Welding Module 1-6

Republic of the Philippines
Department of Education
PUBLIC TECHNICAL-VOCATIONAL
HIGH SCHOOLS
Unit of Competency: REPAIR WELD
Module No.: 6 Module Title: REPAIRING WELD
www.shsph.blogspot.com
ACKNOWLEDGMENTS
Copyright Department of Education 2008
First Published JUNE 2008
This draft was prepared at the Competency-Based Learning Materials

Development Workshop conducted at the Marikina Hotel, Marikina City on
February 18-22, 2008.
This learning instrument was developed by the following personnel:
Technology Teacher:
June L. Dimalibot
Bauan Technical High School
Poblacion II Bauan, Batangas
Resource Person:
Mr. Clodualdo Paiton
TESDA Specialist
Mr. Jose D. Gonzales Jr.

Principal III
RESPSCI
Contextual Teacher:
May L. Sangalang
AFG Bernardino Memorial Trade School
Lias, Marilao, Bulacan
(English)
Encoders:
Maria Eliza R. Rivera
Catherine P. Gonzales
Evangeline C. Nuesca
Magara, Roxas, Palawan
This work was produced with funding provided by the Department of

Education.
ACKNOWLEDGMENT
The Department of Education (DepED), Central Office through Technical

Vocational Task Force wishes to extend its gratitude and appreciation to all the
Module Writers for sharing their time and expertise in the Refinement and
Enrichment of Competency-Based Learning Materials for Strengthening
Technical Vocational Education Program (STVEP) held at Marikina Hotel,
Marikina City on April 20-25, 2009.
MODULE WRITERS:
WELDING
JIMMY P. OCAMPO
Rizal Experimental Station and Pilot School of Cottage Industries
(RESPSCI)
Maybunga, Pasig City NCR
JIMMY P. DOMINGO
San Pedro Relocation Center NHS
San Pedro, Laguna Region IV-A
JEFFREY G. MORENOS
Assemblywoman Felicita G. Bernardino
Memorial Trade School
Lias, Marilao, Bulacan Region III
BENJIE R. SAN JUAN

Community VHS (Calapan City NHS)
Calapan City, Oriental Mindoro Region IV-B
SCIENCE
EDNA M. PASAMONTE
B.S. Aquino National High School
Concepcion, Tarlac Region III
MATH
FRANCISCO M. JAVIER
Muntinlupa Business High School
Espeleta St., Buli, Muntinlupa City NCR
ENGLISH
MA. NONELA B. CASTILLO

Rizal Experimental Station and Pilot School of Cottage Industries
(RESPSCI)
Maybunga, Pasig City NCR
FACILITATOR :
VICTORIO N. MEDRANO
Principal IV
San Pedro Relocation Center NHS
San Pedro, Laguna Region IV-A
EDITOR:
MRS. CAROLINA F. CHAVEZ

Principal II
Muntinlupa Business High School
Muntinlupa City NCR
ENCODER :
MA. RIZA B. ZAMORA

DepED – Budget Division, Meralco Ave., Pasig City
EVANGELINE C. NUESCA
Magara, Roxas, Palawan
This work was produced with funding provided by the Department of

Education.
TABLE OF CONTENTS
Page
How to Use this Module ................................................................................... i

Introduction .................................................................................................... ii
Technical Terms ............................................................................................. iii
Learning Outcome (LO) 1 Mark/Locate Weld Defects… ................................... 1
 Learning Experiences/Activities ............................................................. 2
 Information Sheet 1.1 ....................................................................... 3-10
 Self-Check 1.1 ................................................................................ 11-12
 Self-Check 1.2 ..................................................................................... 13
Learning Outcome 2 Prepare Tools and Materials…...……………………………..14

 Learning Experiences/Activities………………………………………………….15
 Information sheet 2.1…………………………………………………………..16-17
 Self check 2.1…………………………………………………………………………18
Learning Outcome 3 Remove Weld Defects…………………………..……………….19
 Learning Experiences/Activities…….……………………………………………20
 Self-Check 3.1………………………………………………………………………..21
 Job sheet 3.1…………………………………………………………………………22
Learning Outcomes 4 Perform Re-welding……………………………………………23
 Learning Experiences/Activities…………………………………………………24
 Job Sheet 4.1…………………………………………………………………………25
 Self check 4.1…………………………………………………………………….…..26
Pre test/Post test …………………………………………………………………….…27-29
Answer Key ……………………………………………………………………………...30-31
HOW TO USE THIS MODULE
Welcome to the Module “Repairing Weld”. This module contains training

materials and activities for you to complete.
The unit of competency “Repair Weld” 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.
Recognition of Prior Learning (RPL)
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.
i
Program/Course Shielded Metal Arc Welding (SMAW) NC-1
Unit of Competency Repair Weld
Module Title: REPAIRING WELD
INTRODUCTION:
This module contains information and suggested learning activities on

Repair of Weld. It includes instruction and procedure on how to Repair Weld.
Completion of this module will help you better understand the

succeeding module on Interpreting Drawings and Symbols.
This module consists of four (4) 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.
SUMMARY OF LEARNING OUTCOMES (LO)
Upon completion of the module the students should be able to:
LO1 Mark/locate weld defects;

LO2 Prepare tools and equipment;
LO3 Remove weld defects;
LO4 Perform re-welding
ASSESSMENT CRITERIA:
Refer to assessment criteria of learning outcomes 1-4 of this module.
PREREQUISITE:
ii
TECHNICAL TERMS
1. Defect is a discontinuity or discontinuities which by nature

or accumulated effect render a part or product
unable to meet minimum applicable acceptance
standard or specification.
2. Weld Defect an irregularity that spoils the weld appearance or

impairs the effectivesness of the weld or weldment
by causing weakness or failure.
3. Rectify Weld Defect correct weld defect base on the acceptable standards.
4. Distortion a tendency of the metal to bend or twists out of

shape as a result of being excessively heated during
cutting and welding process.
5. Arc Blow magnetic disturbance of arc which causes it to wave

from its intended path
6. Angular Distortion warping of a part of a structure due to application of

heat and pressure.
7. Fusion a filler metal and base metal melting together to form

a weld.
8. Porosity a structural defect cause by gas pockets in welded
metal
9. Inclusion a non-metallic composition in metal which inhibits
its mechanical properties.
10. Slag a mixture of flux and impurities
11. Under cut a defect which results when cutting a groove melts
into the base metal next to the toe or root of weld and
is not filled by weld metal.
12. Under fill a depression on the face of welds or root surface that
extends below the surface of the base metal.
13. Over lap a weld defect where the weld metal “spills over”
beyond the toe or root of the weld.
14. Crater Crack a crack in the weld bead crater.
15. Oxy-Acetylene
Cutting a method where the metal is cut in high temperature
by the chemical reaction of oxygen with the base
metal.
iii
16. Oxygen a colorless and odorless gas which supports
combustion and combines readily with other
elements.
17. Acetylene a colorless gas produced by containing hydrogen and

carbon, widely used with oxygen as a fuel for welding.
18. Root of weld the points in cross-section where the back of the weld
crosses the base metal surfaces.
19. Root penetration the depth that a groove weld extends into the root of a
joint, measured at the center.
20. Tack Weld a weld that holds parts of weld mention proper
alignment until the final weld is made.
21. Tail a part of an arrow symbol on a welding blueprint

where welding specifications are placed.
22. Ampere It is a unit in measuring the rate at which electrons

pass a point in the conductor.
23. Welding Machine equipment used to perform welding operation.
24. Fillet Weld a triangular shape weld that joints two surfaces at
approximately right angles to each other in a T, lap
and corner joint.
25. Preheating temperature to which a metal is heated before an

operations is performed on the metal.
26. Post heating temperature to which a metal is heated after an

operations has been performed on the metal.
iv
Program/Course: SHIELDED METAL ARC WELDING
Learning Outcome 1:
Mark/locate weld defects
Assessment Criteria:
1. Locations of weld defects are identified/determined in accordance with

industry standard.
2. Weld defects are marked for repair in accordance with industry standard.
3. Procedures in locating weld defects is applied per approved procedure.
REFERENCES:
Welding Technology
Second Edition
Gower A. Kennedy
Welding Inspection Technology

Education Department
American Welding Society, Inc
Welding Principles and Application

Larry Jeffus and Harold V. Johnson
1
LEARNING EXPERIENCES/ACTIVITIES
Learning Outcome 1: Mark/locate weld defects
Learning Activities Special Instructions
NOTE: Answer the pre test before  Practice checking of weld

reading this module.
defects.
1) Read the attached information
sheet 1.1 and identify the kinds
of weld defects.  Answer the self-check without
2) Answer the self-check No.1 to looking at the information sheet
test your knowledge on the weld

defects.
3) Compare your answer on
answer keys
4) If you missed some of the items,
go over this enabling objective
again
5) When you are ready, you can
proceed to the next enable
objective
NOTE: Answer the post test after

2
INFORMATION SHEET No. 1.1
WELDING DEFECTS
1. Porosity is the result of gas being entrapped in solidifying weld material

a. Uniformity Scattered Porosity May be distributed throughout single
pass welds or throughout several passes of multiple pass welds.
b. Cluster Porosity is a localized grouping of pores that may result from

improper initiation or termination of the welding arc.
c. Linear Porosity may be aligned along

1) A weld interface;
2) Root of the weld; and
3) A boundary between weld beads.
3
d. Elongated Porosity
 Piping porosity is a term for elongated gas pores.
 Piping porosity in fillet welds normally extends from the root of the
weld toward the face.
2. Slag Inclusion
 Is a non-metallic material trapped in the weld metal or at the weld
metal interface.
 Generally, results from faulty welding technique and improper access
to the joint for welding.
3. Incomplete Fusion means incorrect welding techniques, improper

preparations of the materials for welding or wrong joint designs promote
incomplete fusion in welds.
4
4. Poor Penetration
 This condition may result from insufficient welding heat, improper
joint design, incorrect bevel angle or poor control of welding arc.
5. Undercut
 Visible undercut generally associated with improper welding
techniques or excessive welding current.
 It is generally located parallel to the junction of weld metal and base
metal at the toe or root of the weld.
6. Under fill
 Results simply from the failure of the welder or welding operator to fill
the joint with weld metal.
5
7. Overlap
 Are usually/caused by incorrect welding procedure, wrong selection of
welding materials or improper preparation of the base metal prior to
welding.
8. Crack of Weld
 occurs in weld metal and base metal when localized stresses exceed
the ultimate strength of the metal.
 Cracks can be classified as either hot or cold types.
 Identification of cracks according to location in weld base metal

1. Crater crack in weld metal
2. Transverse crack in weld metal
3. Transverse crack in heat-affected zone
4. Longitudinal crack in weld metal
5. The crack in base metal
6. Under bead crack in base metal
7. Fusion line crack
8. Root crack in weld metal
9. Hot cracks in weld metal
10. Weld defects, causes and remedies
9. Weld defects causes and remedies

6
1. Porous Welds
Why What to do
1. Short arc with exception of low 1. Hold longer arc.

hydrogen and stainless. 2. Allow sufficient puddling time
2. Insufficient puddling time. for gases to escape.
3. Impaired base metal.  Use proper current
4. Poor electrode. 3. Check impurities of the base
5. Improper shield coverage. metal
4. Use proper electrode for the
job.
5. Weave your weld to eliminate
pin holes.
2. Poor Penetration
1. Speed too fast 1. Use enough current to obtain
desired penetration-weld
2. Electrode too large slowly.
2. Select electrode according to
3. Current too low welding groove size.
3. Leave proper gap at the bottom
4. Faulty preparation of weld.
3. Warping
1. Shrinkage of weld metal 1. Peen joint edges before welding.
2. Faulty clamping of parts. 2. Weld more rapidly.
3. Faulty preparation. 3. Avoid excessive space between
4. Overheating at joint. parts.
4. Use proper sequence.
5. Clamp or track parts properly
back up tool.
6. Adopt a proper welding
procedure.
7
4. Undercutting
1. Faulty electrode of gun 1. Use a uniform weave in butt
manipulation. welding.
2. Faulty electrode usage. 2. Use proper electrode animeter.
3. Current too high 3. Avoid excessive weaving.
4. Use moderate current, weld
slowly.
5. Hold electrode at safe distance
from the vertical plane in
making horizontal fillet weld.
5. Crack Welds 1. Design structure to eliminate

1. Wrong electrode rigid joints
2. Weld parts size unbalanced 2. Heat parts before welding
3. Faulty weld (preheating)
4. Faulty preparation 3. Avoid weld on string beads
5. Rigid joint 4. Keep end free to move as long
as possible
5. Make sound weld of good fusion
6. Adjust weld size to part size
7. Allow joint to proper and
uniform gap
8. Work with amperage as low as
possible.
6. Poor Appearance 1. Use proper welding

1. Faulty electrode techniques
2. Overhang 2. Avoid overheating
3. Improper use of electrode 3. Use uniform weave
4. Wrong arc voltage and 4. Avoid overly high current
current design
8
7. Poor Fusion
1. Wrong speed 1. Adjust electrode to match the
2. Current improperly adjusted joint.
3. Faulty preparation 2. Weave must be sufficient to
4. Improper electrode size melt side joint.
3. Select proper current and
voltage.
4. Keep weld metal from flowing

away from plates.
8. Brittle Welds
1. Wrong electrode 1. Preheat at 30ºF. If welding on
2. Faulty preheating medium carbon steel or certain
3. Metal hardened by air alloy steels.
2. Make a multiple layer welds
3. Stress relieving after welding
4. Use low hydrogen processes for
increased weld ductility.
9. Spatter
1. Arc blow 1. Clean parts in weld area.
2. Current too high 2. Adjust current properly
3. Arc too long 3. Adjust voltage
4. Faulty electrode 4. Pick suitable electrode
10. Magnetic Blow

1. Magnetic fields cause the arc to 1. Use steel block to alter
deviate from its intended course. magnetic path around the arc.
2. Divide the ground into parts
3. Weld in same direction the arc
blow
4. Use the short arc length
5. Locate the ground properly on
the work
6. Use A.C welding
9
11. Weld Stresses
1. Faulty weld 1. Allow parts to move free as
2. Faulty sequence long as practical
3. Rigid joints 2. Make as few passes as
practical
3. Peen the deposit
4. Stress relieve according to
thickness of weld
5. Move parts slightly when
welding the rigid joint to
reduce stresses.
10
ASSESSMENT (SELF – CHECK) No. 1.1
Direction: Write your answer in a separate paper.
A. Identify the cracks to determine weld defects.
B. Answer the following questions briefly

1. List the causes and remedies of crack weld
Cause Remedy
1.a) 1.a)
1.b) 1.b)
1.c) 1.c)
1.d) 1.d)
1.e) 1.e)
1.f)
1.g)
1.h)
11
2. Briefly explain the different types of Porosity
2.a)
LINEAR POROSITY
2.b)
CLUSTER POROSITY
2.c)
UNIFORMITY POROSITY
2.d)
ELONGATED POROSITY
12
SELF CHECK 1.2
Mark /Locate Weld Defects
Procedure: The student will be provided with a welding specimen. The student
should identify and mark the various weld defects present in the
metal.
Visual examination procedure on the following defects:
PRESENCE OF WELD DEFECTS

BASIC WELD DEFECTS
YES NO
1. Porosity
2. Under cut
3. Slag Inclusion
4. Incomplete Fusion
5. Poor Penetration
6. Under cut
7. Under fill
8. Overlap
9. Crack of Weld
10. Others Specify
Condition: If all weld defects are identified correctly, proceed to LO2 which is
the preparation of tools and equipment for weld repairs.
13
Learning Outcome 2:
Prepare Tools and equipment
1. Tools and equipments are prepared in conformity with the job

requirements.
2. Tools and equipments are properly checked in accordance with the job
requirements.
REFERENCES:
Welding Technology
Second Edition
Gower A. Kennedy


14
Learning Outcome 2: Prepare Tools and Equipment
NOTE: Answer the pre test before

1. Read the attached information

sheet 2.1 in preparing tools and  Answer the self-check without
looking at the information sheet
equipment.
2. Answer the self-check 2.1 to
test your knowledge in preparing
tools and equipment.
3. Compare your answer on
answer key.
4. If you missed some items, go
over this module.
5. If you passed, then proceed to the
next L.O.
15
INFORMATION SHEET 2.1
Prepare Tools and Equipment
Tools and Equipment
●Angle Grinder – is a
versatile tool that can
grind, cut and brush
metal without using
water.
● Rough Grinding – the best

rough results can be
achieved with 30 to 40
approach angle. Move the
machine back and forth with
moderate pressure. In this
manner, the work piece will
not overly heat up nor
discolor and no ridges will be
formed.
● Electrode Oven - equipment use to
store all types of welding electrode
particularly the low hydrogen. Electrode
which requires in some critical welding
joints to be fabricated. The temperature
requirements varies based the needed
specific job.
 Welding Helmet
a) Welding Shielded Helmet – is used
to protect our face and eyes from the
arc rays, heat and spatter from the
molten metal. The arc is viewed
through a filter which reduces the
intensity of radiation but allows a safe
amount of light to pass for viewing the
weld pool and end of electrode.
b) Hand held Shielded

Helmet – allows only
one hand free to work.
16
● Oxy-Acetylene – an oxy fuel gas cutting process used to cut and
bevel metals by means of the chemical reaction of oxygen with the base
metal at elevated temperature. The necessary temperature is
maintained by gas flames resulting from the combustion of acetylene
with oxygen.
Major accessories of Oxy-Acetylene cutting equipment
a) Cylinder – a portable
round container where
compressed gas is stored
b) Regulator – a welding tool

used to control the gas
delivery, producing constant
pressure regardless of higher
pressure variation of the gas
source.
c) Twin Hose – are used

to carry the gas to the
welders work. Red hose
connect to the acetylene
while green hose is for the
oxygen.
d)Spark
Lighter/Igniter –
ignites the implement
used for igniting the
torch.
e) Cutting Torch – used

to cut metal
17
ASSESSMENT (SELF CHECK) 2.1
Directions: Encircle the letter of the correct answer. Write your answer in a
separate paper.
1. Welding equipment where welding electrode is stored in a given

temperature
a) welding machine b) shop room c) electrode oven d) stock room
2. A tool use to protect our eyes and face using only one hand.
a) goggles b) hand held shield c) lens d) gloves
3. Oxy-Acetylene accessory used to control the gas delivery.
a) regulator b) spark lighter c) hose d) cylinder
4. A colorless gas that supports combustion and combines readily with other
elements.
a) acetylene b) hydrogen c) carbon d) oxygen
5. Power tool to grind, cut and brush surface of a metal.
a) angle grinder b) chipping hammer c) speed cutter d) hand drill
6. Gas cutting process use to cut metal by means of chemical reaction.
a) grinding b) hack sawing c) oxy-acetylene d) drilling
7. Tool use for igniting torch
a) hose b) spark lighter c) regulator d) cylinder
8. Angle applied in rough grinding
a) 35- 60 b) 40- 50 c) 30 - 40 d) 70 - 80
9. Type of a welding helmet use to protect our face and eyes from the arc rays
and the spatter from the molten metal.
a) apron b) welding Shield Helmet c) gloves d) dark lens
10. A round portable container where compressed gas is stored.
a) acetylene b) oxygen c) cylinder d) regulator
18
Learning Outcome 3:
Remove Weld Defects
1. Weld defects are removed/excavated in accordance with welding

procedures.
2. Removal of non-defective welds is minimized and cleaned.
3. Visual and dye-penetrant tests are performed to verify the extent of the
removal of defects.
Resources:
Welding Technology
Second Edition
Gower A. Kennedy


19
Learning Outcome 3: Remove Weld Defects

1. Read the attached job sheets

3.1 in removing weld defects.  Answer the self-check without
test your knowledge in removing
weld defects.
answer key.
over this module.
next L.O.
20
Direction. The student should identify, remove, excavate weld defects

based on the approved weld repair procedures.
The weld specimen is

BASIC WELD properly rectified base
DEFECTS on the acceptable
standard
NO
YES
3. Porosity
4. Undercut
5. Crater Crock
6. Pinholes/Blowholes
7. Slag Inclusion
8. Other specifications
Condition: If the weld specimen passed the acceptable standards for repairing
weld, proceed to Perform Rewelding.
21
JOB SHEET 3.1
REMOVE WELD DEFECTS
Materials:
1. Defective welded plate
Tools and Equipments:

a. Angle grinder
b. Working table with bench vise
c. Apron
d. Clean hand shield mask
e. Gloves
f. File (Flat, triangular)
g. Steel brush
h. Chipping hammer
Procedure:
a. Mount the welded plate on the bench vise.

b. Engage the power plug into 220 volts current supply.
c. Switch on the angle grinder.
d. Apply 15 degree to 40 degree in grinding to the defective welded
metal in removing bead.
e. Move the machine back and forth with the moderate pressure.
f. Continue grinding until the defects of the welded plate are removed.
g. Observe safety precaution.
22
23
Learning Outcome 4:
Perform re-welding
1. Re-welding is performed in accordance with approved repair procedure.

2. Weld is visually checked after re-welding for acceptability.
3. Weld defects/damages are avoided re-welding.
REFERENCES:
Welding Technology
Second Edition
Gower A. Kennedy


24
Learning Outcome 4: Perform Re-Welding

1. Read the attached job sheets

4.1 in performing re-welding.  Answer the self-check without
test your knowledge in performing
re-welding.
answer key.
over this module.
next module.
25
JOB SHEET 4.1
Perform Re-Welding
Re- welding of defective specimen
Materials:
1. Welding Electrode
2. Weld Specimen
Equipments:
1. Welding Table
2. SMAW (AC/DC) welding machine with accessories
3. Portable grinder
4. Welding Booth
Tools/Accessories:
1. Welding mask
2. Steel brush
3. Chipping hammer
4. Welding Apron
5. Welding Gloves
6. File (Flat, triangular)
Steps:
1. Put the weld specimen on the welding table.

2. Locate the defective area to be repaired.
3. Set-up welding machine to the required job.
4. Perform re-welding
5. Clean and check visually the weld
6. Observe safety precautions
26
Direction. The student should perform rewelding based on the acceptable

welding standard and specification.
Assessment Criteria PASSED FAILED
1. Rewelding performed
in accordance with
approved repair
procedure
2. Task performed in
accordance with
company or industry
requirement and
safety procedure.
3. No new weld defects
or damages occurred
during rewelding.
4. Weld visually check
after rewelding for
acceptability
Condition:
If all the assessment criteria are attained , this means that the student
passed the given activity.
If one of the criteria is not attained, the student should review and repeat
the activity until it reaches the desired result.
27
PRE TEST/POST TEST FOR MODULE # 6 REPAIRING WELD
LO I. Mark/locate weld defects
1. Below are causes of porosity except:
a) insufficient puddling time

b) impurities on base metal
c) too short arc
d) current too high
2. Below are causes of poor penetration and incomplete fusion except:
a) Uniform weave motion

b) Improper electrode size and type
c) Current too low
d) Too fast travel speed
3. Below are causes of slag inclusion except:
a) extremely short arc

b) too fast travel speed
c) improper electrode manipulation
d) none of the above
4. Below are causes of undercutting except:
a) too low current

b) improper electrode size
c) faulty electrode manipulation
d) current too high
5. Below are causes of poor weld appearance except:
a) long arc
b) over heating
c) uniform weave
d) improper travel speed
6. Below are causes of spattering except:
a) arc blow
b) excessive current
c) too long arc
d) too slow travel speed
7. Below are causes of weld cracks except:
a) weld too small

b) rigid joints
c) too fast travel speed
d) improper pre heat treatment
28
8. It is a weld defect where the weld metal spills over beyond the toe or root of the
weld
a) porosity
b) overlap
c) slag inclusion
d) undercut
9. Temperature to which a metal is heated before an operation is performed on the

metal.
a) post heating
b) reverse polarity
c) preheating
d) brazing
10. Below are causes of warping except:
a) faulty clamping of parts

b) faulty metal preparation
c) speed too fast
d) overheating at joint
LO2, LO3, LO4: Prepare Tool and Equipment, Remove Weld Defects and
Perform Re-Welding
11. Power tools to grind, cut and brush surface of a metal
a) angle grinder
b) hydraulic cutter
c) oxy acetylene
d) regulator
12. Tool used for igniting torch
a) punch
b) chisel
c) spark lighter
d) blow torch
13. Gas cutting process use to cut metal by chemical means is:
a) grinding
b) hack sawing
c) drilling
d) oxy acetylene
14. Angle applied for rough grinding
a) 35 – 60
b) 40 – 45
c) 30 – 40
d) 70 – 80
29
15. Colorless gas that supports combustion and combines readily with other
elements
a) acetylene
b) hydrogen
c) carbon
d) oxygen
30
ANSWER KEY
Self Check # 1.1
A.
1. Crater crack in weld metal
2. Transverse crack in the weld
3. Transverse crack in heat-affected zone
4. Longitudinal crack in the weld
5. Toe crack in back metal
6. Under bead crack in back metal
7. Fusion line crack
8. Root crack in the weld
9. hot cracks in the weld
B.
Write the causes and remedies of crack weld.
Cause Remedy
1. a) Incorrect electrode 1.a) design structure to eliminate rigid
joint
1. b) Weld part size unbalanced 1.b) Heat parts before welding
1. c) Faulty weld 1. c) Avoid weld on strong beads
1. d) Faulty operation 1.d) Keep and free to move as long as
possible
1. e) Rigid joint 1. e) Make sound weld of good fusion
1. f) Adjust weld size to part size
1.g) Allow joint to proper and uniform
gap
1. h) Work amperage as low as possible
2.a. Linear Porosity – may be designed along a weld interface, root of the weld
and boundary between weld beads.
2.b. Cluster Porosity – is a localized grouping of pores that may result from
improper initiation or termination of the weld arc.
2.c. Uniformity Porosity – may be disturbed throughout single passes of

multiple pass weld.
2.d. Elongated Porosity – is the term for elongated gas pores, in fillet weld,
welds normally extends from the root of the weld towards
the face.
31
Self Check # 2.1
1. C 4. D 7. B 10. C
2. B 5. A 8. C
3. A 6. C 9. B
PRE TEST/POST TEST FOR MODULE # 6 REPAIRING WELD
LO 1. MARK/LOCATE WELD DEFECTS
1. d
2. a
3. b
4. a
5. c
6. d
7. c
8. b
9. c
10. c
LO 2 – LO 4
10. a
11. c
12. d
13. c
14. d
32
Republic of the Philippines
PUBLIC TECHNICAL-VOCATIONAL
HIGH SCHOOLS
Unit of Competency: INTERPRET DRAWINGS AND SYMBOLS
Module No.: 7 Module Title: INTERPRETING DRAWINGS AND SYMBOLS

Welding Module 1-6

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Welding Module 1-6

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Republic of the Philippines

Unit of Competency: REPAIR WELD

Module No.: 6 Module Title: REPAIRING WELD

Copyright Department of Education 2008

First Published JUNE 2008

This draft was prepared at the Competency-Based Learning Materials

This learning instrument was developed by the following personnel:

Mr. Jose D. Gonzales Jr.

This work was produced with funding provided by the Department of

The Department of Education (DepED), Central Office through Technical

BENJIE R. SAN JUAN

MA. NONELA B. CASTILLO

MRS. CAROLINA F. CHAVEZ

MA. RIZA B. ZAMORA

This work was produced with funding provided by the Department of

How to Use this Module ................................................................................... i

Learning Outcome 2 Prepare Tools and Materials…...……………………………..14

Welcome to the Module “Repairing Weld”. This module contains training

You are required to go through a series of learning activities in order to

Recognition of Prior Learning (RPL)

This module is prepared to help you achieve the required competency,

Unit of Competency Repair Weld

Module Title: REPAIRING WELD

This module contains information and suggested learning activities on

Completion of this module will help you better understand the

This module consists of four (4) learning outcomes. Each learning

Upon completing this module, report to your competence teacher for

SUMMARY OF LEARNING OUTCOMES (LO)

Upon completion of the module the students should be able to:

LO1 Mark/locate weld defects;

Refer to assessment criteria of learning outcomes 1-4 of this module.

1. Defect is a discontinuity or discontinuities which by nature

2. Weld Defect an irregularity that spoils the weld appearance or

4. Distortion a tendency of the metal to bend or twists out of

5. Arc Blow magnetic disturbance of arc which causes it to wave

6. Angular Distortion warping of a part of a structure due to application of

7. Fusion a filler metal and base metal melting together to form

17. Acetylene a colorless gas produced by containing hydrogen and

21. Tail a part of an arrow symbol on a welding blueprint

22. Ampere It is a unit in measuring the rate at which electrons

23. Welding Machine equipment used to perform welding operation.

25. Preheating temperature to which a metal is heated before an

26. Post heating temperature to which a metal is heated after an

Mark/locate weld defects

1. Locations of weld defects are identified/determined in accordance with

Welding Inspection Technology

Welding Principles and Application

Learning Outcome 1: Mark/locate weld defects

Learning Activities Special Instructions

NOTE: Answer the pre test before  Practice checking of weld

test your knowledge on the weld

NOTE: Answer the post test after

1. Porosity is the result of gas being entrapped in solidifying weld material

b. Cluster Porosity is a localized grouping of pores that may result from

c. Linear Porosity may be aligned along

3. Incomplete Fusion means incorrect welding techniques, improper

 Identification of cracks according to location in weld base metal

9. Weld defects causes and remedies

1. Short arc with exception of low 1. Hold longer arc.

5. Crack Welds 1. Design structure to eliminate

6. Poor Appearance 1. Use proper welding

4. Keep weld metal from flowing

10. Magnetic Blow

Direction: Write your answer in a separate paper.