PROCEDURE TO CONTROL

STRESSES
 Modify the joint design.
 Minimize the heat input by modifying the welding process.
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Example: Back step welding or intermittent welds
 Select alternate filler metals or base metals.
 Peen the weld lightly to help it stretch.
Note: Peen with care, because too much peening will add stress or cause
the weld to strain harden and become brittle.
 Stress relieve by using a post weld heat treatment.

 Add thermal control by using preheating, inter-pass heating, post
heating, or all three.
 Add mechanical control by using clamps, wedges, or mechanical jigs
and fixtures.
RESULTS OF LONGITUDINAL AND TRANSVERSE STRESS IN BASIC

WELDS
 In butt weld, the first passes can produce distortion down the length
of the weld bead; this is called longitudinal stress.
 In a butt weld, the first passes solidify, the movement across the weld
bead is restricted; this is called a transverse stress.
In a butt weld, the combination of longitudinal and transverse stresses

results in distortion that usually causes the plates to rise from an even
position to a slight angle.

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In a fillet weld, the combination of longitudinal and transverse stress not
only causes a change from flat to a slight angle, but the combination can
result in a C roll or twist along the length of the parts.
HEAT APPLICATIONS AND THEIR USES IN WELD QULITY CONTROL
 Preheating a part before a welding process starts can help control

cracking, reduce stresses from shrinkage, and promote slower cooling
to prevent excessive hardening.
 Heating between welding passes with inter-pass heat helps maintain

the required temperature.
Note: Most welding processes provide sufficient inter-pass heat, but on
large assemblies, heating between passes may be required.
Post heating after the welding process ends allows slow cooling which
promotes stress relief in the weld and the base metal.

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GUIDELINES FOR PREHEATING IN SPECIAL CONDITION
 Preheat when welding large or bulky parts or when welding

parts with complicated shapes.
 Preheat when atmospheric temperature is cold or when the
temperature of the part is cold.
 Preheat when the carbon or alloy content of steel is high.
 Preheat when a fast welding speed is specified.
 Preheat when small-diameter welding rods are specified.
TYPES OF STEELS AND THEIR RECOMMENDED PREHEAT

TEMPERATURE
 Mild steels- Preheating is not normally required, but if

temperature is below 50˚ F or higher, if the plate thickness is
over 1”.
 Medium-carbon steels –preheat from 200˚F to 400˚ F, retain the
same inter-pass temperature, and post-heat is recommended,
especially on thicker metals.
 High - carbon steels – preheat and inter-pass temperatures
should be a minimum of 400˚F, and post-heat is recommended,
especially on thicker metals.
METHODS FOR CONTROLLING DISTORTION WITH THE WELDING

PROCESS
 Do not over-weld because excessive filler metal added to the

joint increases shrinkage forces but does not increase weld
strength.

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 Use intermittent welds when you can because they provide
strength, yet reduce the amount of heat and filler metal
required.
 Use as few passes as specifications permit larger electrodes and

fewer passes are better than smaller electrodes and more
passes.
 Place welds at or along a neutral axis to lessen the leverage of

forces that cause distortion.
 Use back-step
 welding, welding usually proceeds left to right, but place beads
right to left in order to spread heat uniformly to the outer edges
and to bring plates back into alignment.

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 Weld in an alternating sequence, use intermittent welding,
welds alternately on fillet welds so that shrinkage in the second
weld will counter balance shrinkage in the first weld, and other
alternate welds will counterbalance each other.
METHODS FOR CONTROLLING DISTORTION WITH MECHANICAL

MEANS
 Modify the edge preparation, especially on thicker metal,

decrease he bevel angle and increase the root opening or use a J
– or U- joint design.
 Use a double V – joint in a place of a single V-joint because the
double requires about half the weld metal for the same plate
thickness.

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 Anticipate the places and amount of the shrinkage and preset
parts so that shrinkage forces will pull them into alignment
during welding.
Note: Presetting parts requires good estimating but a few practice welds
should demonstrate how it works.
 Pre bend and clamp parts to make the joints longer do that
shrinkage will cause the joint to lie flat as the plate cools and
the clamp are remove.
 Clamp parts front to back, if possible, to help distortion forces
work against each other for shrinkage control.

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METHODS FOR CONTROLLING DISTORTION WITH RESTRAINING
DEVICES AND THEIR APPLICATIONS
 When welding butt plates, tack weld clips along the edges of one
plate, than drive wedges under the open side of the clips to force
the edges into alignment.
 For aligning plates, tack weld is a yoke to a backup strip, slip

the yoke between the edges, then place a yoke guide on top of
the plates and a drive a wedge through the first yoke to
complete alignment.

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 For but welds on thicker plates, tack weld is a yoke on top of one
plate, tack well a bar to the top of the second plate, then drive a wedge
between the yoke and the bar to complete alignment.
 Several strong backs together could restrain a weld so much

that the weld could crack as it cools, so when several strong
backs are required, position them at 45 angle across the
joint to allow for transverse movement.

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Self check 1.1-6
Essay:
1. What is preheating?
2. What is post heating?
3. What are the methods of controlling distortion with the welding

process?

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Answer Key
Self check 1.1-6
1. Preheating before welding process starts can help control cracking,

reduce stresses from shrinkage and promote slower cooling to
prevent excessive hardening
2. Post heating after welding process ends allows slow cooling which
promotes stress relief in the weld and the base metal.
3.
A. Do not over weld
B. Use intermittent weld
C. Use Few passes
D. Use back-step welding

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Weld Defects, Causes and Remedies
After reading this INFORMATION SHEEET, YOU MUST be able to i dentify
the defects, the probable cause and remedies in welding
Introduction:
This module covers the skills, knowledge, and attitudes required in welding
carbon steel plates using SMAW process.

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Self-check 1.1-7
MATCHING TYPE:
Write your answer on your answer sheet
1. Failure of weld metal to extend into the root of the joint.
A. Slag inclusion B. Porosity C. Incomplete Fusion
2. Weld metal melting through base metal hanging underneath weld.
A. Distortion B. Undercut C. Excessive penetration
3. Small cavities or holes resulting from gas pockets in the weld metal.
A. Slag inclusion B. Distortion C. Porosity
4. These are the slag trapped in the weld metal.
A. Overlapping B. war-page C. Slag inclusion
5. The expansion and contraction of a base metal being welded.
A. Incomplete fusion B. weld puddle C. Distortion
Answer Key
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Self-check 1.1-7
1. Incomplete fusion
2. Excessive penetration
3. Porosity
4. Slag inclusion
5. Distortion

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Welding Procedure Specification (WPS)
After reading this INFORMATION SHEEET, YOU MUST be able to:
1. Define the meaning of Welding Procedure Specification.
2. Explain the importance of WPS to the welders
Introduction:
This Information sheet the learners should be able to Identify the different
Welding Procedure Specification.
WPS is a document that describes how welding is to be carried out in

production. They are recommended for all welding operations and many
application codes and standards make them mandatory
What information should they include?
Sufficient details to enable any competent person to apply the information
and produce a weld of acceptable quality. The amount of detail and level of
controls specified on a WPS is dependent on the application and criticality of
the joint to be welded.
For most applications the information required is generally similar to that
recorded on a Procedure Qualification Record (PQR) or Welding Procedure
Approval Record (WPAR), except that ranges are usually permitted on
thicknesses, diameters, welding current, materials, joint types etc.
If a WPS is used in conjunction with approved welding procedures then the
ranges stated should be in accordance with the approval ranges permitted
by the welding procedure.
However careful consideration should be given to the ranges specified to
ensure they are achievable, as the ranges given by welding procedure
standards do not always represent good welding practice. For example
welding positions permitted by the welding procedure standard may not be
achievable or practical for certain welding processes or consumables.
A Welding Procedure Specification (WPS) is a formal written document
describing welding procedures, which provides direction to the welder or
welding operators for making sound and quality production welds as per the
code requirements. The purpose of the document is to guide welders to the
accepted procedures so that repeatable and trusted welding techniques are
used. A WPS is developed for each material alloy and for each welding type
used. Specific codes and/or engineering societies are often the driving force
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behind the development of a company's WPS. A WPS is supported by a
Procedure Qualification Record (PQR or WPQR). A PQR is a record of a test
weld performed and tested (more rigorously) to ensure that the procedure
will produce a good weld. Individual welders are certified with a qualification
test documented in a Welder Qualification Test Record (WQTR) that shows
they have the understanding and demonstrated ability to work within the
specified WPS.

code requirements. The purpose of the document is to guide welders to the
specified WPS.

code requirements . The purpose of the document is to guide welders to the
specified WPS.
Self-check 1.1-8

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Write your answer on your answer sheet
1.What is the meaning of WPS?

2. Explain the purpose of WPS?

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Answer key
Self-check 1.1-8
1. WPS – Welding Procedure Specification
2. WPS is a formal written document describing welding procedure which

provides direction to the welder.

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Safety Welding Practices

1. Identify hazardous area
2. Explain and apply safety welding practices
3. Identify the proper use of Personal Protective Equipment
Introduction:
This Information sheet covers the important uses of Personal Protective
Equipment (PPEs)
WELDING SAFETY -Have you ever heard the saying “some people are
accident prone”? The important is that’s accidents just seem to follow some
individuals no matter what they do. They just seem plagued with bad luck.
Actually, there is no such thing as being accident-prone. People have
accidents simply because they are careless, or indifferent to safety
regulations.
Each year thousands of people suffer the pain of injury because they failed
to use good judgment in many ways, safety can be considered a habit a kind
of behavior. A habit is acquired; you are not born with it. It is result of
reception-doing something over and over again until is becomes part of you.
Finally safety is not something you read about or practice only on occasion.
It has to be observed constantly. Industry places a high premium on safety-
asks anyone in industry and they will tell you that a tremendous amount of
time and effort is given to safety. So never take a chance, you will enjoy work
more if you learn to become a safe worker.
IDENTIFY HAZARDOUS AREA

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WARNING:
The outcome of childish tricks and pranks are often impossible to protect.
Therefore, practical jokes and general horseplay are no accepted behavior
for the workplace.
All work places have their own special hazards and it’s the employers
responsibility to provide and maintain a safe working environment.
However, when you enter the work area, you accept certain responsibilities.
These require you to familiarize yourself with the special safety
considerations which may apply and to observe all the agreed working
practices for your work area.
NOTE:
If you are unsure about the safety rules and working practices for your
work area, ask your supervisor.
In general, you share the responsibility for keeping the workplace clean and
tidy, which normally prevents most safety hazards from becoming a
problem. This is often termed Good Housekeeping.
GOOD HOUSEKEEPING
The following is a brief list of the common practices which lead to good
housekeeping:
 Keep your passageways, walkways, aisles and exits clear.
 Keep your work area clear and tidy and do not allow discarded or
waste material to accumulate.
 Dispose of waste materials and chemicals in the correct manner.
 Remove spillages of oils, greases, paints or other fluids promptly.
 Report any hazardous incidents to your supervisor immediately.
HAZARDS IN THE WORKPLACE

There are three primary types of hazard which all workshops can be
expected to be include:
 Fire
 Chemicals and dangerous materials
 Electricity

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WARNING:
Before attempting to tackle any fire, be certain that you are not placing yourself or
your workmates at risk. Taking unnecessary risk to try to put out is foolish and
pointless.
ELECTRICITY
If you have any reason to the doubt the safety or serviceability or any
electrical equipment or power leads, report it to your supervisor
immediately. Do not use or allow anyone else to use the equipment
until otherwise instructed by someone competent to make that
decision.
WELDING SAFETY CHECKLIST
HAZARD Severity Factors Precaution Summary
Electric Wetness Insulate welder from work piece and

shock can Welder in or ground using dry insulation. Rubber mat
kill work piece dry wood
Confined Wear dry, hole-free gloves. (Changes as
space necessary to keep dry.)
Electric Do not touch electricity
holder and “hot” parts or electrode with bare skin or
cable wet clothing
insulation If wet area and welder cannot be insulated
from work piece with dry insulation, use a
semiautomatic, constant voltage welder
with voltage reducing device.
Keep electrode holder and cable insulation
in good condition. Do not use if insulation

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Fumes Confined area Use ventilation or exhaust to keep air
and Positioning of breathing zone clear, comfortable
gasses welder’s head Use helmet and positioning of head to
can be Lack of minimize fume in breathing zone
dangerous general Read warnings on electrode container and
ventilation material safety data sheet for electrode
Electrode Provide additional ventilation/exhaust
types, where special ventilation requirements
manganese, exist
chromic etc. Use special care when welding in a
Base metals confined area
coating, Do not weld unless ventilation is adequate.
galvanize
paint
Welding Containers Do not weld on containers which have held

sparks which have combustible materials. Check before
can cause held welding
fire or combustibles Remove flammable materials from welding
explosion Flammable area or shield from sparks, heat.
materials Keep a fire watch in the area during and
after welding
Keep a fire extinguisher in the welding area
Wear fire retardant clothing and hot use
earplugs when welding overhead
Arc rays Process: gas Select a filter lens which is comfortable for
can burn shielded arc you while welding
eyes and are most Always use helmet/ head shield when
skin severe welding
Provide non flammable shielding to protect
others
Wear clothing which protects skin while
welding

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Confined Metal Carefully evaluate adequacy of ventilation
space enclosure especially where electrode requires special
Wetness ventilation or where gas may displace
Restricted breathing air.
entry If basic electric shock precaution cannot be
Heaver than followed to insulate welder from work and
air gas electrode, use semiautomatic, constant-
Welder inside voltage equipment with cold electrode or
or on work stick welder with voltage reducing device
piece Provide welder helper and method of
welder retrieval from outside enclosure
General Cluttered Keep cables, materials, tools neatly

work area area organized.
Indirect work Connect work cable as close as possible to
(welding area where welding is being performed. Do
ground not allow alternate circuits through
connection) scaffold cables, hoist chains, ground leads
Electrical Use only double insulated or properly
equipment grounded equipment
Engine- -always disconnect power to equipment before
driven servicing
equipment
Gas cylinders Use in only open, well ventilated areas
-Keep enclosure complete and guards in
place
-Refuel with engine
Never touch cylinder with the electrode
-Never lift machine with cylinder attached
-Keep cylinder
SAFETY IN ARC WELDING - Arc welding includes shielded metal-arc, gas

shielded arc resistance welding. Only be indicated for these areas because
arc welding equipment varies considerably in size and type. Equipment may
range from small portable shielded metal-arc welder to highly mechanized
production spot or gas-shielded arc welders. In each instance specific
manufacturers recommendations should follows.

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Install welding equipment according to provisions of the National
Electric Code.
1.Be sure a welding machine is equipped with a power disconnect switch is

conveniently located or near the machine so the power can be shut off
quickly.
2. Don’t make repairs to welding equipment unless the power to the
machine is shut OFF. The high voltage used for arc welding machines can
inflict severe and fatal injuries.
3. Don’t use welding machines without proper grounding. Stray current may
develop which can cause severe shock when grounded parts are touched. Do
not ground to pipelines carrying gases or flammable liquids.
4. Don’t use electrode holders with loose cable connections. Keep
connections tight all times. Avoid using electrode holders with defective jaws
or poor insulation.
5. Don’t change the polarity switch when the machine is under a load wait
until the machine idles and the circuit is open. Otherwise the contact
surface
6. Don’t operate the range switch under load. The range switch which
provides the current setting should be operated only while the machine is
idling and the current is open. Switching the current while the machine is
under a load will cause an arc from between the contact surfaces.
7. Don’t overload welding cables or operate a machine with poor
connections. Operating with currents beyond the rated cable capacity
causes overheating. Poor connections may cause the cable to arc when it
touches metal grounded in the welding circuit.
8. Don’t weld in damp areas and keep hands and clothing dry at all times.
Dampness on the body may cause an electric shock. Never stand lie in
puddles of water, on damp ground. Or against grounded metal when welding
without suitable insulation. Use a dry board or rubber may to stand on.
9. Don’t strike an arc if someone without proper eye protection is nearby.
Arc rays are harmful to the eyes and skin. If other persons must work
nearby. The welding area should be partitioned off with a fire-retardant
canvass curtain protect them from the arc welding flash.
10. Never pick up pieces of metal which have just been welded or heated.
11. Always wear protective eye goggles when chipping or grinding. A small
particle of slag or metal may cause a sever eye injury.
12. Don’t weld on hollow (cored) casting unless they have been properly
vented, otherwise an explosion may occur.
13. Be sure press-type welding machine are effectively guarded.

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14. Be sure suitable spark shields are used around equipment in flash
welding.
15.When welding is completed. Turn OFF the machine-pulls the power
disconnected switch hang the electrode holder in its designated place.
CAUSES OF ACCIDENTS
An accident often has more than one cause. Accidents can be prevented by
removing their causes. Finding out what caused an accident is important. It
can help in planning how to prevent similar accidents.
There are two causes of accidents:
 UNSAFE ACTS
 UNSAFE CONDITIONS
The person who gets hurt does not always cause the accidents. However,
accidentally are caused by some person falling to act safely, or to correct an
unsafe condition.
 Using equipment without having received proper training in it is
use.
 Using tools or equipment the wrong way.
 Not using the personal protective equipment, such as goggles,
when the job requires it.
 Fooling and playing about.
 Hurrying and taking dangerous short cuts through the
workshops or on the job.
 Distracting others from their work, or allowing yourself to be
distracted.
Consider these examples of unsafe conditions for the worker.

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BAD PRACTICE
No face protection 1.Hazardsarc eye, burn

No arm protection 2.Burn
Exposed cloth 3.Fire
Exposed solvent 4.Fire/explosion, toxic vapor
Bystander exposed to arc 5.Arc eye
Fire exit obstructed 6.Fire, burns
Fire bucket unsuitable for 7.Electric shock
Electrical fires should
Contain sand
Fume extraction not effective 8.Fume
No work earth (if required) 9.Electric shock
Cable damaged 10. Tray arc, burns, electric shock
BODY PROTECTION - In any welding or cutting operation sparks,

dangerous ultraviolet and infrared rays are generated. Consequently,
suitable clothing and proper eye protection are necessary. Sparks may lead
to serious burns and rays are extremely dangerous to the eyes. More specific
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instructions concerning correct apparel and eye shield will be found in other
sections dealing with various phases of welding and cutting. At the moment
it is sufficient to point out that a welder must be aware of possible body
dangers during any welding or cutting operation and learn the safe practices
for his or her personal welfare.
USE PERSONAL PROTECTIVE EQUIPMENT
Goggles - To protect from slag, sparks and intense light.
Welding mask / head shield -To prevent flying object to your face and hair
like flux or spatter. Safety glasses or some other approve from eye.
Protection should be worn when welding or cutting.
Respirator -A respirator is a device which is fitted over the face to remove

contaminants from the air being breathe.
Two types of respirator:

Fume/Vapor prevention – where the respirator can effectively remove
traces of chemicals from the air passing through it. These respirators

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includes special filters which are able to react chemically with as it
passes through them.
Dust/Mist prevention – where respirator is capable of removing only
fine particles from the air. These respirators cannot provide effective
protection from chemical fumes and vapors.
Leather Apron – To protect against heat, fire and burns.
Leather jacket – To protect hot objects.
Over all suits – To protect body from arc, hot falling materials or heavy dirty
works during welding.
Safety shoes - To protect feet from hot objects, flux or spatter.

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Welding gloves – To prevent hot objects, slag or spatters from coming
contact with the skin.
Ear plug -Use to protect our ear from noise area.
Self-check 1.1-9
MULTIPLE CHOICE:
Instruction: Choose the letter of the correct answer on your answer sheet.

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1. To protect your ear from too much noise.
A. Respirator B. Ear plugs C. Over all suit D. gloves
2. A device which is fitted over the face to remove contaminants from the
air being breath.
A. Head shield B. Ear plug C. respirator D. all of the
above
3. To prevent eye injury due to splashing or air born chemicals and

materials.
A. Leather Apron B. Safety shoes C. Goggles D. All of the Above
Answer key
Self-check 1.1-9

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1. Ear plugs
2. Respirator
3. Goggles
Welding Technique & Procedure

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1. Identify the Welding Process and Welding Principles
2. Differentiate the different welding techniques
Introduction:
This Information Sheet , you should be able to identify the different
Welding techniques.
SHIELDED METAL ARC WELDING PROCESS
Travel direction
To begin the SMAW Process, you must first strike an arc.

This can be done using one of the following techniques:
STRIKING AN ARC
SCRATCH START - Scratch the electrode on the base metal like a match.

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1Electrode
2.Workpiece
3.Arc
Drag electrode across work piece like striking a match, immediately lift
electrode slightly after touching work. If arc goes out, electrode was lifted too
high. If electrode sticks to the work piece, use a quick twist to free it.
TAP START TECHNIQUE - Tap the rod against the base metal
1.Electrode
2.Workpiece
3 .Arc
Bring electrode straight down to work piece; then lift slightly to start arc. If
arc goes out, electrode was lifted too high. If ele Refer/ Compare your
answer to answer key. electrode sticks to work piece, use a quick twist to
free it.
RESTARTING A BEAD
Here is the proper technique for restarting a weld:

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1. Strike Arc Here
2. Move Electrode to Crown of Crater
3. Resume Forward Travel
FILLING THE CRATER
Stay on the leading edge of the puddle
At the end of the weld, the operator breaks the arc which creates a ‘crater’
Use a short pause or slight back step at the end of the weld to fill the crater
Large craters can cause weld cracking.

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ELECTRODE MOVEMENT DURING WELDING
A single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove
weld joints or bridging across gaps, a weave bead or multiple stringer beads
work better.
1. Stringer Bead − Steady Movement along Seam
2. Weave Bead − Side To Side Movement along Seam
3. Weave Patterns
Use weave patterns to cover a wide area in one pass of the electrode. Limit
weave width to a maximum of 2-1/2 times diameter of electrode
WELD BEAD
A weld resulting from pass
Weave bead stringer bead
TECHNIQUES
STRINGER: (drag) (whip)

WEAVE:
Circles Crescent ZigZag Box Weave Double J

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PROGRESSION (VERTICAL)
UP
-Deeper penetration
-Higher deposit rate
-Use 90 degree travel angle or slightly up
DOWN
-Faster (point to point)
-Less penetration for thin metal
-Less dilution
-Use steep drag angle
Positioning Electrode Holder
After learning to start and hold an arc, practice running beads of weld metal
on flat plates using a full electrode.
Hold the electrode nearly perpendicular to the work, although tilting it

ahead (in the direction of travel) will be helpful.
To produce the best results, hold a short arc, travel at a uniform speed, and
feed the electrode downward at a constant rate as it melts.
Fillet Welds

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Groove Welds
SHIELDED METAL ARC WELDING (SMAW) PROCEDURE
1. Stick Welding Power Source − Constant Current (CC), AC Or DC

2. Insulated Electrode Holder
3.Workpiece
4 .Work Clamp

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Typical Stick Welding Set - up
Welding current starts as soon as electrode touches the work piece.

Weld current can damage electronic parts in vehicles. Disconnect both
battery cables before welding on a vehicle. Place work
clamp as close to the weld as possible.
Always wear appropriate personal protective clothing.
1. Work-piece
Make sure work piece is clean before welding.
2. Work clamp
Place as close to the weld as possible.
3. Electrode
Before striking an arc, insert an electrode in the electrode holder. A
small diameter electrode requires less current than a large one. Follow
recommendations of the electrode manufacturer when setting weld
amperage.
4. Insulated electrode holder
5. Electrode holder position
6. Arc length
Arc length is the distance from the electrode to the work piece. A short
arc with correct amperage will give a sharp, crackling sound.
7. Slag
Use a chipping hammer and wire brush to remove slag. Remove slag
and check weld bead before making weld pass.
Tools Needed

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ELECTRODE SELECTION CHART
Self-check 1.1-10

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Answer the following questions on your answer sheet:
1. Explain how to do scratch start technique.
2. Explain the proper technique for restarting a weld.
3. What are the weaving techniques?
Answer key
Self-check 1.1-10

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1. Drag the electrode across work piece like striking a match,
immediately lift electrode slightly after touching work.
2. The proper technique for staring and re starting a bed is first strike
an arc then move the electrode to the crown of crater then resumes
your travel forward.
3. The weaving techniques are : Circle; crescent; zigzag ; box weave;

and double J Refer/ Compare your answer to answer key.
TASK SHEET 1.1-10

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Title: Perform Welding Technique
Performance Objective: Given the necessary tools, materials and
equipment you should be able to Perform Welding Technique in accordance
with approved WPS standard in 1 hour.
Supplies/Materials : Information Sheet 1.1-10
1/8”, Mild steel plates
Welding Rod
Tools :
Chipping hammer
Ball-peen hammer
Pliers
Steel brush
Grinder angle
Spanner
Equipment: SMAW welding machine, Personal Protective Equipment,

portable grinder
Steps/Procedure:
1. Prepare the equipment and materials.
2. Perform the following techniques:
STRIKING AN ARC
A. SCRATCH START - Scratch the electrode on the base metal like a

match.

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1Electrode
2.Workpiece
3.Arc
B. TAP START TECHNIQUE - Tap the rod against the base metal
1.Electrode
2.Workpiece
3 .Arc
Bring electrode straight down to work piece; then lift slightly to start arc. If
arc goes out, electrode was lifted too high. If ele Refer/ Compare your
answer to answer key. electrode sticks to work piece, use a quick twist to
free it
C. RESTARTING A BEAD

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Here is the proper technique for restarting a weld:
1. Strike Arc Here

2. Move Electrode to Crown of Crater
3. Resume Forward Travel
D. FILLING THE CRATER
Stay on the leading edge of the puddle
At the end of the weld, the operator breaks the arc which creates a ‘crater’
Use a short pause or slight back step at the end of the weld to fill the crater
Large craters can cause weld cracking.

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ELECTRODE MOVEMENT DURING WELDING
A single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove
weld joints or bridging across gaps, a weave bead or multiple stringer beads
work better.
1. Stringer Bead − Steady Movement along Seam
2. Weave Bead − Side To Side Movement along Seam
3. Weave Patterns
E. Stringer Bead − Steady Movement along Seam

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stringer bead
Weave bead
Assessment Method:
Demonstration with Performance criteria checklist
Performance Criteria Checklist 1.1-10
CRITERIA
YES NO
Did you….?

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1. Prepare the materials and equipment
2. Wear appropriate PPE
3. Observe safety procedures at all times
4. Perform Scratch start technique
5. Perform Tap start technique
6. Perform Re-Starting a Bead Weld technique
7. Perform Filling the Crater use back-step technique
8. Perform Weld Bead (stringer bead and weave bead)
technique
9. Perform the task on time

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Procedures in Welding Steel Plates in Flat Position (1G)
After reading this INFORMATION SHEEET, YOU MUST be able to identify

the best technique in welding steel plates in flat position (1G)
Introduction:
This Information Sheet will guide you on what technique is best
applied in welding steel plates in flat position (1G).
Flat Position Welding

This type of welding is performed from the upper side of the joint. The face of
the weld is approximately horizontal. Flat welding is the preferred term;
however, the same position is sometimes called down hand.
Note: The axis of a weld is a line through the length of the weld,
perpendicular to the cross section at its center of gravity.
Flat Position Welding Procedures
In order to make satisfactory bead welds on a
plate surface, the flare motion, tip angle, and position of the welding
flame above the molten puddle should be carefully maintained. The
welding torch should be adjusted to give the proper type of flame for
the particular metal being welded.
Narrow bead welds are made
by raising and lowering the welding flare with a slight circular motion
while progressing forward. The tip should form an angle of
approximately 45 degrees with the plate surface. The flame will be
pointed in the welding direction.
CBLM on Shielded Date Developed: Document No. NTTA-TM1-01

Metal Arc Welding NC
II Date Revised: Issued by:
NTTA Page 8 of 53
plates using SMAW Romeo E. Carmona Jr
Revision #
Flat Position Narrow Bead Weld
To increase the depth of fusion, either increase the angle between the tip
and the plate surface, or decrease the welding speed. The size of the
puddle should not be too large because this will cause the flame to burn
through the plate. A properly made bead weld, without filler rod, will
be slightly below the upper surface of the plate. A bead weld with
filler rod shows a buildup on the surface..A small puddle
should be formed on the surface when making a bead weld with a welding
rod. The welding rod is inserted into the puddle and the
base plate and rod are melted together. The torch should be moved
slightly from side to side to obtain good fusion. The size of the bead
can be controlled by varying the speed of welding and the amount of

NTTA Page 9 of 53
Revision #
metal deposited from the welding rod.
Tack welds should be used to keep the plates aligned. The lighter
sheets should be spaced to allow for weld metal contraction and thus
prevent war-page.
The following guide should be used for selecting the number of passes (fig.
11-8) in butt welding steel plates:
Plate thickness, in number of passes
1/8 to 1/4 - 1
1/4 to 5/8 - 2
5/8 to 7/8 - 3
7/8 to 1-1/8 - 4
The position of the welding rod and torch tip in making a flat position
butt joint is shown in figure 11-13. The motion of the flame should be
controlled so as to melt the side walls of the plates and enough of the
welding rod to produce a puddle of the desired size. By oscillating the
torch tip, a molten puddle of a given size can be carried along the
joint. This will ensure both complete penetration and sufficient filler
metal to provide some reinforcement at the weld.
Care should be taken not to overheat the molten puddle. This will result in
burning the metal, porosity, and low strength in the completed weld.

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Revision #
JOB SHEET 1.1-11
Title: Weld V groove butt joint carbon steel plates in flat position 1G
Performance Objective: Given the necessary materials tools and

equipment, you should be able to weld on carbon steel plates in flat
position (1G) following the WPS in 3 hours.
Tools and Materials Needed:
Chipping hammer and wire brush

Portable grinder with grinding stone/disk
Two pieces metal 1/8 to ¼-1 carbon steel plates
Electrode as specified
Gap wire as specified (root opening may vary)
Straightedge or piece of angle iron
Pliers
Personal protective equipment as specified in welding standard
Equipment:
SMAW Welding Machine
STEPS/PROCEDURES
1. Check work area to make sure it is free of flammable materials

and well ventilated and note the location of the nearest fire
extinguisher.
Fig.1 pictorial appearance of practical work area
Note: Wear Personal Protective Equipment before entering the practical

work area.
NTTA Page 11 of 53
Revision #
2. Adjust welding machine for correct amperage settings.
3. Prepare metal for welding
3.1 Bevel one long side of each plate by grinding 1/8 root face
3.2 Remove all burrs if flame cut.
4. Place metal together parallel to each other leaving a root gap from 1/8
4.1 Hold plates together highly, separated by one end spacer wire.
4.2 Remove spacer wire immediately after deposit tack.
5. Start weld puddle using E6011, and then melt out keyhole as large as
Electrode diameter.
6. Use slight whipping motion: one electrode diameter in direction of
travel, then one-half an electrode diameter back to puddle. Do not
increase arc length when moving the electrode to and from puddle.
Note: Travel from right to left (if left handed travel from left to right).
7. Move electrode back and forth to preheat weld zone, push electrode
crater to fill bead on root side then continue welding.
8. Chip off slag and clean the bead thoroughly.
9. Weld second bead as hot pass using E7018/E6013. Weld on top of the
first bead. Work angle 90 travel angle 5°-10° using “W” movement and
pause at dots to fill in undercut.
Chip off slag and clean thoroughly.
10. Weld third bead as filler pass using E7018/E6013, using the same
welding techniques as used for the second bead.
11. Chip off slag and clean thoroughly.
12. Weld cap using E7018/E6013. Use the same welding techniques as
used from second bead and third bead.
M. Always clean the bead thoroughly every pass.
N .Cool plates in still air slowly.
(caution: do not cool in water
13. Have your trainer inspect for weld defects.

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Revision #
PERFORMANCE CRITERIA CHECKLIST 1.1-11
CRITERIA
YES NO
Did you….?
1. Prepare work area
2. Prepare tools, equipment and materials
3. Wear appropriate PPE
4. Observe safety procedure at all times
5. Perform task in accordance with company or
industry requirements and safety procedure.
6. Perform root pass in accordance with WPS and/or
client specifications
7. Check defects and repaired as required
8. Check weld visually applicable codes and
standards
9. Clean root pass and free from defects and
discontinuities
10. Weld subsequently/filling passes is
performed in accordance with approved WPS
11. Perform capping in accordance with
approved WPS and/or client specifications
12. Clean work area
13. Dispose generated waste properly
14. Perform job within the specified time
BIBLIOGRAPHY
NTTA Page 13 of 53
Revision #
WEBSITE REFERENCES
www.youtube.com/watch?v=I1P5GuVHFQA
www.weldingschool.com/blog/welding/an-introduction-to-smaw-shielded-metal-arc-welding
www.youtube.com/watch?v=I1P5GuVHFQA
weldguru.com/welding-history
https://www.youtube.com/

NTTA Page 14 of 53
Revision #

CBLM For SMAW Dondon

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Competency-Based Learning Material

Sector : METALS AND ENGINEERING

Qualification Title : SHIELDED METAL ARC WELDING (SMAW) NC II

Unit of Competency: Weld Carbon Steel Plates Using SMAW

Module Title : Welding Steel Plates using SMAW

JAGUPIT NATIONAL HIGH SCHOOL

In the development of this CBLM, I would like to express my sincere

I would like to show my sincere gratitude also and appreciation to

Special thanks to my lovely son Romeo E. Carmona-I for their

Date Developed: Document No.

Date Developed: Document No.

UNIT OF COMPETENCY: Weld Carbon Steel Plates Using SMAW

Module Title: Welding Carbon Teel Plates Using SMAW

MODULE DESCRIPTOR: This module covers the skills, knowledge and

At the end of this module you will be able to:

1. Weld V groove butt joint carbon steel plates in flat position 1G

Date Developed: Document No.

Weld V groove butt joint carbon steel plates in flat position 1G

1. Root pass in carbon steel plate in flat position (1G) is performed in

Date Developed: Document No.

Date Developed: Document No.

Date Developed: Document No.

Learning Activities Special Instruction

Date Developed: Document No.

Answer self check No. 1.1-7

Date Developed: Document No.

Date Developed: Document No.

WELDING TERMS AND DEFINITIONS

Acetylene- a highly combustible gas composed of carbon and hydrogen.

Date Developed: Document No.

Date Developed: Document No.

Date Developed: Document No.

Date Developed: Document No.

CBLM on Shielded Date Developed: Document No.

Date Developed: Document No.

Date Developed: Document No.

Date Developed: Document No.

Date Developed: Document No.

Date Developed: Document No.

Date Developed: Document No.

Date Developed: Document No.

Date Developed: Document No.

Date Developed: Document No.

1. A welding process or method in which pressure id used to complete the

Date Developed: Document No.

Date Developed: Document No.

THE ESSENTIALS OF ARC WELDING

Terms and Definition:

Date Developed: Document No.

Date Developed: Document No.

Note: Welding leads must connect to correct terminals if machine has

2. CORRECT ELECTRODE DIAMETER

The choice of an electrode involves such items as position of the weld,

Date Developed: Document No.

SELECTING CORRECT ELECTRODE

PROPERTIES OF BASE METAL

JOINT DESIGN AND FIT-UP

Date Developed: Document No.

Core Rod (Metal Filler)

In this classification, each types of electrodes has been assign specific

AWS DESIGNATION FOR MANUAL ELECTRODE

Such as power type DC