Republic of the Philippines

Department of Education
National Capital Region
Division of City Schools – Manila

TECHNOLOGY AND LIVELIHOOD EDUCATION

Shielded Metal Arc Welding

Grade 10

Welding Techniques and Procedures

QUARTER 1
Week 6-7
Module 6
(NOT FOR SALE)

1
 Welding Techniques and Procedures
LESSON 1 – WELD CARBON STEEL PLATES IN FLAT POSITION (1F)

LESSON 2 - WELD CARBON STEEL PLATES IN HORIZONTAL POSITION (2F)

EXPECTATION:

1. Perform stringer or layered beads in accordance with welding standards.

2. Observe uniformity of bead ripples in accordance with welding standards.
3. Observe weld capping/ final pass not exceeding allowable tolerances
specified by welding codes/ standards.
4. Conducts visual inspection on the finished weldment in accordance with
welding standards.
5. Use appropriate Personal Protective Equipment (PPE).
6. Perform proper housekeeping (5S).

PRE-TEST:

I. Multiple Choices: Write in your paper the letter of your choice.

1. The function of an electrode holder is to hold the

a. welding tools
b. base metal
c. welding rod
d. welding positioner

2. The recommended current settings for electrodes may vary in range

depending on the

a. welders
b. consumers
c. manufactures
d. shop management

3
3. In scratching method the electrode is brought down to the stock at an
approximate angle of

a. 15 to 20 degrees
b. 10 to 15 degrees
c. 5 to 10 degrees
d. 12 to 15 degrees

4. In tapping method the electrode is brought down to the stock at an approximate

angle of

a. 90 degrees
b. 80 degrees
c. 75 degrees
d. 70 degrees

5. An electrode is considered ideal if it meets the criteria:

a. It gives minimum weld strength

b. It has slow deposition
c. It gives bad arc stability.
d. It produces minimum spatter

6. Which of the following tools used to remove slag in welding.

a. cold chisel
b. ball peen hammer
c. file
d. chipping hammer

7. An ideal electrode holder is one that is

a. insulated
b. expensive
c. handy
d. economical

4
 8. A head shield has the advantage over a hand shield because

a. it is handy to put on and remove

b. it could be swung to any direction
c. it is designed for the head
d. it could be swung upward

9. The process of joining two or more metals together by means of heat and
sometimes pressure?

a. riveting
b. forging
c. welding
d. soldering

10. In electric arc welding, the material used as filler is called

a. solder
b. electrode
c. lead
d. silver

LOOKING BACK AT YOUR LESSON

II. Multiple Choices: Write in your paper the letter of your choice.

a. The 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.

a. Welding Procedure Specification

b. American Standards for Mechanical Engineer
c. American Welding Society
d. All of the above

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2. Weld handheld fillet gauge measures:

a. flatness of the weld

b. convexity (how the weld is welded outward)
c. concavity (how the weld is rounded inward)
d. All of the above

3. A record of a test weld performed and tested (more rigorously) to ensure

that the procedure will produce a good weld.

a. Procedure Qualification Record

b. Welder Qualification Test Record
c. Individual Qualification Test Record.
d. All of the above

4. Techniques used in science and technology industry to evaluate the

properties of the material, component or system without causing damage?

a. non-destructive test
b. impact test
c. destructive test
d. hardness test

5. 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.

a. Procedure Qualification Record

b. Welder Qualification Test Record
c. Individual Qualification Test Record.
d. All of the above

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BRIEF INTRODUCTION

Working with metal is both exciting and empowering. As the sparks fly and the
heat turns up, welders are able to transform some of the world’s strongest materials into
the shapes and products they envision. This skill requires work and practice to acquire,
and its best learned with the assistance and guidance of industry professionals.
Learning the ropes of a new trade can be time consuming. You need to become familiar
with the entire working process from start to finish and master each level before moving
on. This attention to detail is what makes a great welder and a more versatile potential
employee.

Shielded Metal Arc Welding (SMAW) operation requires a setup and then weld:

In general, the operator factor, or the percentage of the operator’s time spent laying
weld, is approximately 25%. The rest is spent in preparation and in removing slag.

The actual welding technique utilized depends on the electrode, the composition of the
work piece, and the position of the joint being welded.

The choice of electrode and welding position also determines the welding speed.

Flat welds require the least operator skill and can be done with electrodes that melt
quickly but solidify slowly. This permits higher welding speeds.

Sloped, vertical or upside-down welding requires more operator skill and often
necessitates the use of an electrode that solidifies quickly to prevent the molten metal
from flowing out of the weld pool.

However, this generally means that the electrode melts less quickly, thus increasing the
time required to lay the weld.

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SMAW Operation Set-Up:

Before starting make sure that you are using a good helmet for SMAW welding as well
as protective clothing.

1. Clean the work piece

2. Clamp the work close to the weld
3. Insert the electrode into the insulated holder. Set amperage at levels
recommended by the electrode manufacturer.
4. Determine the best arc length. As a guideline the arc for a 1/16″ to 3/32″
diameter electrode is 1/16″ (1.6mm). The arc length for a 1/8″ and 5/32″
electrode is 1/8″ (3mm).
5. Have a chipping hammer available to remove any slag and before doing a 2nd
pass with the weld.

Stick Welding Examples

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Poor weld bead characteristics include large spatter deposits, use of the wrong arc,
higher/lower amperage levels than recommended and poor penetration.

Operation
Starting the Arc
Scratch Start Technique:

To strike the electric arc when starting a SMAW operation, the electrode is brought into
contact with the work piece, dragged like lighting a match, and then pulled away slightly.
If the arc lights and then goes out, that means the electrode was pulled too far away
from the base metal. If the electrode sticks to the metal, give a twist and it should come
free.

Tapping Technique:

Move the electrode straight down to the base metal. Then lift slightly. The arc should
start. If the arc goes out, that means it was lifted too high off the work piece.

Operating the Electrode Holder

This initiates the melting of the work piece and the consumable electrode and causes
droplets of the electrode to be passed from the electrode to the weld pool.

As the electrode melts, the flux covering disintegrates, giving off a vapor that protects
the weld area from oxygen and other atmospheric gases.

In addition, the flux provides molten slag which covers the filler metal as it is travels
from the electrode to the weld pool.

Once part of the weld pool, the slag floats to the surface and protects the weld from
contamination as it solidifies.

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Groove (Butt) Joint Welding
Tack Welds

Tack Weld

Tack welds the two pieces of metal to hold them in place. This will reduce joint
distortion, which is caused by the expansion and contraction of metal as it is heated and
cooled.

Double V-Groove, Single V-Groove & Square Groove Welds:

When performing a groove weld, hold the electrode perpendicular to the weld. Lean the
electrode in the direction of the weld.

A single string bead is all that is needed for a narrow groove weld joint. For wider
groove weld, then a weave bead or many stringer beads is a better option.

Square Groove Weld

Square Groove Weld

If thickness of materials are 3/16″ (5MM) they can usually be welded with a square
groove weld and no prep.

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Single and Double V-Groove Welds

Single and
Double V-Groove Welds

V-Groove

For SMAW operation welds that require thicker metals it may require that edges are
prepared (v-groove) of butt joints for good welds.

V-groove is recommended for metal thickness of 3/16″ to 3/4″ (5 to 19mm). It is also

used for any thickness when welding can only be done from one side.

The bevel can be created (at 30 degrees) using a grinder, or plasma or oxyacetylene
cutting equipment. After creating the bevel remove scale.

11
T-Joint Welding
Fillet Weld

The electrode (1) should be kept at a 45

degree angle or less when creating a fillet weld.

For a fillet weld, hold the electrode at a 45 degree angle or less to the weld. Lean the
electrode 10 degrees to 30 degrees in the direction of the weld.

Use a short arc and move at a steady speed. For upright sections weld both sides.

When necessary for strength add a second layer (remove slag before adding another
layer).

Move the electrode using a circular motion.

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Single Layer Fillet Weld

When Applying A Single Layer or

Multi-Layer Welding Pass Move The Electrode In A Circular Motion

When welding a lap joint the electrode should be held at a 30 degree angle or less. Use
one or two weld passes as needed. Before the second pass remove any slag.

Welding Positions:

Each welding position is described below. Note that not every electrode is right for
each position. Check the manufacturer’s directions before proceeding with any SMAW
operation.

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Horizontal
Single Pass Bead Weld

When Doing A Horizontal Weld The Welder Needs To Take Account Of Distortion
Caused By Gravity

The issue with the horizontal welding is the distorting effect gravity will have on
the weld pool. If necessary or if it will help, tack weld a backing strip. Beveled edges
can also be of help.

When welding during the SMAW operation keep the electrode at 90 degrees to the
weld. Lean into the weld direction by 15 degrees.

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Materials Beveled For Horizontal Weld

Multi-Pass Weld Locations

Each Number Indicates the Location of Each Weld

Pass. Note use of a backing plate. Slap must be removed after each weld.

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Vertical Welding Position
Multi-Pass Vertical Weld Diagram

Illustration
of Welding Direction and Location of Each Weld Pass When Completing A Vertical
Weld

The weld direction can move from top to bottom or bottom to top. It is easier to weld in
an upward direction.

Use a tack welded backing plate if needed and for thicker materials bevel the edges.

Hold the electrode at 90 degrees to the material being welding.

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Vertical Tee Joint Welding Diagram

Be Aware of The
Distorting Effect of Gravity. Weld The Joint on Both Sides to Maximize Strength. Use a
Weaving Motion When Traveling Along The Weld With the Electrode.

17
Lap Joint Weld Diagram

Overhead Welding Position

For an overhead weld the arc should be positioned slightly away an doubt from the
crater. Tack welds a backing plate and use beveled edges if necessary.

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Overhead Groove Joint Diagram

Overhead Tee Joint

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Testing the Weld
Weld Strength Test Diagram

Test
Welds Using a Hammer in the Direction Shown Above. Weakness can be Due to
Porosity (holes in the weld), Incorrect Heat or Fast Travel Speed.

Use a hammer to strike the joint on the material welded to the base. The weld should
bend slightly and not break.

Breakage could be due to too many holes (porous) in the weld, or if the weld contains
slag.

Also note if any of the beveled area is visible.

If it is, this could indicate that the filler material was not fully melted due to traveling too
fast with the electrode or by not using enough heat.

Slag Removal:

Once hardened, it must be chipped away to reveal the finished weld.

As welding progresses and the electrode melts, the welder must periodically stop
welding to remove the remaining electrode stub and insert a new electrode into the
electrode holder.

This activity, combined with chipping away the slag, reduce the amount of time that the
welder can spend laying the weld, making SMAW one of the least efficient welding
processes.

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ACTIVITY 1
Direction: Read and answer the given questions. Write your answer on your notebook.

1. What are the two methods before starting an arc?

REMEMBER
Slag Removal:

Once hardened, it must be chipped away to reveal the finished weld.

As welding progresses and the electrode melts, the welder must periodically stop welding
to remove the remaining electrode stub and insert a new electrode into the electrode
holder.

This activity, combined with chipping away the slag, reduce the amount of time that the
welder can spend laying the weld, making SMAW one of the least efficient welding
processes.

CHECK YOUR UNDERSTANDING

DIRECTION. Write in your paper the full word TRUE or FALSE in the statement below.

1. Paint your weld with a suitable rust-preventative primer to protect it from

corrosion.

2. Chip off the slag to remove any foreign material.

3. Adjust your welder's output amperage to suit the material you are welding and
the desired penetration of the arc.

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 4. The arc gap should be no greater than the electrode diameter.

5. Another way to strike an arc is like striking a match.

6. Never strike an electric arc without protecting your eyes.

7. Hold the stinger in your dominant hand by the insulated handle.

8. Some welding machine fans only operate when the machine requires cooling.

9. Select the correct rod and amperage range for the work you are attempting.

10. Rust or paint will interfere with the grounding of your work piece, making it
difficult to create an arc when you begin welding.

1.
POST TEST

Multiple Choices: Write in your paper the letter of your choice.

1. The function of an electrode holder is to hold the

a. welding tools
b. base metal
c. welding rod
d. welding positioner

22
2. The recommended current settings for electrodes may vary in range depending
on the

a. welders
b. consumers
c. manufactures
d. shop management

3. In scratching method the electrode is brought down to the stock at an

approximate angle of

a. 15 to 20 degrees
b. 10 to 15 degrees
c. 5 to 10 degrees
d. 12 to 15 degrees

4. In tapping method the electrode is brought down to the stock at an approximate angle of

a. 90 degrees
b. 80 degrees
c. 75 degrees
d. 70 degrees

5. An electrode is considered ideal if it meets the criteria:

a. It gives minimum weld strength

b. It has slow deposition
c. It gives bad arc stability.
d. It produces minimum spatter

6. Which of the following tools used to remove slag in welding.

a. cold chisel
b. ball peen hammer
c. file
d. chipping hammer

7. An ideal electrode holder is one that is

23
 a. insulated
b. expensive
c. handy
d. economical

8. A head shield has the advantage over a hand shield because

a. it is handy to put on and remove

b. it could be swung to any direction
c. it is designed for the head
d. it could be swung upward

9. The process of joining two or more metals together by means of heat and
sometimes pressure?

a. riveting
b. forging
c. welding
d. soldering

10. In electric arc welding, the material used as filler is called

a. solder
b. electrode
c. lead
d. silver

24