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Senior High School
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Table of Contents
What This Module is About.……………………………….………………………………….….1
Recognition of Prior Learning……………………………………………………………………1
What I Need to Know…………………………………………….……………………………….2
How to Learn from this Module……………………………………………………………….….2
Technical Terms ………………………………………………………….……………......….….3
Icons of this Module……………………………………………………………………………….5
What I Know………………………………………………………………………………………..6
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What This Module is About
Welcome to the Module “LAYING OUT BEADS ON CARBON STEEL PLATES”. This
module contains training materials and activities for you to complete.
The unit of competency “Surface Weld on carbon Steel Plates” contains the
knowledge, skills and attitudes required for Shielded Metal Arc Welding (SMAW) required
to obtain the National Certificate (NC) level I.
You are required to go through a series of learning activities in order to complete each
of the learning outcomes of the module. In each learning outcome there are Information
Sheets, Job Sheets, Operation Sheets and Activity Sheets. Do these activities on your
own and answer the Self-Check at the end of each learning activity?
If you have questions, do not hesitate to ask your teacher for assistance.
If you can demonstrate competence to your teacher in a particular skill, talk to your
teacher so you do not have to undergo the same module again. If you have a qualification or
Certificate of Competency from previous trainings show it to him/her. If the skills you acquired
are consistent with and relevant to this module, they become part of the evidence. You can
present these for RPL. If you are not sure about your competence skills, discuss this with your
teacher.
After completing this module, ask your teacher to assess your competence. Result of
your assessment will be recorded in your competency profile. All the learning activities are
designed for you to complete at your own pace.
In this module, you will find the activities for you to complete and relevant information
sheets for each learning outcome. Each learning outcome may have more than one learning
activity.
This module is prepared to help you achieve the required competency, in receiving
and relaying information. This will be the source of information that will enable you to acquire
the knowledge and skills in Shielded Metal Arc Welding (SMAW) independently at your own
pace with minimum supervision from your teacher.
1
What I Need to Know
This module contains information and suggested learning activities on surface weld on
carbon steel plates. It includes instruction and procedure on how laying out beads on carbon
steel plates.
Completion of this module will help you better understand the succeeding module on
fitting up welds.
This module consists of two (2) learning outcomes. Each learning outcome contains
learning activities supported by instruction sheets. Before you perform the instruction, read the
information sheets and answer the self- check and activities provided. To ascertain your
competence, your teacher will assess what you have acquired when the knowledge necessary
to perform the skill portion of the what particular learning outcome.
Upon completing this module, report to your competence teacher for assessment to
check your achievement of knowledge and skills requirements of this module. If you pass the
assessment, you will be given a certificate of completion.
2
What is It
TECHNICAL TERMS
1. Welding is a method of joining two metals by applying heat to melt and fuse them,
producing a coalescence of materials with or without the use of filler metal.
2. Flux Coated Electrode is a metal rod coated with a special substance called flux,
which determines the nature of the electrode. During welding it is melted to fill up
joints in the base metal.
3. Bare Electrode a filler metal electrode use in arc welding, consisting of a metal wire
with no coating on its surface.
4. Flux is a fusible material or gas used to dissolve and/or prevent the formation of
oxides, nitrides or other undesirable inclusions formed in welding.
8. Stringer Bead/Straight Weld Bead a type of weld bead with appreciable transverse
oscillation or side to side movement.
10. Electrode Angle it is an angle from the electrode which is perpendicular to the base
metal.
11. Arc Length is a normal distance of approximately equal to the diameter of the
electrode.
12. Puddle part of the weld that is melted (molten) due to heat of welding.
13. Pass refers to the layer of beads which has been deposited in the base metal.
14. Ripple is the shape/appearance of the beads which results from the movement of
the electrode.
15. Crater is the flattened portion produced when the electrode comes in contact with the
base metal
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16. Slag refers to the outer covering of the deposited bead when the electrode melts
during the welding process.
17. Blowholes are the cavities produced by gas entrapment during the solidification of
the weld metal.
18. Penetration refers to the depth of fusion of beads with the base metal.
20. Welding Position the stock to be welded may assume any of the main welding
positions, namely, flat, horizontal, overhead and vertical.
21. Spatter in arc and gas welding, it is the metal particles expelled during welding and
which do not form part of the weld.
22. Travel Angle is the angle of the electrode in relation to the axis of weld when the
electrode is perpendicular to the axis of weld.
23. Work Angle is the angle of an electrode in relation to the surface or surfaces of a
work piece when the electrode is perpendicular to the axis of weld.
24. Coalescence the growing together or growth into one body of the materials being
welded.
25. Fusion Welding the melting together of filler metal and base metal, or of base metal
only to produce a weld.
26. Shielded Metal Arc Welding arc welding process that produces a coalescence of
material by heating them with an arc between a covered electrode and work piece.
Shielding is obtained from the composition of the electrode cover; pressure is not use
and filler metal is obtained from the electrode.
4
Icons of this Module
What I Need to This part contains learning objectives that
Know are set for you to learn as you go along the
module.
Answer Key
5
What I Know
Direction: Write the letter of the correct answer in every item. Provide a separate
answer sheet.
1. What is the basis for identifying the recommended arc length to be maintained when
striking an arc?
a. diameter of filler metal c. type of electrode
b. diameter of the flux d. thickness of the base metal
3. What is the recommended travel angle and work angle in striking an arc in flat
position?
a. 65° - 75°, 90° c. 70°, 90°
b. 75° - 85°, 95° d. 60°, 85°
7. What is the prescribe safe lens shade if the electrode size is 1/16 – 5/32 and
amperage is 75-200 amperes?
a. # 8 b. # 10 c. # 12 d. # 14
8. What is the prescribe safe lens shade if the electrode size is 5/16 – 3/8 and
amperage is 400+ amperes?
a. # 8 b. # 10 c. # 12 d. # 14
6
11. The growing together or growth into one body of materials being welded is called.
a. coalescence c. fusion welding
b. spatter d. bead
13. A non-metallic solid material entrapped or formed on top of weld metal or between
the weld metal and base metal is called.
a. Slag b. flux c. bead d. spatter
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LO - 1 Strike an Arc
Assessment Criteria:
1. Weld procedure in striking arc is applied according to weld standard.
2. Methods of striking an arc are applied accordingly.
Learning Experiences/Activities:
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Information Sheet 1.1
What’s New
A welding arc is maintained when the welding current is forced across a gap between the
electrode tip and the base metal. A welder must be able to strike and establish the correct arc
easily and quickly.
What Is It
The scratching method is easier for beginners and when using an AC machine. The
electrode is moved across the plate inclined at an angle, as you would strike a match. As the
electrode scratches the plate an arc is struck. When the arc has formed, withdraw the
electrode momentarily to form an excessively long arc, then return to normal arc length (see
figure 1).
The principal difficulty encountered in striking the arc is "freezing," or when the
electrode sticks or fuses to the work. This is caused by the current melting the electrode
tip and sticking it to the cold base metal before it is withdrawn from contact. The extra high
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current drawn by the "short circuit" will soon overheat an electrode and melt it or the flux,
unless the circuit is broken. Giving the electrode holder a quick snap backward from the
direction of travel will generally free the electrode. If it does not, it will be necessary to open
the circuit by releasing the electrode from the holder.
Warning: Never remove your face shield from your face if the electrode is frozen. Free the
electrode with the shield in front of your eyes, as it will "flash" when it comes loose.
Tip: Brush your work free of dirt and scale before you strike an arc.
https://www.lincolnelectric.com/en-ca/support/welding-how-to/Pages/strike-establish-arc-detail.aspx
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What I Have Learned
Self-Check # 1.1
LO - 1: Strike an Arc
Directions:
Choose the correct answer from the series given for every item. Write the letter only. Use a
separate answer sheet.
4. It is done by touching the electrode to the base metal like scratching a match.
a. Tapping Method
b. Scratching Method
c. All of these
d. None of there
5. It is done by moving the electrode downward until it steps to the base metal then
bringing the electrode up slightly to form an arc.
a. Taping Method
b. Scratching Method
c. All of these
d. None of these
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Information Sheet 1.2
What’s New
The electrode is held by the welder in an electrode holder with an insulated handle. The
holder grips the bare end of the electrode for good current transfer.
The welder strikes and draws an arc which melts the base metal forming a weld pool at
the same time. The tip of the electrode melts and metal droplets are projected into the weld
pool.
The chemicals and minerals in coating, melt and decompose to serve as an alloying
element and to form a protecting gas shield around the arc and weld pool. Furthermore, a slag
is formed to cover the deposited weld.
What Is It
SELECTING ELECTRODE
Objective: The learner will select the type of arc welding electrodes.
Selecting an electrode
• The choice of the right electrode depends on the following factors:
1. Kinds of Base Metal. Electrodes are classified according to the kind of the base metal
for which they are recommended into mild steel low hydrogen, low energy, cast iron,
stainless steel and various non-ferrous electrodes.
2. Types of Welding Equipment. Determine what current is available, as not all electrodes
can be used for both AC or DC current and others are more economical to use with one
type of current than the other. It may also be necessary to check the open circuit voltage
of the welding machine to be used for source electrodes (e.g. basic low hydrogen type) It
requires higher open circuit voltage than other for best performance.
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3. Dimension and Design of Parts. Heavy materials of complicated design require
electrodes of high ductility thin plates require low penetration electrodes with stable arcs
at low current values.
4. Joint Preparation and Set up. Deep penetration electrodes are required when edge is
not levelled and fit-up is tight. Mild penetration, thin- coated electrodes are best when
gaps are open.
5. Welding Position. Some electrodes are preferable to others for off- position welding
8. Cost Limits. The choice of expensive electrodes whose qualities or properties exceed
those normally demanded by the job is economically unwise when less expensive
electrodes, just as suitable quality electrodes and win the risk of the weldment failing in
service or having the job redone at additional cost when dependable brands are in the
market
ELECTRODES
https://www.mechanicwiz.com/welding-rod-chart/
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https://calsignsolutions.com/todo_aws_tungsten_electrode_chart.php
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ELECTRODE CODING
Electrode Classification End Color Spot Color Group Color
E-6010
6011 Blue
6012 White
6013 Brown
6020 Green
7010-Al Blue White
7011-Al Blue Yellow
7016 Blue Orange Green
7018 Black Orange Green
7020-Al Blue Yellow Silver
8015-B1 White Brown Green
8016-B1 White Black Green
9016-B3 Brown Blue Green
10013 Green Brown Silver
10015 Red Red Green
10016 Green Orange Green
12016 Orange Orange Green
Table #2 Electrode Coding
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ELECTRODE CLASSIFICATION
Electrode Capable of producing
Type of coating or
Classification satisfactory weld in Type of Current
covering
Number position
E-45 series-minimum tensile strength of deposited metal in non-stress relived condition
45,000 Psi
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Welding Flux
a. Arc stream is created by holding an electrode approximately 1/8" (3 mm) away from
the base metal.
b. The arc stream creates a molten pool or crater that tends to flow away from the arc
and cools of solidify as it moves
c. Flux from the electrode covering forms a slag on the top of the weld to protect it
from contaminants during cooling.
a. flux covered electrode have a core of metal wire with a baked on chemical covering
b. the wire core melts in the arcs stream and droplets of metal are transferred across
the arc to make the molten puddle and provide the filler metal to fill the gap or
groove between two base metal
c. the flux covering also melts in the arc stream to stabilize the arc to provide a shield
around the arc, to keep it free from atmospheric impurities and to form slag
covering to protect the weld
Welding Lens
Steps in selecting a safe lens shade for shielded metal arc welding:
1. Determine the electrodes size and amperage range because this are used to dictate
the lens protection required.
2. Select lens shade according to the lens manufacturer’s selection chart, but never
select less than a # 8 length shade for shielded metal arc welding.
Note: When you remove your hood after arc welding and you see white spots or white blotches
as after image it means that you are getting much light through the lens and you should switch
to a shade at least at least one number darker, or check the seal on your lens.
A rule of thumb is that the larger the diameter of the electrodes, the higher the number
required for a lens shade.
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https://weldinghelmetpros.com/smaw-stick-welding
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What I Have Learned
Self-Check # 1.2
Directions:
Choose the correct answer from the series given for every item. Write the letter only. Use a
separate answer sheet.
5. The diameter of the electrode to be used in welding operation depends upon the:
a. Thickness of the Base Metal
b. Welding Position
c. Type of Base Metal
d. None of these
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Operation Sheet 1.1
What I Can Do
Performance Objective: The learner will perform the striking of an arc using Tapping and
Scratching.
Conditions or situations for the operations:
1. The distance of an arc must be equal to the diameter of electrode regardless of the
method you used in striking an arc.
2. The materials and equipment must be properly checked.
Supplies/Materials:
1. Video or PowerPoint presentation for: Striking an Arc
2. Electrode E6013, 3.2mm. Diameter
3. Safety gears (Gloves, Safety Helmet, Apron)
4. 10mm x 50mm x 100mm steel plate
5. Chipping hammer
6. Steel brush
Equipment: AC Welding Machine with Accessories
Precautions:
1. Always check the welding machines and its accessories before and after using them
2. See to it that there are no combustible materials near the welding area.
3. Always wear protective gears.
4. Observe safety measures while working.
Quality Criteria:
1. The height of the arc is maintained not more than diameter of electrode. The proper
distance of an arc must be maintained for at least 5-10 seconds
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WELDING PROCEDURE:
1. SCRATCHING
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2. TAPPING
22
What I Have Learned
Directions:
Use the check-list below as basis for judging whether you meet the required competency.
Write YES or NO for your answer in a separate answer sheet.
In performing striking an arc you should be able to hold the arc for 10 seconds. The arc
length should not be bigger than 4mm at angle of approximately 75O.
CRITERIA YES NO
2. Able to strike the end of the electrode on the plate surface similar to
striking a match.
3.Able to withdraw the electrode quickly and draw an arc of approximately
3.
6 mm.
4.Able to reduce the arc length to a distance equal to the diameter of the
electrode.
What’s More
Have learners assess their performance. For criteria needing assistance, provide the
appropriate intervention/s.
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Information Sheet 2.1
What’s New
Bead Formations:
Objectives:
1. Identify the types of weld beads
2. Identify the different types of weaving motion beads.
3.Determine the appropriate electrodes to be used applicable for the specific bead
and weld positions.
Type of beads
a. Stringer Bead- a straight forward bead in which you either drag or push the
electrode across the joint with minimal side to side movement.
b. Weave motion Beads - is a method for electrode manipulation in joining metal
to achieve good weldment.
Fig.# 1.
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Fig. # 2
Crescent
Figure of 8
Circular
1. Circular Motion- often used in flat position weld on butt,tee,and outside corner joints for
build-up surfacing operation.
2. Crescent Weave Motion- A half round bead formation in which formed a side to side semi
circular electrode movement.
3. Figure of eight motion weave –An electrode manipulation pattern where a continuous figure
of number eight is formed.
4. V- Pattern motion weave – a weave pattern commonly used in Hot pass and cap pass by
forming V-motion.
5. Stringer Bead- - a straight forward bead in which you either drag or push the
electrode across the joint with minimal side to side movement.
6. Square Pattern motion Bead – good for flat welds but they can also be used for
vertical position. They can also be used if there is a large gap to be filled.
7. J- pattern weave motion- works well on flat and horizontal positions.
8. T- pattern weave motion – works with fillet weld in vertical and over head position.
.It can also be used for deep grove welds for the hot pass.
9. Zigzag pattern motion weave–used as cover passes in flat and vertical positions.
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What I Have Learned
Self-check 2.1
MATCHING TYPE:
Match column A. with column B. Write the letter of the correct answer on the blank
provided before the number. Use separate answer sheet.
A B
_____1. Crescent motion
a. A straight forward bead with minimal side
_____2. Square Pattern motion
to side motion
_____3. J- Pattern motion
_____4. Circular motion b. Works well on flat and horizontal positions
_____5. Figure of 8 motion
c. Used as a cover passes in flat and vertical
_____6. V- Pattern motion
positions.
_____7. T- pattern motion
_____8. Zigzag motion d. A half round bead in a semi circular
_____9. Stringer bead movement.
e. A continuous movement using number
eight pattern
f. Commonly used in hot pass formed by V-
motion
g. Works with fillet weld in vertical position
with letter T- formation.
h. Often used in flat position weld on butt ,Tee
and outside corner joints for build –up.
i. Good for most flat weld but it can also be
used for vertical position weld.
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LO - 2 Deposit Straight Bead
Assessment Criteria:
1. Uniformity of bead ripples is checked in accordance with welding standard.
2. Stringer or Straight beads are deposited in accordance with welding standards.
3. Finish weldment is performed based on acceptable standards for:
• Spatter
• Slag
• Uniformity of beads
LEARNING EXPERIENCES/ACTIVITIES
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Information Sheet 2.2
What’s New
Objective:
What is it
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Operation Sheet 2.2
What I can do
Performance Objective: To weld stringer bead flat position. The bead should be straight,
of even height and width and with fine ripples.
Supplies/Materials:
1. Video or PowerPoint presentation for: Striking an Arc
2. Electrode E6013, 3.2mm. Diameter
3. Safety gears (Gloves, Safety Helmet, Apron)
4. Mild steel plate, 6mm x 75mm x 150mm (1 pc)
5. Chipping hammer
6. Steel brush
Equipment: AC Welding Machine with Accessories
Precautions:
1. Always check the welding machines and its accessories before and after using them
2. See to it that there are no combustible materials near the welding area.
3. Always wear protective gears.
4. Observe safety measures while working.
Plan/ Illustration:
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PROCEDURE:
2. Set up the welding machine. Check the electrical connections before switching
on the machine. Set current between 90-140 amperes.
4. Lay the plate flat in a welding table where you are comfortable as possible when
welding commences.
stevenling-ilpks.blogspot.com%2Fp%2Fset-up-smaw-equipment.html
5. Strike an arc on the first line of the plate. If you are right-handed, the weld should
start from the left to right, but if you are left-handed, start from right to left.
6. When the arc is established, position the electrode at 75o travel angle and 90o work
angle.
75o
7. Move the electrode with constant rate of travel controlling and maintaining the width
of bead at about 2 ½ times of the diameter of the electrode.
8. Continue welding until you reach the end of the line. Quickly withdraw the
electrode if you want to stop or reach the end of the line.
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9. Clean the weld using a chipping hammer and steel brush. Use clear goggles when
chipping. The direction of chipping should be away from you.
10. Inspect the weld run. The weld should be straight, of even thickness and width
with fine ripples. The thickness of the bead should be about one and one-half of
the electrode diameter.
11. Finish all the laid-out lines. Avoid the same mistakes you did on your first try.
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What I Have Learned
Self-Check 2.1
The marking system below will guide you in assessing the quality of your weld. Follow the
marking schedule in rating your weld and record the marks on the table provided for the
purpose. Subtract the total marks from 20 points, which is the highest rating to determine your
final points.
MARKING TABLE
CRITERIA MARKS SUBTRACTED
1. Straightness
2. Width of bead
3. Height of bead
4. Ripple
20 - Deductions
FINAL POINTS =
MARKING SCHEDULE:
1. Straightness
Subtract 1 mark for each degree of deflection from the line of weld.
2. Width of Bead
Subtract 2 marks for each 10mm length of bead which is 1mm less than or more than
the bead width of 8mm.
3. Height of Bead
Subtract 2 marks for 10mm length of bead which exceeds the bead height of 3mm.
4. Ripple
Subtract 3 points for uneven and coarse ripple.
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Information Sheet 2.3
What Is It
33
Assessment: (Post-Test)
Direction: Write the letter of the correct answer in every item. Provide a separate
answer sheet.
2. What is the basis for identifying the recommended arc length to be maintained when
striking an arc?
c. diameter of filler metal c. type of electrode
d. diameter of the flux d. thickness of the base metal
4. What is the recommended travel angle and work angle in striking an arc in flat
position?
c. 65° - 75°, 90° c. 70°, 90°
d. 75° - 85°, 95° d. 60°, 85°
8. What is the prescribe safe lens shade if the electrode size is 1/16 – 5/32 and
amperage is 75-200 amperes?
b. # 8 b. # 10 c. # 12 d. # 14
16. What is the prescribe safe lens shade if the electrode size is 5/16 – 3/8 and
amperage is 400+ amperes?
b. # 8 b. # 10 c. # 12 d. # 14
34
19. The growing together or growth into one body of materials being welded is called.
c. coalescence c. fusion welding
d. spatter d. bead
21. A non-metallic solid material entrapped or formed on top of weld metal or between
the weld metal and base metal is called.
b. Slag b. flux c. bead d. spatter
35
36
ANSWER KEY
Self-Check Self-Check
No. PRE-POST TEST KEY
1.1 1.2
1. A 16. circular weave B A
2. B 17. crescent weave C B
3. C 18. square weave C B
4. D 19. figure 8 weave B A
5. B 20. V weave A A
6. D 21. base metal/parent metal
7. B 22. weld metal
8. D 23. slag
9. A 24. arc length
10. B 25. flux covering
11. A 26. filler/core metal
12 D 27. electrode
13. A 28. welding gases
14 D 29. penetration depth
15. D 30. molten pool
ANSWER KEY
References:
"How to Strike and Establish an Arc | Lincoln Electric Canada." Lincolnelectric. Accessed
January 28, 2020. https://www.lincolnelectric.com/en-ca/support/welding-how-
to/Pages/strike-establish-arc-detail.aspx.
Jacob. "SMAW (Stick Welding)." SlideServe. Last modified January 23, 2012.
https://www.slideserve.com/jacob/smaw-stick-welding.
JEFFUS, LARRY, and HAROLD JOHNSON. Welding Principles and Application. n.d.
37