Welding Y2

Republic of the Philippines
Department of Education
PUBLIC TECHNICAL-VOCATIONAL
HIGH SCHOOLS
Unit of Competency: USE BASIC HAND TOOLS
Module No.: 1 Module Title: USING BASIC HAND TOOLS

ACKNOWLEDGMENT
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 Teachers:
Jimmy P. Ocampo
Rizal Experimental Station and Pilot School of Cottage Industries
(RESPSCI)
Maybunga, Pasig City
NCR
Contextual Teacher:
May L. Sangalang
AFG Bernardino Memorial Trade School
Lias, Marilao, Bulacan
Encoder:
Maria Eliza R. Rivera
Catherine Gonzales
Facilitator:
Cloudualdo Paiton
TESDA Especialist
Jose D. Gonzales Jr.

Principal III
RESPSCI
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
(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

(RESPSCI)
FACILITATOR :
VICTORIO N. MEDRANO
Principal IV
EDITOR:
MRS. CAROLINA F. CHAVEZ

Principal II
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 1 Select and Classify Hand Tools.……………..1
 Learning Experiences/Activities………………………………….2
 Information Sheet 1..…………………………………………...3-15
 Self-Check 1.1……………………………………………………...16
 Information Sheet 1.2…………………………………………...17
 Self Check 1.2……………………………………………………..18
Learning Outcome 2 Use Hand Tools….…………………………….19
 Learning Experiences/Activities.……….………………………20
 Operation Sheet 2.1……………………………………….…21-28
 Self Check 2.1.…………………………………………………….29
● Information Sheet 2.2 ……………………………………….30-32
● Self Check 2.2 ………………………………………………………33
Learning Outcome 3 Maintain Hand Tools……………………….34
● Experiences/Activities …………………………………………….35
● Information Sheet 3.1.………………………………………….36-39
● Self Check 3.1 …………………………………………………..40-41
● Answer Keys ………………………………………………………….42

HOW TO USE THIS MODULE
Welcome to the Module “USING BASIC HAND TOOLS”. This
module contains training materials and activities for you to
complete.
The unit of competency “Using Basic Hand Tools” contains

the knowledge, skills and attitudes required for a welding course.
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. Follow these
activities on your own and answer the Self-Check at the end of
each learning activity.
If you have questions, don’t hesitate to ask your facilitator

for assistance.
Recognition of Prior Learning (RPL)
You may already have some or most of the knowledge and

skills covered in this module because you have:
been working for some time
already completed training in this area.
If you can demonstrate to your trainer that you are

competent in a particular skill or skills, talk to him/her about
having them formally recognized so you don’t have to do the same
module again. If you have a qualification or Certificate of
Competency from previous trainings show it to your trainer. If the
skills you acquired are still current and relevant to this module,
they may become part of the evidence you can present for RPL. If
you are not sure about the currency of your skills, discuss this
with your trainer.
After completing this module ask your trainer to assess your

competency. 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.
Inside this module you will find activities for you to complete
followed by relevant information sheets for each learning outcome.
Each learning outcome may have more than one learning activity.
i
Program/Course Shielded Metal Arc Welding (SMAW) NC-1
Unit of Competency Use of Basic Hand Tools
Module USING BASIC HAND TOOLS
INTRODUCTION:
This module contains information and suggested learning activities in

using basic hand tools. It includes instructions and procedures on
how to use hand tools.
Completion of this module will help you better understand the

succeeding module on preparation of weld materials.
This module consists of three (3) learning outcomes. Each learning

outcome contains learning activities supported by instruction sheets.
Before you perform the instructions, read the information sheets and
answer the self-check and other activities provided to ascertain
yourself and your instructor that you have acquired the knowledge
necessary to perform the skill portion of the particular learning
outcome.
Upon completing this module, report to your instructor for

assessment to check your achievement of knowledge and skills
requirements. If you pass the assessment, you will be given a
certificate of completion.
SUMMARY OF LEARNING OUTCOMES:
Upon completion of the module you should be able to:
LO1 Select and classify hand tools;

LO2 Use hand tools; and
LO3 Maintain hand tools.
ASSESSMENT CRITERIA:
Refer to assessment criteria of learning outcomes # 1-3 of this

module.
PREREQUISITE:
First year exploratory
ii
TECHNICAL TERMS
1. Hand Tools are tools operated and manipulated by

our hands.
2. Equipments these are mechanically operated such
as electrical, hydraulic and pneumatic.
3. Measuring tools are hand tools for quantifying
length, distance, height, diameter, etc.
4. Cutting tools are hand tools for dividing one piece of
metal into two or more elements
through sawing, filing, or scraping.
5. Driving tools are hand tools for penetrating screws
or nails in a body either by hammering
or by rotating screws.
6. Holding tools are hand tools used to keep materials in
place while performing work.
7. 5 S is the systematic approach to organize
work areas, keep rules and standards,
and maintain discipline to perform job
well.
8. Lubricant is anything that looks greasy and
applied to prevent friction of any
moving parts.
9. Defective hand tools are hand tools that cannot correctly
perform their intended use. Such
tools can affect both quality
and productivity of the services
and products.
10. Storage of hand tools is one way of keeping tools
in order and having a well
11. Air Vacuum is an equipment used for drying
and cleaning someone automotive part
after washing.
iii
Program/Course SHIELDED METAL ARC WELDING (SMAW)
NC-1
Unit of Competency Use Basic Hand Tools
Module Title USING BASIC HAND TOOLS
Learning Outcome # LO1:
(LO title) Select hand tools
Assessment Criteria:
1. Hand tools were selected and classified according to the job

requirements.
2. Unserviceable or defective tools are identified and marked for
repair according to 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: Select Hand Tools
Learning Activities Special

Instructions
1) Read the attached information sheet No. 1.1/1.2  Answer

Select and Classify Hand Tools the Self-
2) Answer self-check No.1.1/1.2 check
3) Compare your answer to answer key without
4) If you fail to meet the 80% equivalent passing looking at
standard, go over again to the information sheets the
5) If you passed, then proceed to the next LO. informatio
n sheet
 Answer
the Self-
check
within the
least
possible
time
allotment
Assignment sheet
will be issued as
an advanced
requirement
prior to leaning
the next
information sheet
no.02
2
INFORMATION SHEET # 1.1
Select and Classify Hand tools
Introduction:
Selection from the available hand tools in the welding shop and
in the work sites are essential requirements for students, to acquire
an adequate knowledge and skills in selecting appropriate hand tools.
A list of common hand tools and their uses is thereby provided

with picture illustration for better comprehension on the part of the
students.
Hand tools are classified into four:
(1) measuring tools;

(2) cutting tools;
(3) driving tools; and
(4) holding tools.
Each classification has different types and uses.
3
1. MEASURING TOOLS
 Pull-Push Rule. Is flexible rule that when extended will support
itself, but may also be used to measure curved in irregular
surfaces. Steel tape rule blade is usually ½ inch wide and 72
inches long. The graduation is sixteenths except for the first 6
inches which are graduated is thirty-seconds of an inch.
 Steel tape. Is similar to a steel tape rule but differs in that it is

entirely flexible number of feet are marked on the tape. The tape is
3/8 inch wide and available lengths from 25 to 100 feet.
 Steel rule. The most common tool used in tool room. It is made of
tampered steel about 1/8 inch thick and ¾ inch wide and 6 to 12
inches long, same style maybe obtained in length from 1 to 48
inches.






4
Try Square. It is an instrument used to measure the squareness
of an object.
 Combination Square. It is an instrument combined with 45°, 90°

and a protractor.
5
 Dividers. Are used for measuring or setting of distances, and to
lay out arcs and circles.
2. CUTTING TOOLS
 Hacksaw. Is a tooth cutting tool usually with a solid and

adjustable frame. The main parts are handle, blade, tightening
screw and nuts. The tool is mainly use in cutting metals like
plates, pipes, rods, bars, angulars, etc. but of minimal thickness,
width and length. Sometimes this tool is used for cutting plastic
pipes and other materials that suit to its purpose.
o Frame. It is the main body of the hacksaw which holds the
blade. The different types of frames are the following:
a. Fixed or solid frame. It is intended to hold only one size of

blade at about 10 inches long
b. Adjustable frame. Its frame can be adjusted to hold blades of

different sizes such as 10, 12 and 14 inches in length.
6
Length of blade
o Blade. It is made of thin, high grade steel usually 1.27 mm

thick and 30.48cm long with an inclined row of teeth serving as
cutter.
The two types of blades are:
a. All hard. This type, the entire blade is hardened and
tempered, making it very brittle. Use this type in cutting
steel and cast iron. This type costs around P50.00 to
P60.00 in the market.
b. Flexible back. In this type, only the teeth portion is
hardened and tempered, making the blade springy and
less likely to break.
The following are the recommended teeth-per-inch of blades for
different kinds of stocks to be cut:
a. 14 teeth-per-inch. It is used for brass, aluminum, cast
iron and soft iron.
b. 18 teeth-per-inch. It is used for drill rod, mild steel, tool
steel and general work
7
c. 24 teeth-per-inch. It is recommended for thin tubing and
pipe
o Handle. It is the part of the hacksaw which is gripped when
pushing and pulling during the cutting operation.
o Tightening nut and screw. It is used to adjust the tension of the
blade.
 Files. Are made of high grade steel hardened and tempered. It has
rows of teeth that form, shape and finish metal by removing small
chips and smoothing rough edges of the metal surface. They differ
in length, shape, cut and coarseness.
Kinds and uses of files:
1. Mill File. It is a single-cut file used for filing and finishing

brass and bronze.
2. Flat File. It is rectangular in shape and tapered slightly in

width and thickness. It is one of the most commonly used
files for general work.
8
3. Square File. It is intended for filing square or rectangular
holes.
4. Round File. It is used primarily for enlarging holes. It as

also known as rattail file.
5. Half-round File. It is used for filing curved or concave

surfaces.
6. Triangular File. It is used for filing surfaces that meet at

least 90º. It is exclusively used for sharpening wood saws
and for smoothening rectangular opening. It is also known
as three-square file.
 Cold Chisel. A wedge-shape tool used to shear, cut and chip

metal.
Types of cold chisel and their particular functions.
1. Flat Chisel. It is used for chipping flat surfaces; cutting off

rivets or metal fasteners, thin sheets, and small bars; and for
general purposes. Its cutting edge ranges from 13 to 25mm.
9
2. Cape Chisel. It has a narrow edge suited for cutting narrow
grooves or slots.
3. Diamond-point Chisel. It has a diamond-shaped cutting edge

intended to cut V-grooves.
4. Round-nose Chisel. It has a round nose cutting edge for

cutting round and semi-circular grooves.
 Scraper. Is used in removing points, burrs and sharp edges from

metal surface and similar parts. This tool is made of hardened
steel of various shapes that fit according to each purpose. These
are bearing scrapes, flat, sharper, three-connected scraper.
1. For the removal of the high spots on metal surface.
2. For scraping the surface of cylindrical bearing when fitting

shafts into.
3. For the removal of burrs a sharp internal edges from soft

brushing and similar parts
10
 Punches. Are used for permanent marking on surface of metal.
KINDS AND USES OF PUNCHES
Prick Punch. Is a small center punch which is also known a layout

punch. Its point is ground at an angle of 30 degrees.
Center Punch. Has one end guard to a 90 degrees conical point.
11
3. DRIVING TOOLS
 Hammers
1. Ballpeen hammer. It is used for straightening bending and

deforming metals. It has two faces. One is flat in striking cold
chisels and punches. The other side the “peen” is rounded for
bending and sharpening metals.
Ballpeen hammer generally has a wood or fiberglass handle
from 10-16 inches long. Head weight range from 2-48 oz. A
20oz hammer is good for general purpose.
2. Chipping hammer. It is used for removing slags on weld and

with two faces, the tapered from one side and round pointed on
the other side.
 Wrench. Is used for loosening and tightening light and heavy

nuts and bolts. There are kinds and sizes of wrenches designed
according to uses and function. A tool steel of on movable jaws.
12
1. Adjustable wrench has a movable jaw which makes it
adjustable to various sizes of nuts. Heavy type of adjustable
wrench is a monkey/pipe wrench.
Single-ended Double-ended
2. An open-ended wrench is one that is made to fit one size of

nut or bolt. This is the most inexpensive type of wrench of
that quite efficient in ordering situations.
Single-ended Double-ended
3. A closed-end wrench is similar to a single ended wrench,

but as it entirely encloses a nut there a little danger of the
wrench slipping off the nut or the jaws spreading apart.
 Screw Driver. Is a hand tool that is designed to turn screws.

The blade is made of steel, attached to one end of which a
wooden or plastic handle. The other end is flattened to fit slots
in the heads of screws on bolts. The other kinds of screw
drivers are called a Phillips screw driver and helical-ratchet
screw driver.
Phillips Flattened Helical-ratchet
13
4. HOLDING TOOLS
 Clamps. Are made of different sizes and appearance that fitted to
its purpose. These devices have been designed to hold work
securely which performing skills through grinding, bending, fitting
and cutting of metals. Some types of clamps and metal vises.
1. Tool maker clamp for holding small parts both at the bench
and at machine. This tool is also known a parallel clamp.
2. C-Clamp is in all-purpose that is generally used to all kinds

of work.
3. Drill vise is a sturdy steel vise with movable jaw that easily
back or forth by raising the handle.
4. Machinist vise a work holding tool for machining activity.
14
5. Hand vise V block with clamp is used to hold metal stocks
for small machining operation.
6. Vise Grip. A tool used to gripped the stock and tight enough
to hold the object.
7. Tong. Used to hold the metal to be forged and it must be

held securely while it is being worked.
15
SELF-CHECK 1.1
LO1.
Directions:
Read the instruction carefully. Match A with column B. Write the letter
of the correct answer on the blanks provided before the number.
A B
1. Phillips screw
2. Box wrench A.
3. Scraper K.
4. Square file B.
5. C-clamp L.
6. Steel tape
7. Cold Chisel C.
8. Machinist vise M.
9. Ballpeen Hammer
10. Hand vise D.
11. Open ended
E.
wrench
12. Hack saw
13. Steel rule
N.
14. Helical-ratchet
screw driver F. O.
15. Chipping
hammer
G.
P.
H.
J.
I.
16
INFORMATION SHEET 1.2
Defective and Non-Defective Hand tools
Introduction:
There are many ways in identifying hand tools. One of these is to

identify them according to their uses and function. Moreover,
awareness of defective and non-defective hand tools is a primordial
concern of workers/welders.
Below are the recommended practices to identify defective and non-

defective hand tools.
1. Through visual inspection:

Defective tools can easily be distinguished from the functional ones
through visual inspection. The physical appearance of tools will
describe such characteristics like dullness, sharpness, dismantled
parts, and unevenness of the teeth of the cutting tools.
2. Functionality:
Another way is to check the quality of the manufactured tools. Is it
already susceptible to wear and tear? Has it already exceeded its
service life? Is it made with quality and has passed the
manufacturer’s quality control test?
Some hand tools issued for years in shops and few pieces of these can
be subjected for condemnation.
3. Performance:
Performance of hand tools is determined after the actual use has been
tested and evaluated, and the outcomes will be the basis if the hand
tools are still worth for work.
4. Service span:
Hand tools are issued to shop teacher at one time. However, this must
be recorded to determine when it was received and how long the tools
were kept in the shop. A hand tool which is too old is unsafe for both
the students and workers. These should be marked defective and
segregated from the good ones.
17
SELF-CHECK 1.2
LO1.
Direction:
Choose the letter of the correct answer. Use separate answer sheet.
1. Defective hand tools are kept and
a) Marked as defective.
b) Mixed together with non-defective tools.
c) Put anywhere in the shop.
d) Placed in the shop unlabeled.
2. Way of checking hand tools as either defective or non-defective:
a) Length of service
b) Trade mark of the manufacturer
c) Physical appearance
d) All of the above
3. _________ of hand tools is determined after the operation is tested

through:
a) Service span
b) Performance
c) Physical appearance
d) Repair Maintenance
4. All defective hand tools are subjected for:
a) Repair
b) Condemnation
c) Display/sample
d) All of the above
5. Service span pertains to:
a) Maintenance Schedule
b) Determine when the tool is acquired
c) Hand tools considered functional
d) All of the above
18
Program/Course: Shielded Metal Arc Welding (SMAW) NCI
Unit of Competency: Use hand tools
Module: Using Basic Hand Tools
Learning Outcome # 2: Use of Hand Tools
1. Hand tools are selected and classified to produce desired outcomes

for the job specifications.
2. Tasks performed in accordance with workplace procedure.
References:
Manufacturing Production and Maintenance Department.

By Williams
SNAP on Catalog 800

(Quality Tools and Service Equipment)
Welding Technology 2nd Ed.

By Gower A. Kennedy

By Larry Jeffus and Harold Johnson
19
Learning Experiences/Activities:
Learning Outcome # 2 Use hand tools
Learning Activities Special Instructions:
Read the attached Operation Sheet Answer the Self-check without

# 2.1 and Information sheet # 2.2 referring to the operation sheet.
Answer Self-check # 2.1 and # 2.2 Answer the Self-check in the least
possible time allotted.
Compare your answer with Answer Assignment sheet will be issued as

Key an advance requirement prior to
learning the next LO.
If you failed to meet the 80% of
equivalent passing standard, go
over again the operation sheet and
information sheet.
20
Operation Sheet no. 2.1
LO2: USE OF HAND TOOLS

Introduction:
Using hand tools properly and correctly to comply with the basic
requirements is the sole responsibility of the person in the workplace.
The combined knowledge and manipulative skills in performing varied
tasks like assembling, dismantling and other practical operations in
using hand tools.
Below are illustrations of basic hand tools that include skills in
performing tasks.
 Hacksaw
Steps in Mounting Blade to the Metal Frame
TEETH
1. Select the correct type of blade.

2. Attach the blade to the frame by pointing the teeth away from the
handle.
3. Tighten the wing nut of the handle until the blade is tight enough.
21
Safety Measures:
Tighten the wing nut securely enough to prevent from buckling and
breaking.
Steps in Fixing Stock In Metal Vise and Operation Position
25-30 cm
1. Fasten the stock in vise with lay-out line as close as possible to the
end of the used vise jaws.
2. Stand with your feet 25 to 30 centimeters apart and one foot
forward.
3. Lean the body a little forward as shown in the drawing.
22
Steps in Sawing the Stock
1. Start the saw by guiding the blade with the thumb of your left
hand while taking one or two light strokes with your right-hand.
2. Move the saw with steady and even motion of about 40 to 60
strokes per minute.
3. Apply pressure during the forward stroke and release during the
return strokes.
4. Hold the stock with your left hand to avoid cuts and as your saw
with right hand.
Steps in Bending 90o with Ball Peen Hammer
1. Force the metal over the vise jaws using left-hand.

2. Strike it several times near the hand with flat head of a hammer.
23
Steps in Squaring off a 90 o Bend (cont.)
3. Place the metal in the bench vise and tighten strongly.

4. Strike the metal with a flat head of a hammer in the direction of
the arrow indicated.
Circular Bend
1. Place the metal over a pipe or round bar and clamp in a bench
vise.
2. Strike the metal with a glancing blow using the flat head of a
hammer until the desired curve is obtained.
24
 Cold Chisel is used for cutting and chipping cold metals.
The illustration above presents the Two Hands Positioning in cold

chiseling which shows the proper grip in using the tool. For heavy work,
hand gripping of tool should be strong and tight; for fine and small
work, hold the tool lightly.
Observe the manner the person works with the ball peen hammer and
the chisel as shown in the illustration above. A cold chisel will cut
metals only if you strike it with the flat head of a ball peen hammer. The
complete safety protection device and the body position when performing
the task (chiseling) are evidently done.
25
 Wrench is used for loosening and tightening light and heavy nuts
and bolts. There are various kinds and sizes of wrenches designed
according to uses and function. A tool steel on movable jaws.
A repair worker often uses tools to remove and replace damaged parts.
The wrenches are used to tighten and loosen the nut and bolts that hold
the parts in place. Other tools are used to hold parts for cutting, welding
and other works.
26
Wash type of wrench is usually used for only one or two different jobs.
Figure above shows a repair worker using a box of wrench and an open-
end wrench to remove a deck lid bolt in an automobile. The ends of the
wrench are offset (the hand is lower than the handle). In this way, the
worker’s hand is above the surface of any object as the nut of bolt is
turned.
A combination wrench of open-end and a box-end will tell the advantage

of box-end over open lid. Box-end wrench has complete contact with six
points on the bolt head. This completely surrounds the grips of the bolt
head or nut allowing less chances of wrench slippage.
 Screw Drivers
Cross Head Flat Head
Screw drivers are usually made in different sets. This tool is used to
tighten and loosen screws by pushing or pulling screws in a rotating
manner. In the above illustration, a set of standard and Phillips tips of
different sizes are shown.
27
Screw driver is driven by fully turning the blade clockwise motion until
the entire screw removed to the wood and metal. The purpose is to hold
or fix two pieces and by no chances to space apart even opposing force
occurs.
28
SELF-CHECK # 2.1
(Demonstration)
Direction:
Use the checklist below as basis for judging whether you meet the
required competency. Write yes or no on separate answer sheet.
Yes No
1. Can select correct type of blade of a hacksaw.
2. Can move the body a little forward while sawing the
metal.
3. Can apply pressure during forward stroke and release
in return while sawing.
4. Can strike the metal with flat head of a hammer.
5. Can use wrench in loosening and tightening nuts and
bolts.
6. Can use types of screw drivers correctly.
7. Can perform actual operations of hand tools by
following safety practices.
8. Can hold cold chisel properly while hammering with a
hammer.
9. Can follow steps in rounding stock with the use of a
hammer.
10. Can assemble and disassemble properly some
movable hand tools.
Over all: Did the student meet the standard requirements?
29
Information Sheet 2.2
5S
What is 5S?
 It is a systematized approach to organize work areas, keep rules and

standards, and maintain discipline to do good job.
 The practice of 5S develops positive attitude among workers and

cultivates an environment of efficiency, effectiveness and economy.
 It utilizes workplace organization and work simplification techniques

to make work easier, faster, cheaper, safer and more effective.
Japanese English
Seiri Sort
Seiton Systematize
Seiso Sweep
Seiketsu Standardize
Shiketsu Self-Discipline
30
 SEIRI (Sort)
Sort out unnecessary items and dispose them properly.
 Make work easier by eliminating obstacles.
 Provide no chance being disturbed by unnecessary items.
 Eliminate the need to take care of the unnecessary items.
 Prevents accumulation of unnecessary items.
 SEITON (Systematize)
Arrange necessary items in good order so that they can easily pick for
use.
 Classify necessary items into frequency of handling.
 Locate jigs and tools that are used very often near to the point
of use.
 Locate the material at the defined position to ensure “First-in,
First-out”, as well as to make the work easy.
 Store and dies molds together with the specific tools necessary
for this set-up.
 Clearly label machinery, equipment parts, jigs, tools and their
locations so that everything is understandable and visible to
everyone at a glance.
 SEISO (Sweep)
Clean your workplace completely so that there are no dust on the
floor, machinery and equipment.
 To make the workplace clean, safe and comfortable.
 To make it easy to produce quality products.
31
 To check whether the machinery and equipment are in good
condition or not.
 Assign responsible persons to each machine, equipment and
area.
 SEIKETSU (Standardize)
Maintain high standard of workplace organization and housekeeping
at all times.
 To prevent the deterioration of Seiri, Seiton, and Seiso activities.
 To minimize causes that will make the workplace dirty and
uncomfortable.
 To protect workers from dangerous conditions.
 To make the workers happy and vivid giving them a chance to
present their talent and creativity.
 SHITKUSE (Self-discipline)
Do things spontaneously without being told or ordered.
 Seiri, Seiton, Seiso, Shitsuke, these 4S’s are techniques and
actions to make the workplace well-organized.
 Shitsuke is a condition in which all members practice these
4S’s continuously, spontaneously and willingly.
 Shitsuke is the creation of strong cooperation culture filled with
spirit of high productivity through implementation of these 4S’s,
as well as motivation, education and training for all the
members.
 Management should give good examples.
32
Self-Check 2.2
Direction:
Read the instruction carefully. Match column A with column B. Write
letters of the correct answer on the blanks provided before the number.
Use separate answer sheet.
Column A Column B
_____1. standardize A. Clean your workplace
completely so that there is
no dust on the floor,
machinery and equipment.
_____2. sort B. Do things spontaneously
without being told or
ordered.
_____3.self-discipline C. Sort out unnecessary
items and dispose them
properly.
_____4. systematize D. Maintain high standard
of workplace organization
and house keeping at all
times.
_____5. sweep E. Arrange necessary items
in good order so that they
can easily pick for use.
33
Unit of Competency: Use of Hand Tools
Module: Using Basic Hand Tools
LO3: Maintain Hand Tools
1. Routine maintenance of hand tools is undertaken according to
standard operating procedure
2. Hand tools are stored in designated location in accordance with
manufacturers’ standard procedure.
References:
Manufacturing production and Maintenance Departments

By Williams (Quality Tools for Industry Service 1882)
Snap on Catalog 800

(Quality Tools and Service Equipment Copyright 2006 Snap-on
Incorporated)
Welding Technology, 2nd Ed.

Harold Johnson

Larry Jeffus, Harold Johnson
34
Learning Experiences/Activities
Learning Outcome: # 3 Maintain Hand Tools
1) Read the attached Information Answer the Self-check without

Sheet # 3.1 Maintain Hand Tools. referring to the information sheet.
2) Answer Self check # 3.1. Answer the Self-check in the least

possible time allotted.
3) Compare your answer with Assignment sheet will be issued as

answer key. an Advance requirements prior to
learning the next LO.
4) If you failed to meet the 80% of
over again the information sheet.
35
LO3 Maintain hand tools

Introduction:
Hand tools are very important for the welder in welding shops or in
welding productions. The presence of machines and equipment are
equally important with hand tools. The necessity of doing the tasks such
as assembling, dismantling and other related works call for high demand
of our hand tools. Some welders do not follow correct practices of
handling tools. In some cases, they try to force the tool to perform a job
which is not appropriate to its intended use.
A routine maintenance proper storage and occupational health and

safety standard are the controlling device to follow and practice to assure
warranty and safety in all job undertakings.
36
 ROUTINE MAINTENANCE
Maintenance of hand tools and machines are both primordial concerns of

a repair technician in the welding shops and/or in the welding
production. The activities should be on schedule and with proper
coordination with the production people. The term “repair” and
“maintenance” works are two of different meanings. Repair, unusually
focuses on the program of works done in the operation of power plants in
machines that are in trouble of stopping its function. While the term
“Maintenance” means a scheduled or a planned visit of tools or
equipments for inspection and from there, reports and recommendation
developed and next tasks to be decided like in performing such cleaning,
application of lubricants, dismantling and etc.
Some of the simple maintenance activities for hand tools, and the
maintenance schedule should be posted in the readable corner of the
shop.
37
 Lubricating. A task performed in the shop/production. Through
the application of the lubricant substance to the identified items in
parts like barrels, rollers, springs, bearing, bolts and nuts, and
other automotive parts.
 Tightening/Loosening. In an assembly of structures, we have

tools fittings need to tight and loosen and in application to the
metal structures that demand a high risk in safety. Tightening
bolts and nuts and other fittings require procedures and for
standard compliance.
 Hand Sharpening. Some tools are needed to be sharpened. Those

blades of knife, cold chisel, punches and many others. To do
hand sharpening for hand tools requires techniques and
application. In some multi knives cutter, manufacturers produce
knife sharpening system to hold or clamp the blade for ensuring
strong blade to stone contact during sharpening and also provided
with course to fine honing stones. For cold chisel and punches, the
right file-size and grades used for repairing the defective anvil
curve.
 Simple Repair. Repair practices of hand tools still available

anytime. But, to some extent, tools are checked yearly and many
of the hand tools are eligible for condemnation and the whole items
are to be replaced by a new unit. However, there are instances
that minor repair can be performed, like replacement of wooden
handle of a hammer and mushroomed head of a cold chisel.
 Cleaning. Simple process applied to hand tools. The cleaning
approach may differ from one another. For example, cleaning of the
38
rack corners of hand tools by using air vacuum or by a piece of
clothe. Similar process may be applied to identical cleaning
situations.
By piece of cloth By Air vacuum
 PROPER STORAGE OF HAND TOOLS/EQUIPMENTS

(5S Implementation)
 Clearly label machinery, equipment, part, jigs, tools, and their

locations, so that everything is understandable, and visible to
everyone at a glance.
 Don’t pile up jigs, tools, and materials without separators
(shelves). They should be picked up easily.
 Rearrange machinery and equipment to make smooth
production flow, when necessary.
 Maintain the space around the fire extinguishers and
evacuation passages free.
39
Self Check 3.1
LO3 Maintain hand tools
Directions:
Choose the letter of the correct answer. Use separate answer sheet.
1. A maintenance process of moving assembled parts and hand tools
through the use of oil and greases.
a. Simple Repair
b. Lubricating
c. Hand Sharpening
d. Tightening
2. What is considered a minor repair?

a. The task not too long to perform
b. Whole item to be replaced
c. Motor over hauling
d. None of the above
3. Proper storage of hand tools is like simply saying that:

a. Hand tools are placed together in one place.
b. In the tool cabinet with proper labeling
c. In any place in the tool room
d. All of the above.
40
4. “Urgent repair” a term similar to:
a. Maintenance schedule
b. Maintenance Inspection
c. An ordinary routine
d. An immediate repair
5. Don’t pile up jigs, tools and materials without:

a. Label
b. Separator
c. Identification
d. Stamping
41
ANSWER KEYS
Self Check # 1.1
1. F 8. H 15. J
2. N 9. D
3. G 10. M
4. L 11. I
5. C 12. E
6. O 13. B
7. K 14. A
Self Check # 1.2
1. a
2. c
3. b
4. b
5. c
Self Check # 2.1 (Y/N Operation)
1. 6.
2. 7.
3. 8.
4. 9.
5. 10.
Self Check # 2.2
1. d
2. c
3. b
4. e
5. a
Self Check # 3.1
1. b
2. a
3. b
4. d
5. b
42
HIGH SCHOOLS
Unit of Competency: Prepare Weld Materials
Module: 2 Preparing Weld Materials

ACKNOWLEDGMENT
This draft was prepared at the Competency-Based Learning Materials

Development Workshop conducted at the Marikina Hotel, Marikina City on
February 18-22, 2008.
Technology Teachers:
Jimmy P. Ocampo
RESPSCI
Contextual Teacher:
May L. Sangalang
Encoder:
Ma. Eliza R. Rivera/Catherine P. Gonzales
Facilitator:
Mr. Clodualdo Paiton
TESDA Specialist
Mr. Jose D. Gonzales Jr.

Principal III
RESPSCI
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
(RESPSCI)
JIMMY P. DOMINGO
JEFFREY G. MORENOS
BENJIE R. SAN JUAN

SCIENCE
EDNA M. PASAMONTE
MATH
FRANCISCO M. JAVIER
ENGLISH

(RESPSCI)
FACILITATOR :
VICTORIO N. MEDRANO
Principal IV
EDITOR:

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

Evangeline C. Nuesca
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 term……………………………………………………………………………iii
Learning Outcome #1 Set-up Cutting Equipment..……………………….1
 Learning Experiences/Activities………………………………………..2
 Information Sheet #1………….………………………………………..3-6
 Self-Check #1.0……………….………………………………………….7-8
 Operation Sheet # 1.0…….…………………………………………..9-14
 Self-Check #1.1……………………….…………………………………..15
Learning Outcome #2 Cut and Prepare Edge of Materials……..………16
 Learning Experiences/Activities………………………………………………17
 Operation Sheet # 2.1……………………………………………….18-24
 Self-Check #2.1……………………………………………………………25
Learning Outcome #3 Prepare Welding Consumables .…………………26
 Information Sheet # 3.1..….………………………………………..28-31

 Self-Check #3.1…………………………………………………………….32
Learning Outcome #4 Clean Surfaces and Edges..……………………….33
 Information Sheet # 4.1..….………………………………………..35-36
 Self-Check #4.1…………………………………………………………….37
Learning Outcome #5 Prepare Protective Welding Equipment..……….38
 Learning Experiences /Activities..…………………………………..…39
 Information Sheet # 5.1..….…………………………………........ ... 40-41

 Self-Check #5.1……………………………………………………………42
 Answer Key.……………………………………………………………..…43
Welcome to the Module “PREPARING WELD MATERIALS”. This module

contains training materials and activities for you to complete.
The unit of competency “Prepare Weld Materials” 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.
You may already have some basic knowledge and skills covered in this
module.
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 training 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.
Inside 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.
i
Program/Course Shielded Metal Arc Welding (SMAW) NC1
Unit of Competency Prepare Weld Materials
Module Title: Preparing Weld Materials
INTRODUCTION:
This module contains information and suggested learning activities on

Preparing Weld Materials. It includes instruction and procedure on how to
Prepare Weld Materials.
Completion of this module will help you better understand the succeeding
module on Setting up Welding Equipment.
This module consists of five (5) 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.
LO1 Set up cutting equipment;

LO2 Cut and prepare edge of materials;
LO3 Prepare welding consumables;
LO4 Clean surfaces and edges; and
LO5 Prepare protective welding equipment.
Refer to assessment criteria of learning outcomes 1-8 of this module.
PREREQUISITE:
ii
TECHNICAL TERMS
1. Oxy-acetylene is an equipment for cutting and welding outfit requires

compressed oxygen and acetylene gases.
2. Regulator a valve with controls flow of gases for processes such as welding
by oxyacetylene
3. Gauges a device use to indicate the magnitude of pressure in the cylinder.
4. Working pressure gauge is the gauge attached to the regulator which

determines the gas working pressure during cutting.
5. Welding torch is a device used in oxy-fuel gas welding, cutting, brazing,

and soldering directing the heating flame produced by the
controlled combustion of fuel gas.
6. Cutting outfit is a unit of cutting equipment used for cutting metals.
7. Plasma cutting is a process using plasma to transfer an electric arc to

metal. The metal is heated to its melting point by the heat of
the arc and blown away by air.
8. Coupling distance is the gap between the end of the pre-heat cones and the
surface of the material being cut.
9. Gas flow is the amount of gas released from the regulator which passes
through the hose towards the direction of the torch tip.
10. Gas storage an area free from fire hazard. A storage for tanks filled with
proper air ventilation.
11. Gas volume is the amount of pressure gas.
12. Drying oven is an oven where electrodes are baked with a temperature
from 200 0 C – 300 0 C.
13. LP Liquified Petroleum
14. MAPP (R) Methylacetylene Propadiene
iii
Module: Preparing Weld Materials
Learning Outcome LO1: Set-up Cutting Equipment
1. Cutting equipment is set in conformity with acceptable standard.
2. Cutting equipment fittings, connection and the power source (flame) are
checked in accordance with the standard procedure.
References:

By Gower A. Kennedy
Total Auto Body Repair, 3rd Ed.

L.C. Rhone


Education Department, American Welding Society
1
Learning Experiences/Activities:
Learning Outcome # 1 Set-up Cutting Equipment
1. Read the attached Information Answer the Self-check without

Sheet # 1.1 and Operation sheet referring to the operation sheet.
# 1.2
2. Answer Self-checks # 1.1 and Answer the Self-check in the least
# 1.2 possible time allotted.
3. Compare your answer with Assignment sheet will be issued as

answer keys an advance requirement prior to
learning the next operation sheet.
4. If you failed to meet the 80% of
over once again operation sheet
and information sheet.
2
INFORMATION SHEET # 1.1
Introduction:
Preparation of materials prior to welding is just one task to perform in the shop.
The appropriate cutting equipment must be installed and properly used in order
to meet the cutting requirement.
The activity is focused on the set-up of cutting equipment and includes the
accurate mixture of gases applied to all cutting operations.
 Oxy-Acetylene Cutting Equipment
A typical oxy-acetylene cutting and welding outfit

requires compressed oxygen and acetylene gases
that are stored in the cylinders separately. Oxygen
gas is placed in the tall tank and the acetylene gas
is stored in the small tank.
Parts of the basic oxy-acetylene outfit:
1. Oxygen Cylinder - A tall tank cylinder where

oxygen gas is stored.
2. Acetylene Cylinder – A tank of lesser height where

acetylene gas is stored.
3. Regulator (Oxygen) – Separate regulator for oxygen pressure gauge.
4. Regulator (Acetylene) – A separate regulator with acetylene gas pressure

gauge that indicates the direction of the flow towards the torch body.
5. Acetylene Hose (Red) – A type of hose wherein acetylene gas flows towards
the direction of the torch body.
6. Oxygen Hose (Green) – A type of hose wherein oxygen gas flows towards
the direction of the torch body.
7. Safety Chain - A metal chain wrapped around the body of the cylinders
and tied securely in the metal frame stand.
3
 Pressure Regulator
All regulators do the same type of job. They all work in the same principle
whether they are of low or high pressure; single or multiple stages; cylinder,
manifold, line, type with the gas they regulate. The regulator which reduces
high pressure to lower working pressure must be held constant over a range of
flow rates and volumes.
 Working Pressure gauge
Measures pressure gas that flows or is released from the torch body to the
nozzle or tip.
 Cylinder Pressure gauge
A registered gas pressure found in the cylinder.
 Safety release valve
Is made up of a small ball held tightly against a seat by a spring.
 Gauges
Show the working pressure and the other indicates the magnitude of pressure
in the cylinder.
 Regulators
Work by holding the forces on both sides of a diaphragm in balance.
Acetylene cylinder Oxygen cylinder valve

valve
4
There are varieties of inlet or cylinder fittings available to ensure that the
regulator cannot be connected to the wrong gas or pressure (see figure 4-8 A
and figure 4-8 B). A few adaptors are available that will allow some regulators to
be attached to a different type of fitting.
Two most common types:
1. Adapt a left-hand male acetylene cylinder fitting to a right-handed female

regulator fitting or vice-versa.
2. Adapt a female acetylene cylinder fitting to a male regulator fitting.
CUTTING OXYGEN
VALVE LEVER HOSE CONNECTION
CUTTING
OXYGEN TUBE
NEEDLE VALVE
TIP
Cutting Torch
Oxy-acetylene cutting torch is the same as oxy-fuel cutting torch. The assembly
of torch vary in sizes for different types of work. There are small torches for
jewelry work, large torches in heavy plates and special torches for heating,
brazing and soldering. Some uses fuel-air mixture. There are no industrial
standards for tip size, tip threads, or seats. Each style, size, and type of torch
can be used only with tips made by the same manufacturer to fit-in the specific
tank.
MIXER
MIXING CHAMBER
The diagram showing how two gases, the fuel gas and oxygen mixed-up in the
chamber with equal pressure. The two gases are completely mixed before they
leave the tip and create the flame. (Methods of mixing oxygen and fuel gas to
produce flames)
1. Uses equal balance pressures; the gases are mixed in the mixing chamber.
2. Uses a higher oxygen pressure; the gases are mixed in the injection chamber.
5
MIXIER
COIL MIXIING CHAMBER
A diagram showing a metal coil in the oxygen tube spinning the gas ensuring a
complete mixing of gases.
INJECTOR
MIXER
MIXING CHAMBER
VENTURI
A diagram showing an injector mixing system. The injector torch works both
with equal gas pressure or low fuel gas pressures. The injector allows oxygen at
the higher pressure to draw the fuel gas into the chamber, even when the fuel
gas pressure is as low as 26.3 g/cm2. The injector works by passing the oxygen
through a venture which create a vacuum to pull the fuel gas in and then mixes
the gases together. An injector-type torch should be used in a low-pressure
acetylene generator or a low-pressure residual.
6
Self-Check # 1.1
LO1: Set-up Cutting Equipment
Direction: Write the letter of the correct answer in every item. Provide a
separate answer sheet.
1. Injection torches can use fuel gases with pressures as low as:
a. 7 psi (0.49 kg/cm2 )
b. 2 psi (0.14 kg/cm2)
c. 6 oz./in2 (26.3 g/cm2)
d. 9 oz./in2 (39.4 g/cm2)
2. Oxygen and acetylene hoses should be color coded, which from the given
answers is correct.
a. Oxygen green, Acetylene black or red
b. Oxygen green or black, Acetylene red
c. Oxygen green, Acetylene red
d. Oxygen green or black, Acetylene red or black.
3. Considered as a line pressure gauge.
a. Regulator
b. Low pressure gauge
c. High pressure gauge
d. Valve gauge
4. A typical characteristic of a neutral flame.
a. Acetylene and with excess Oxygen

b. Balance of Acetylene and Oxygen
c. Oxygen and with excess Acetylene
d. Acetylene burning in the atmosphere
7
5. OFC is an acronym for:
a. Oxy-fuel cutting
b. Oxy-fused cutting
c. Oxygen fueled cutting
6. The term “cracking” means:
a. Blowing-out of dirt lodged in the valve.
b. Release of gas from the torch valve.
c. Release of gas from the pressure gauge.
d. Release of gas from the torch tip.
Operation Sheet # 1.2
 Procedures in Setting-up a Cutting Torch
1. Secure oxygen and acetylene cylinders to the cart or wall before the removal
of the safety caps.
8
Slots are provided as anchoring Removing the valve protection cap
point for the safety chains on the from the cylinder secured in
welding cart. the cart.
2. After removing the safety caps, stand to one side and crack (open, then
quickly close) the cylinder valves to ensure no dust and/or any other may be
a source for ignition of fire.
3. Visually check all parts for any damage.
4. Attach the regulators to the cylinder valves, and tighten securely with a
wrench.
Installing regulator using a special kind of wrench
5. Attach the reverse flow valves in the gas outlet, and then attach the hose.
9
The reverse flow valve is Tightening of the hose
already attached to the connection.
regulator before attaching
the hose connector.
6. If the torch is a combination-type torch, attach the cutting head.
Attaching the torch flame pipe to the hose
7. Install the cutting tip in the torch.
Typical cutting torch assembly with attached torch tip
8. Before the cylinder valve is opened, back-out the pressure regulating screw
so that the valve opens the gauge back to zero for welding pressure.
10
Turning the adjustable handle to back-out pressure
and turn zero pound on meter gauge reading
9. Stand on the side of the regulator as the cylinder valve is opened slowly.
Opening of cylinder valve to merge in the hose
Note: Oxygen valve is opened all the way until it becomes tight and acetylene
valve is opened not more than half turn.
10. Open one torch valve and then turn the regulating screw slowly until 2 psi
to 4 psi (1 ksi-2ksi) for working pressure gauge.
Turning the adjustable handle of the valve to regulate

the amount of working pressure needed.
11
11. If you are using a combination welding and cutting torch, the oxygen
valve nearest the hose connection must be opened before the flame
adjusting valve of cutting lever will work.
The oxygen valve near the hose connection must be opened,

before the cutting lever will work.
12. Cutting set-up is ready for the next task.
OXYGEN REGULATOR
OXYGEN HOSE
ACETYLENE REGULATOR
ACETYLENE HOSE SAFETY CHAIN
OXYGEN CYLINDER
ACETYLENE CYLINDER
12
 Calibration of the Cutting Equipment
During the set-up and operation of the cutting equipment, there are several
observable things that might occur which need immediate attention. One of
these is the failure of the cutting unit to function well and requires adjustment
and correction. The student will be guided for some of the recommended
practices.
Oxygen and acetylene pressures for different cutting and welding jobs
Tip # Thickness Oxy- Acetylene Oxygen flow

of metal acetylene Flow (cfh)
(mm) Pressure (cfh)
Psi(kpa)
00 0.3 1 0.1 0.1
0 0.7 1 0.4 0.4
1 1.5 1 1 1.1
2 2.3 2 2 2.2
3 3.1 3 8 8.8
4 4.7 4 17 18
5 6.3 5 25 27
6 7.9 6 34 37
7 9.5 7 43 47
8 12.7 8 52 57
9 15.8 9 59 64
10 19.0 10 67 73
Where:
mm- millimeter
cfh – cubic feet per hour
psi – pounds per square inch
The table shows the tip size, thickness of metal, work pressure and the speed.
For cutting, use larger size of tip with corresponding data as shown in the table
above. This information will support the succeeding activities in relation to
cutting of materials.
Check gas leaks
Check gas leaks
13
There is now a pressured gas through out the system. A mixture of soapy water
is applied to all regulators, the hose connection and other fittings to check its
appropriateness.
After checking, gas leaks may occur through the reaction of a soap solution, the
connection has to be tightened properly. If no more leaks are found, reopen the
torch valve.
Caution:
Leaking cylinder valve stem should not be repaired when gas pressure is
present. Turn off the valve, disconnect cylinder and mark or label the defective
unit.
Cracking oxygen and fuel cylinder valves
“Cracking” is one way of blowing out any dirt lodged in the valve. The quick
release and the sudden closing of the valve should be done. This is applicable
for both oxygen and fuel gas.
Caution:
Force the valve of cylinders away from any source of ignition or any object or a
person that might be damaged or harmed by the flame when it is lit.
Checking or cutting tip for leaks
Check the assembled torch tip for a good seal, place your thumb over the end of
the tip, turn on oxygen valve, and spray the tip with a leak detecting selection.
14
SELF-CHECK # 1.2
(OPERATION SHEET)
Direction:
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.
YES NO
1. Can secure Oxygen and Acetylene cylinders to the

cart or wall correctly.
2. Can remove safety caps and crack cylinder valve
properly.
3. Can check all parts for any damage.
4. Can attach regulators to cylinders securely.
5. Can attach flow valves and hoses to the gas outlet.
6. Can install the cutting tip.
7. Can back-out the pressure regulating screw before
opening the cylinder valves.
8. Can adjust the regulating screw to satisfy the
working pressure needed.
9. Can set-up cutting outfit correctly ready for use.
15
Learning Outcome 2: Cut and prepare edge materials.
1. Materials are cut to the specified dimensions and specifications.

2. Tasks are performed in accordance with the work standard.
References:

By Gower A. Kennedy
Total Auto Body Repair, 3rd Ed.

L.C. Rhone

Wielding Inspection Technology

16
Learning Outcome 2: Cut and prepare edge materials
Learning Activities Special Instructions
1) Read the attached
operation sheet # 2.1 and
know to cut and prepare
edge materials.
2) Answer the self check #
2.1 to test your knowledge ● Answer the self check without
on cut and prepare edge looking at the information sheet
materials.
3) Compare your answer on
answer key
4) If you missed some items,
go over this enabling
objective again.
5) When you are ready, you
can proceed to the next
enabling objective.
17
Operation Sheet 2.1
Cutting Materials with Oxy-Acetylene

Introduction:
Metals are formed into structures by assembling or connecting each member
parts through the process of welding. Therefore, the materials of varied sizes
and thickness are cut and shaped with specific measurement and dimension. In
this activity, the student shall develop skills in cutting materials with oxy-
acetylene and discover other cutting outfit.
 Flame Cutting Procedure
TIP ENVELOPE
NEUTRAL CONE
TORCH BODY
Pre-heat flame is properly adjusted and as you have taken all the safety
measures, you are ready to do the actual cutting. You may see how fast cutting
goes, but drills and practices will build confidence.
Using the neutral pre-heat flame, heat the spot where you intend to start until
the flame turns cherry red. The pre-heat flame should be held just above the
metal surface so as to protect pre-heat holes against metal flow back from the
pure cutting oxygen. It is also to keep the torch end away from the heat
reflected by the metal surface.
18
The distance between the end of the pre-heat cones and the surface of the
material being cut is known as the coupling distance. When cutting plates up to
2-76 mm (3 inches) thick and with Mapp ® gas, the coupling distance must be
about 3-25mm (1/8”). For cutting, coupling distance should be increased to get
more heat from the secondary flame cones. Materials (plates) over 305mm thick
(12 inches) should cut using 19.9-31.8mm coupling distance.
 Straight Cutting
The stinger is pure oxygen flow out of the center hole of the cutting tip.
Once it starts, it can The cut should travel fast enough

continue through the so that the top edge does not melt.
metal
19
Once the pre-heated spot is cherry red in color, the cutting oxygen lever should
be slowly depressed. This allows the pure cutting oxygen to attack the metal,
removing the metal by flame pressure and oxidation by allowing the cutting
oxygen to flow out slowly, the spot will not be cooled by the fresh oxygen stream.
Cooling could happen if a large gush of oxygen is blown on to the heated spot all
at once. The visible oxygen cutting stream coming from the center hole of the tip
when the cutting oxygen valve is opened is called the stinger.
Manual hand cutting of sheet cut starts with the torch drawn over the gloved
hand. The welder must be comfortable and be free to move the torch along the
line to be cut. It is a good idea for the welder to get into the position and
practice the cutting movements a few times before lighting the torch.
Steady hands are required in manual oxy-acetylene cutting especially when

even straight cuts are needed. Once the cut starts, the torch must be moved
steadily in the direction of the cut.
20
Profile of Flame-cut Plates
The physics of a cut, as the cut progresses along a plate, records of what is
happening during the cut which is preserved along both sides of the key. This
record indicates to the welder what is correct or incorrect with the pre-heat
flame cutting speed and oxygen pressure.
 Bevel Cutting
When bevel cutting is required, the torch head must be inclined in the position
to the preheated metal along the top edge of the parts. This allows the metal to
form the required bevel angle. The tip should be kept high enough so that the
outlet holes are away from any splashing molten metals. Bevel cuts in the
production are usually done by a radiograph. This produces a more accurate
cut with less gas.
21
Position the four pre-heat holes for A bevel cut made by oxy-acetylene
a fixed cut. cutting
 Other cutting equipment/machines for plates and pipes

After performing task on oxy-acetylene and fuel gas cutting, there are other
designed for cutting equipment/machines that produces mass cutting of
materials at the largest welding production segment in the workplace the
illustration/drawing showed, the cutting machines with work descriptions for
the students to comprehend more.
Portable flame-cutting machine
A machine cutting torch sometimes referred to as a flow pipe operates in a

similar manner to a hand cutting torch. The machine cutting torch may require
two oxygen regulators, one for each. Pre-heat the oxygen and the other for the
cutting oxygen stream. The addition of a separate cutting oxygen supply allows
the flame to be more accurately adjusted. It also allows pressure to be charged
during a cut without disturbing the other parts of the flame.
22
A cutting machine can make several complex cuts at one time. Automatic
torches are set the same for pre-heating as the manual torches. However, the
motor drives the automatic torch along the line of cut at the speed it could
easily regulated by a variable control mechanism.
When the starting point on the joint is cherry red, the cutting oxygen is engaged
for a continuous flow of oxygen. Then, the torch travel running mechanism is
moved at a speed necessary for a smooth key edge. The torch head on most
automatic cutting torches can be tilted to several angles for marking different
bevel cuts. Using these machines, many different and complex cuts are made
evenly.
Radius rods are also available for automatic cutting torches for circle cutting.
Multiple cutting heads are commonly used for automatic cutting machines,
especially where many pieces of the same shape are required.
AIR SUPLY
REGULATOR
TORCH WITH LEAD
WORK PIECE
INPUT POWER
WORK CABLE SPARE PARTS KIT
Plasma is a gas that has been heated to a high temperature and converted
(ionized) so that the gas becomes electrically conductive. The plasma cutting
process uses this plasma to transfer an electric arc to the metal. The metal is
heated to the melting point by the heat of the arc and is blown away by air.
Parts of Plasma Arc cutters

 Power cables that works for 210-220 volts.
 The work table.
 Torch with head cable
 Air supply regulator valve.
23
The plasma torch tip has several openings. These openings help operate the
torch. (A) Shows how air keeps the torch on each side of the metal cool and
keeps the hot metal from spattering. (B) Allows the air to enter when the arc
struck between the metal and the electrode is producing a pilot arc. When the
tip is brought close to gas, it produces a stiff constricted cutting arc. This
delivers a high concentration of heat to a very small area.
24
SELF-CHECK #2.1
Direction:
Use the checklist below as basis for judging whether you meet the required
competency? Write YES or NO as your answer in a separate sheet.
YES NO
1. Can adjust pre-heat flame correctly.
2. Can heat the spot and recognize the cherry red
color.
3. Can adjust cutting coupling distance based on
thickness of metals to be cut.
4. Can start hand-cut with the torch drawn over the
gloved hand.
5. Can move free and comfortably while cutting.
6. Can cut bevel by using correct angle.
7. Can check cutting outfit before cutting.
25
LO3 Prepare Welding Consumables
1. Electrodes are maintained sound and acceptable.
2. Consumable gasses are specified and controlled in accordance with the

job requirements.
3. Electrodes are selected in accordance with the job requirements.
References:

By Gower A. Kennedy

Wielding Inspection Technology

26
Learning Outcome 3: Prepare welding consumable
1) Read the attached information sheet
# 3.1 and know to prepare weld
consumables.
2) Answer the self check # 3.1 to test

your knowledge on preparing and ● Answer the self check without
selecting weld consumables. looking at the information sheet
3) Compare your answer on answer

key.
4) If you missed some items, go over

this enabling objective again.
5) When you are ready, you can

proceed to the next enable objective.
27
Information Sheet # 3.1
LO3. Prepare Weld Consumables
Introduction:
All welding consumables used in the welding production will be maintained and
controlled to remain, then supplies sound and acceptable. Handling of various
electrode types and different gasses used in welding fabrication and production
that requires critical post weld inspection needs special attention in performing
task, like how to prepare these consumables in order to produce quality and
acceptable welds. Electrodes are also selected correctly in accordance with
electrode specification and welding procedure requirements. Therefore, the
student/welder will have to develop their skills and knowledge on the
maintenance and control of all consumables, as well as, the correct choice of
using them.
Some recommended acceptable practices for the maintenance, selection and

control of welding consumables are presented.
 Baking/Drying oven
Welding production and fabricators that usually accepts welding jobs are under
the weld code provisions. First and foremost is to come out with a standard plan
for electrode control and maintenance. Electrodes are kept in the stockroom for
quite sometime because of the influence of atmospheric conditions. These
electrodes have to pass to drying or baking process. All electrodes for baking will
be removed from a sealed plastic and will be placed inside the oven in a
classified manner (based on types and diameter size of the electrode) through
the oven shelves and marked accordingly. After loading, set the drying oven
temperature from 200 oC – 300 oC maintaining the temperature for a period of
two hours. Once the maximum of drying (2 hours) is reached shut-off the oven.
28
 Holding oven
After drying, remove the electrodes from the oven and store them in the storing
oven with a maintained temperature of 150 oC plus/minus 20 oC. The electrode
must stay from the oven without reducing the temperature as per requirement.
The electrodes are maintained and controlled under the supervision of a
storekeeper, as he is responsible for the issuance of these electrodes to the
welders and fitters.
 Portable oven
Normally welders perform welding activities in the shop. In cases where welding
should be done on a worksite, he should provide himself with a portable oven
sometimes called welder’s oven. The welder’s oven should be plug to a power
source. The temperature that should be maintained is 70 oC plus/minus 10 oC.
The unused electrodes shall be returned to the storing oven after the end of
day’s work.
29
Types of Electrodes, Diameter size, Current (amp) and Power Source
Mild Steel Electrodes
Electrodes Diameter Size Current Power Source
E-6010 3.25 mm. 90 A – 120 A DC +
E-6013 3.25 mm. 90 A – 120 A AC, DC +
E-6011 3.0 mm. 80 A – 110 A AC, DC +
E-6012 3.0 mm. 80 A – 110 A AC, DC -
Low Hydrogen Electrodes

E-7015 3.25 mm. 90 A – 110 A DC +
E-7016 3.25 mm. 110 A – 130 A AC, DC +
E-7018 3.25 mm. 110 A – 130 A AC, Dc +
Stainless Steel Electrodes

E-308 -16 3.25 mm. 90 A – 110 A AC, DC +
E-316-15 3.0 mm. 80 A – 90 A DC+
E-316-15 3.25 mm. 90 A – 110 A DC +
E-310-16 3.0 mm. 80 A - 90 A AC, DC +
Low Alloy Steel Electrode

E- 8018 3.25 mm. 110 A -130 A AC, DC +
E-9016 4.0 mm. 140 A – 180 A AC, DC +
E-9015 3.25 mm. 110 A – 130 A DC +
E-8016 3.0 mm. 90 A – 110 A AC, DC +
Different types of electrodes, size, current, and power source are the
recommendable data for electrodes that can be the basis for selection. Only
four (4) types of electrodes are reflected in this information, but this will help
you understand their proper use and their existing specification. Further
studies and search of knowledge about electrodes, you will discover many
things about welding consumables.
30
The industrial gases must be stored in a separate storage room and must have
proper air ventilations. The place should be equipped with fire hazard signs and
also a unit of fire extinguisher to be installed in location near the series of filled
full tanks for accessibility. Cylinders must be provided with protection caps to
prevent the valves from being broken. Defective tanks, fitters and others must
be separated and marked defective.
Leaking fuel gas cylinders should be out of the building. Place the cylinders in
an open space and put a danger sign. Slowly release the pressure until the gas
is totally removed.
31
Self-Check # 3.1
LO3: Prepare Welding Consumable
Direction:
Choose the correct answer from the series given for every item. Write the letter
only. Use a separate answer sheet.
1. An electrode oven with a maintaining temperature of 70 oC +/- 10.

a. Drying oven
b. Holding oven
c. Portable oven
d. Heating oven
2. An oven which holds a temperature of 150 oC +/- 20.
a. Holding oven
b. Portable oven
c. Heating oven
d. Baking oven
3. Mild steel electrode.
a. E–316-15
b. E-7018
c. E-9015
d. E-6013
4. Low alloy electrode.
a. E-316-16
b. E-9016
c. E-7015
d. E-6012
5. To prevent the cylinder valves from breaking down, these should be
provided with:
a. Cover
b. Protective caps
c. Wrap with a chain
d. Hazard sign
32
LO4. Clean Surfaces and Edges
1. Surfaces and edges are clean based on the required specifications.
2. Equipment and tools are identified for having clean surfaces and edges.
3. Tasks are performed in accordance with the industry requirement and
safety.
References:
By Gower A. Kennedy

Welding Hand book

Welding Industries of the Philippines, Inc.
33
Learning Outcome 4: Clean surfaces and edges
1. Read the attached
information sheet # 4.1
and know to cut and
prepare edge materials.
2. Answer the self check # ● Answer the self check without

4.1 to test your knowledge looking at the information sheet
on cut and prepare edge
materials.
3. Compare your answer on

answer key
4. If you missed some items,

objective again.
5. When you are ready, you

enable objective.
34
LO4. Clean surfaces and edges
Introduction
Proper cleaning of metal surfaces and edges must be in mind before any fit-up
and tacking took placed. There must be an acceptable cleaning procedures
applied in the surface of the plates and pipes before welding joints. The cleaning
of surfaces and edges is considered one step for achieving quality on the
preparation of materials.
Below are acceptable practices in the preparation of surfaces and edges of the
materials.
Edge
A
Edge
B
Figure # 1
Illustration: Figure 1
Edge A need to grind smoothly and squarely so that no gaps appear on the fit-
up and the surface of the other plate to form Tee-joint. These two sides of the
plate are placed together and see to it that no gaps are found, then tightly
assemble. The contaminants that are found in the fit-up must be cleaned and
removed for welding safety.
35
Safety measures:
Before tacking, air tight fit-up must be checked so as to avoid air pockets in the
fitted edge or surface.
The drawing showing Fig. A and B plates are beveled cut. The gas cutting
results are not properly done, the surface is not smooth and with irregular line
cut caused by incorrect cutting. The surface must be smoothened with the use
of a grinder until such appearance is accepted. The surface of any dirt and
contaminants such as rust, oil, grease, water, scale and old paint must be
removed with appropriate tools and solution.
After root face is made and smoothened on the beveled surface, the two plates
are placed together facing each other with an approximate gap before tacking
may be done. This kind of preparation is applicable for plates and pipes for the
different types of materials. The root face must not exceed the maximum of
3mm thick from wall thickness of 6mm to 20 mm.
36
Self-Check # 4.1
LO4. Clean surfaces and edges.
Direction:
Chose the letter of the correct answer. Use separate answer sheet.
1. Why do cleaning of surface and edges of metal so important?

a. Provide good appearance of the cut material
b. Obey because it was instructed to do so.
c. Dirt and other substance detrimental to weld quality.
d. Very easy to fit-up joint.
2. Removal of metal scales, old points, rust in metal is easy with the use
of:
a. Grinder
b. Scraper
c. Chipping hammer
d. Metal sand paper
3. Why air tight fit-up necessary for Tee-joint preparation?

a. Dirt or contaminant will not stock inside
b. Avoid gas pockets associated from the unfit fit-up.
c. Rust attacked easily
4. Beveled joint is considered “critical” in the category of weld. This means that:
a. Weld joint is necessary for radiography
b. Weld joint is for visual
c. Weld joint with no inspection
d. All of the above.
5. Root face of beveled joint will not exceed a maximum of:

a. 3 mm
b. 5 mm
c. 3 mm
d. 6 mm
37
LO5. Protective Welding Equipment
1.Personnel Protective Equipment (PPE) is applied in accordance with the

occupational safety requirements.
2. Welding Safety practices and protective equipment are checked if in
accordance with the safety standard.
References:

By Gower A. Kennedy

Welding Hand book

Welding Industries of the Philippines, Inc.
38
Learning Outcome 5: Prepare Protective Welding Equipment
1. Read the attached
Information Sheet No. 5.1
2. Answer the self check

No. 5.1 to test your
knowledge on how to ● Answer the self check without
prepare protective looking at the information sheet
welding equipment.
3. Compare your answer

on answer key.
4. If you missed some items,

objective again.
5. When you are ready, you

enabling LO.
39
LO5: Prepare Protective Welding Equipment
Introduction:
The general work clothing is worn by each person working in the shop. All of
these clothing’s may not have frayed edges or holes. In addition to the clothing,
extra protection is needed for each person who is in direct contact with the
materials. Tongs and pliers are used in picking-up hot metals.
Leather Jacket Leather Leather Welding shield Face shield

Apron welding
gloves
STEEL
Safety Welding cap Safety boots Respirator Full-leather

glasses sleeves
Additional extra protection aside from general clothing are: leather jacket,
apron, welding gloves, welding shield, face shield, safety gloves, welding cap,
safety boots, respirators, and full leather sleeves. Full clothing protection will
practically protect the whole body of the welder.
40
For your safety, it is proper to know the uses of your protective gadgets while
working with metals.
o Safety is a reminder to anticipate all of the precaution
possible danger in every welding job.
o Safety glass protects the eyes from weld sparks and always
worn by worker in the shop.
o Welding shield cover the face and allow welder to see
legibly on weldment while performing welding.
o Face shield is a transparent hard plastic covering the
eye while clearing and grinding.
o Welding cap worn by welder as an additional safety for
head and hair.
o Resparator is an equipment that prevent us from fumes and
odor of industrial waste.
o Leather apron a front body protection device while welding.
o Leather jacket worn by welder during welding
difficult position.
o General clothing the usual personal clothing of a welder such as
over-all, welding apron or welding jackets
o Safety Gloves worn by welders to protect the hands in
heat and burns.
o Welding Goggles protective glasses set in a flexible frame
that fit snugly against the face.
o Welding shoes is made of chrome leather and protects our feet
from spattering.
41
Self-Check # 5.1
LO5
Direction:
Read the instruction carefully. Match column A with column B. Write the letter
of the correct answer on the blank provided before the number. Use separate
answer sheet.
_____ 1. Face shield a. Hand protective device

_____ 2. Respirators during welding.
_____ 3. Leather Jacket b. Head and hair protection
_____ 4. Welding cap while welding.
_____ 5. Welding shield c. Feet and legs protection
_____ 6. Leather apron d. Worn always in shop during
_____ 7. Safety gloves tour of duty.
_____ 8. Safety boots e. Additional protection that
_____ 9. Full leather sleeves covers body and shoulder.
_____ 10. Safety glass f. Added protective device in
front side of the body.
g. To be worn in the area with
toxic fumes.
h. Face and eyes protection.
i. Use to protect eye and face
while grinding and cleaning
weld.
j. Shoulder legging sleeves.
k. Picking hot metals.
42
ANSWER KEYS
Self Check # 1.1
1. c 4. b
2. c 5. a
3. b 6. a
Self Check # 2.1 (operation)
1.
2.
3.
4.
5.
6.
7.
Self Check # 3.1
1. c
2. a
3. d
4. b
5. b
Self Check # 4.1
1. c
2. a
3. b
4. a
5. a
Self Check # 5.1
1. i
2. g
3. e
4. b
5. h
6. f
7. a
8. c
9. j
10.d
43
HIGH SCHOOLS
Unit of Competency: SET UP WELDING EQUIPMENT
Module No.: 3 Module Title: SETTING UP WELDING EQUIPMENT

ACKNOWLEDGMENT

February 18-22, 2008
Technology Teacher:
Mr. Ronie A. Mojica

General Mariano Alvarez Technical HighSchool
GMA Cavite
Facilitators:
Mr.Cloduado Paiton.
TESDA Spicialist

Principal III
RESPSCI
Contextual Teacher:
May L. Sagalang
AFG Bernardeno Memorial Trade School
Lias Marilao,Bulacan
Encoder:
Maria Eliza R Rivera
Catherine P. Gonzales
Christo Rey Abad

Education.
REFERENCES:
Welding Technology
Second Edition
Gower A. Kennedy
Metal Works I
SEDP Series
Industrial Technology Welding Guide & Fabrication Shop

Ismael V. Palabric
2
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
(RESPSCI)
JIMMY P. DOMINGO
JEFFREY G. MORENOS
BENJIE R. SAN JUAN

SCIENCE
EDNA M. PASAMONTE
MATH
FRANCISCO M. JAVIER
ENGLISH

(RESPSCI)
FACILITATOR :
VICTORIO N. MEDRANO
3
Principal IV
EDITOR:

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


Education.
4
TABLE OF CONTENTS
Page
How to Use this Module ................................................................................... i

Introduction .................................................................................................... ii
Technical Terms ............................................................................................. iii
Learning Outcome 1 ........................................................................................ 1
 Learning Experiences/Activities ............................................................. 2
 Information Sheet 1.1 ......................................................................... 3-4
 Self-Check 1.1 ....................................................................................... 5
 Self Check 1.2 ....................................................................................... 6
Learning Outcome 2 ........................................................................................ 7
 Information Sheet 2.1 ............................................................................ 9
 Self Check 2.1 ..................................................................................... 10
 Operation Sheet 2.1..............................................................................11
 Self check 2.1……………………………………………………………………..…12
Learning Outcome 3………………………………………………………………………..13
 Learning Experiences/Activities…………………………………………………14
 Information sheet 3.1………………………………………………………………15
 Self check 3.1………………………………………………………………………..16
Answer Key ………………………………………………………………………………… 17
5
Welcome to the Module “SETTING UP OF WELDING

EQUIPMENT”. This module contains training materials and activities for
you to complete.
The unit of competency “SET UP OF WELDING EQIPMENT”

contains the knowledge, skills and attitudes required for a welding
course.
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. Follow 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.
You may already have some or most of the knowledge and skills
covered in this module.
If you can demonstrate competence to your teacher in a particular

skill, talk to your teacher so you do not have to under go 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 may 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.
Inside this module you will find the activities for you to complete
followed by 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 independently at your own pace or with minimum supervision or
help from your teacher.
i
Unit of Competency SET UP WELDING EQUIPMENT
Module Title SETTING UP OF WELDING EQUIPMENT
INTRODUCTION:
This module contains information, suggested learning exercises and

activities on Setting up of welding equipment it includes instruction and
procedure on how to set up welding equipment.

succeeding module on Welding weld on carbon steel plates.
This module consists of three (3) learning outcomes .Each learning out
come contain activities supported by instruction sheets. Read the
information sheets and answer self-check and activities provided to asses
your competency by your teacher that you have acquired the knowledge
necessary to perform the skill portion of the particular learning outcome.
Upon completing this module, report to your 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: Upon completion of the module

the students should be able to:
LO1 Set Up Welding Machine
LO2 Set Up Welding Accessories
LO3 Set Up Welding Positioners and Fixtures
Refer to assessment criteria of learning outcome# 1-3 of this module.
PREREQUISITE:
None
ii
TECHNICAL TERMS
AC/Alternating Current - kind of electricity which reverses its

direction periodically for 60 cycles current. The
current goes in one direction 60 times in the same
seconds, so the cycle changes its direction in 120
times inone second.
DC/Direct Current - it is a current with a definite or specific sign or

symbols positive and negative.
DC Generator – direct current and of a none flexible control of arc

characteristics and a stable current.
AC Transformer – alternating current welding source provide safe

welding voltage
Power Source – an output power of welding machine that supply

during welding. It might supply welding AC or DC
power.
Transformer Rectifier – are designed to provide either AC or DC

outputs.
Electrode – is a metal rod having approximately the same

decomposition as the base metal to be welded.
Base Metal – is a metal to be welded also known as stock and parent

metal.
Molten Pool – is a location of molten metal produce by heat of welding

process.
Slag – is a nonmetallic by product of welding which attaches itself to the

bead.
Bead - is a ridge of deposited and melted formed at a welded joint.
Flux - is a liquid or powder used in soldering, brazing or welding to

dissolve and remove oxides that might weaken bond
between solder and metal being joined.
Unit of Competency Set Up Welding Equipment
Module SETTING UP OF WELDING EQUIPMENT
Learning Outcome # LO 1
SET UP WELDING MACHINE
ASSESSMENT CRITERIA
1. Parts and functions of welding machine parts are identified based

on manufacturer’s manual
2. Setting of welding machine is followed according to power source
requirements:
• AC power source
• DC power source
• AC & DC power source
REFFERENCES:
Welding Technology
Second Edition
Gower A. Kennedy
Metal Works I
SEDP Series

Ismael V. Palabrica
Welding Principles and Applications

Larry Jeffus and Harold Johnson
1
LEARNING EXPERIENCE/ACTIVITIES
SET UP WELDING MACHINE
LEARNING ACTIVITIES SPECIAL INSTRUCTIONS
1. Read the attached information

sheet 1.1 identifying the
components of the welding
machines and its power source.
2. Answer self check 1.1 to test your • Try to answer the self check
knowledge on the components of without looking at the information
the welding machine and its sheet.
power source.
3. Compare your answer to feedback
4. If you missed some of the items go

over this learning outcome.
5. When you are ready, you can

proceed to the next learning
outcome.
2
LO1 : SET UP WELDING MACHINE
WELDING POWER SOURCE
The function of a power source is to provide the voltage necessary to

maintain an arc between the electrode and the work piece and a sufficient
supply of electric to melt the surface of the work piece and the end of the
electrode.
Power sources may supply direct current (DC) or alternating current

(AC) to the electrode. AC is the most common power supply due to the lower
cost and simplicity of the welding machine, however, DC has some
advantages. The DC arc is noticeably more stable when using certain types
of electrodes DC is better for sheet metal.
BASIC PARTS OF WELDING POWER SOURCE
The basic parts of a power source are shown in Fig. 1.1 the function of
these parts.
• Current adjusting wheel is rotated either clockwise or counter

clockwise until the marker in the indicator is set to the desired
current.
• Current range indicator provides the current output reading of the

welding machine.
• Primary windings terminals provide cable connection from the main

power supply.
• Secondary windings terminals provides electrode holder cable and

return cable connections to the welding machine.
3
TYPES 0F POWER CODES
• AC TRANSFORMERS
Alternating current welding
power sources (FIG.1-2) are step
down transformers, which
provide safe welding voltage. The
welding current supplied by the
secondary circuit of the
transformer is controlled by a
variable resistor in this circuit
or by altering either the number
of turns or the magnetic leakage
between the primary and
secondary windings.
Transformer welding machines

are less complex and expensive
than other types.
• DC GENERATORS
The direct current generators

have the advantages of a more
flexible control of arc
characteristics and stable
current. A close-coupled electric
motor, or an internal combustion
engine rotates the armature in
the generator. Varying the current
flowing in the generator field
windings controls welding current
• TRANSFORMER RECTIFIER
Transformer rectifier are designed
to provide either DC or AC
outputs. With no moving parts
like generators, they share with
the transformer the advantages of
quiet operation, convenience and
lower cost.
4
SELF CHECK 1.1
DIRECTION: Encircle the letter of the correct answer for each of the
following questions:
1. What process uses a length of flux-coated electrode which provided filler

material metal and atmospheric shielding?
a. Shielded Metal Arc Welding

b. Arc Welding
c. Welding
d. Shielded Welding
2. It is an insulated handle like tool use to hold the non-coated part of the
electrode.
a. Electrode
b. Ground Clamp
c. Electrode Holder
d. Electrode Cable
3. When the electrode melts during welding process, what is being deposited
on the base metal?
a. Arc Stream
b. Bead
c. Molten Pool
d. Flux Coating
4. It is defined as the depth of fusion beads?
a. Arc Stream
b. Molten Pool
c. Slag
d. Penetration
5. The outer covering of the deposited bead is refer to as?
a. Arc Stream
b. Molten Pool
c. SLAG
d. Penetration
5
SELF CHECK 1.2
I. Identify the labeled parts of the welding power source.
II. What is the main function of the welding power source?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
III. Describe the following power sources.
A. AC Transformer
B. DC Generator
C. Transformer Rectifier
6
Learning Outcome 2
SET UP WELDING ACCESORIES
ASSESSMENT CRITERIA
1. Welding cables/wires and other accessories are identified based on

functions and uses.
2. Setting/connectivity of cables and other accessories are performed in
accordance with manufacturer’s manual.
REFFERENCES:
Welding Technology
Second Edition
Gower A. Kennedy
Metal Works I
SEDP Series

Ismael V. Palabrica

7
LEARNING OUTCOME 2. SET UP WELDING ACCESSORIES

sheet 2.1, operation sheet 2.1 and
set up welding accessories.
2. Answer self check 2.1 and 2.2 to

test your knowledge on set up
welding accessories.  Answer the self check without
looking at the information
3. Compare your answer on answer sheet.
keys.
4. If you missed some items, go over

this learning outcome again.

proceed to the next enable
objective.
8
LO#2 SET UP WELDING ACCESSORIES
WELDING ACCESSORIES
A welding machine consists

of a power source with the
accessories attached to it.
Without these accessories, the
welding machine will not
perform its function.
Before attempting to install

a welding machine, you should
be familiar with its accessories
required before using the
machine
Welding Cables
The welding cables
conduct from the power
source to the work (Fig. 2-
1). The electrode cable is
connected to the electrode
holder. The return cable is
connected to the return
clamp.
Electrode Holders
The electrode holders are

used to grip the electrode.
The most common types
are the collet and the
pincher. The electrode in
the collet-type is inserted
in the head and grip by
twisting the handle (Fig.
2-2. In the pincher type,
the electrode is simply
grip in its spring-loaded
jaws (Fig. 2-3)
Electrode holders
should be relatively light,
fully insulated and sturdy
enough to withstand
continual handling
9
SELF CHECK 2.1
1. Name the accessories and tools shown below.
A.
B.
C.
D.
E.
F.
10
OPERATION SHEET 2.1
MODULE TITLE: SETTING UP WELDING EQUIPMENT

LO2: SET UP WELDING ACCESSORIES
OBJECTIVE: The students will set up welding accessories.
CONDITIONS OR SITUATIONS FOR HE OPERATION:
1. The tools, welding accessories and equipment must be properly

placed and checked according to the manufacture’s manual.
2. The procedure of setting up must be based on manufacturer’s

manual.
EQUIPMENT, TOOLS AND MATERIALS NEEDED:
AC/DC WELDING MACHINE

Welding Cable
Electrode/Return Cable
Ground Clamp
Hexagonal Key
Set of Wrenches
PROCEDURE:
1. Prepare for set up

• Read the operation
manual provided by
the manufacturer to
guide you in
installing, operating
and maintaining the
welding machine
(Fig. 2-1-1)
2. Connect
• Electrode holder to the
electrode cable (Fig. 2-1-
2) and the return clamp
to the return cable.
• Power cable to the main
electrical supply as shown
in the electrical diagram
(Fig. 2-1-4) consult a
qualified electrician for
primary circuit.
• Clamp the return
cable to the welding
table (Fig. 2-1-5)
11
SELF CHECK 2.1
LO2: SET UP WELDING ACCESSORIES
Direction:
Given a welding power source and accessories, set up a welding

machine. Assess your performance by comparing it to the criteria listed in
the Performance Standard.
PERFORMANCE STANDARD
Performance Level
Performance Criteria
YES NO NA
1. Is the electrode holder connected to the

electrode cable?
2. Is the return clamp connected to the return

cable?
3. Are the electrode cable and return cable

connected to the secondary windings terminal?
4. Are the power cables connected to the primary

windings terminal?
5. Are the power cables connected to the main

electrical supply?
6. Is the return cable clamp to the welding table?
If all the items received a YES or NA response,

You can take the Performance Test
12
Learning Outcome 3
Welding Positioner, Jigs and Fixtures
ASSESSMENT CRITERIA
1. Welding positioner, jigs and fixtures are set up in conformity with the
requirements.
2. Work items/materials are protected from strong winds, drafts and
rainfalls.
REFFERENCES:
Welding Technology
Second Edition
Gower A. Kennedy
Metal Works I
SEDP Series

Ismael V. Palabrica

13
LO3 SET UP WELDING POSITIONERS AND FIXTURES
LEARNING ACTIVITIES SPECIAL INSTRUCTION

sheet 3.1– welding positioner and
fixtures.
2. Answer self check 3.1 to test your • Try to answer self check without
knowledge on the welding looking at the information sheet.
positioners and fixtures.
3.Compare your answer to

feedback/answer key.
4. If you missed some of the items go

over this learning outcome
14
WELDING POSITIONERS
Each welding position will be covered more fully under the various
welding techniques in each case, a better weld may be produced if the parts
are positioned differently and or held while being welded.
Various types of both manuals and electric revolving positioners, or

weldment holders, are either available through manufacture’s
manufacturers or can be produced in the shop. Many of these are design to
allow the weld to be made in the flat position. (Fig. 3.1.1) Regardless of the
type of positioner, it should be constructed to hold the desired weld firmly
without along complicated set up time. It should also be constructed so that
most weld joints can be easily approached by the welder without any tiring
motions.
Fig. 3.1.1 A rotating positioner

used for casting and
odd shaped parts.
Fig. 3.1.1a Manually operated

welding positioner.
WELDING FIXTURES
Devices used to speed up

production and lower the cost per unit
are called fixtures when many similar
parts are to be drilled with accuracy,
the parts can be stacked and drilled at
the same time while held by a fixture
(fig. 3.1.2). The fixtures is designed so
that the holes are placed properly.
Fixture should be constructed to

ensure quick and accurate placement of
parts in the fixture, whether for
welding, drilling, cutting, or other
purposes. Ease of removing the finished
part from the fixture is also very
important. Also allowances must be
made for distortion.
15
SELF CHECK 3.1
Direction: Discuss the following very briefly:
1. What is the main function welding fixtures?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
2. What is the purpose of welding positioner?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
16
ANSWER KEY
SELF CHECK 1.1
1. a
2. c
3. b
4. d
5. c
SELF CHECK 1.2
A. ventilation
B. current adjustment
C. power connector
SELF CHECK 3.1
1. The main purpose of welding fixture are to speed up production, lower

the cost per unit and some part are used for accurate drilling.
2. The purpose of the welding positioner is to hold and secure the base
metal while in welding operation, it should also be constructed to hold
the desired weld firmly without a long complicated set up time.
17
HIGH SCHOOLS
Unit of Competency: SURFACE WELDING ON CARBON STEEL PLATES
Module Title: LAYING OUT BEADS ON CARBON STEEL

Module No.: 4
PLATES
ACKNOWLEDGMENT

February 18-22, 2008.
Technology Teacher:
Val A. Canarias (Welding)

Gen. Mariano Alvarez Technical High School
GMA, Cavite Region IV-A
Resource Person:
TESDA Specialist

Principal III
RESPSCI
Contextual Teacher:
May L. Sangalang
(English)
Encoder:
Ma. Riza B. Zamora

Education.
ACKNOWLEDGMENT

MODULE WRITERS:
WELDING
JIMMY P. OCAMPO
(RESPSCI)
JIMMY P. DOMINGO
JEFFREY G. MORENOS
BENJIE R. SAN JUAN

SCIENCE
EDNA M. PASAMONTE
MATH
FRANCISCO M. JAVIER
ENGLISH

(RESPSCI)
FACILITATOR :
VICTORIO N. MEDRANO
Principal IV
EDITOR:

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


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

Introduction .................................................................................................... ii
Technical Terms ..........................................................................................iii-iv
Learning Outcome 1 Strike an Arc………..…………………………… .................... 1
 Information Sheet 1.1 ............................................................................ 3
 Self-Check 1.1 ....................................................................................... 4
 Information Sheet 1.2 ....................................................................... 5-17
 Self-Check 1.2 ..................................................................................... 18
 Operation Sheet 1.3…. ...................... ………………………………………..19
● Activity Sheet 1.4….……………………………………………………………20-22
 Self Check 1.3….……………………………………………………………………23
Learning Outcome 2 Deposit Straight Bead……….……………………………..….24
 Learning Experiences/Activities ………………………………………………..25
 Information Sheet 2.1.…………………………………………………………… 26
 Self Check 2.1………………………………………………………………………27
 Information Sheet 2.2..……………………………………………………… 28-29
 Activity Sheet2.1. ……………………………………………………………….30-32
 Self-Check 2.1..………………………………………………………………………33
 Activity Sheet 2.2 ……………………………………………………………….34-35
 Self-Check 2.2………………………………………………………………………..36
 Information Sheet 2.2..…………………………………………………………37-38
 Pre test/Post test ……………………………………………………………….39-41
 Answer Keys…….. ………………………………………………………………42-43
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.

module.
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.
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
Unit of Competency SURFACE WELDING ON CARBON STEEL PLATES
Module Title: LAYING OUT BEADS ON CARBON STEEL PLATES
INTRODUCTION:

surface weld on carbon steel plates. It includes instruction and procedure on
how laying out beads on carbon steel plates.

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.

completion.
Upon completion of the module the students should be able to:
LO1 Strike an Arc; and

LO2 Deposit Straight Bead.
PREREQUISITE:
ii
TECHNICAL TERMS
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.
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.
Bare Electrode a filler metal electrode use in arc welding, consisting of
a metal wire with no coating on its surface.
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.
Base or Parent Metal The metal that is to be welded or worked.
Weldment an assembly or structure whose component parts are

joined by welding.
Weld Bead it is a deposit of filler metal from a single welding

pass.
Stringer Bead/Straight Weld Bead a type of weld bead with appreciable

transverse oscillation or side to side movement.
Face of a Weld expose surface of the weld.
Electrode Angle it is an angle from the electrode which is

perpendicular to
the base metal.
Arc Length is a normal distance of approximately equal to the

diameter
of the electrode.
Puddle part of the weld that is melted (molten) due to heat of

welding.
Pass refers to the layer of beads which has been deposited

in the base metal.
Ripple is the shape/appearance of the beads which results
from the movement of the electrode.
iii
Crater is the flattened portion produced when the electrode
comes in contact with the base metal
Slag refers to the outer covering of the deposited bead when

the electrode melts during the welding process.
Blowholes are the cavities produced by gas entrapment during

the solidification of the weld metal.
Penetration refers to the depth of fusion of beads with the base

metal
Joint is the point where two or more parts meet
Welding Position the stock to be welded may assume any of the main
welding positions, namely, flat, horizontal, overhead
and vertical.
Spatter in arc and gas welding, it is the metal particles
expelled during welding and which do not form part of
the weld.
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.
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.
Coalescence the growing together or growth into one body of the
materials being welded.
Fusion Welding the melting together of filler metal and base metal, or
of base metal only to produce a weld.
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.
iv
v
Program/Course SHIELDED METAL ARC WELDING (SMAW) NC-1
Unit of Competency Weld Carbon Steel Plates
Module WELDING CARBON STEEL PLATES
Learning Outcome 1: Strike an Arc
1. Weld procedure in striking arc is applied according to weld standard.

2. Methods of striking an arc are applied accordingly.
REFERENCES:
Welding Technology
2nd Edition
Gower A. Kennedy
Welding Guide
Fabrication Shop
Ismael V. Palabrica
Metal Works 1
SEDP Series
Industrial Technology
Basic Manual Metal Arc Welding

National Training Center
for Technical Education and Staff Dev.
1
Learning Outcome No. 1: Strike an Arc

Note: Answer the pretest before
you read this module

sheet 1.1/1.2 Methods of
Striking an Arc
2. Perform the operation sheet 1.3  Answer the self-check without

looking at the information
3. Perform the activity sheet 1.4 sheet.
4. Answer the self-check

1.1/1.2/1.3/1.4 to test your
knowledge on method of
striking an arc.
5. Compare your answer on the

answer keys.
6. If you miss some of the items go

over this information sheets.

proceed to the next LO.
2
INFORMATION SHEET #1.1
Strike an Arc
1. Identify the methods of striking an arc.

2. Prepare the safety gears needed for striking an arc.
Methods of Striking an Arc:
1. Scratching Method. It is done by scratching the electrode to the base

metal like scratching a match. As the electrode scratches the base metal,
an arc will be formed. It is the simplest method for most beginners.
Figure 2. Scratching Method
2. Tapping Method. It is done by moving the electrode downward until it just

taps the base metal, then bringing the electrode up slightly to form an arc with
the same distances to the diameter of electrode.
Figure 1. Tapping Method
3
SELF-CHECK #1.1
Directions:
Encircle the letter of the correct answer. Write your answer in a separate sheet.
1. What method in striking an arc is recommended for the beginners?

a. Tapping method
b. Scratching method
c. Any of these
2. In the symbol E-6013; letter “E” stands for:
a. Electric
b. Energy
c. Electrode
3. Eyes can be protected during welding operations by using:
a. Gloves
b. Leggings
c. Goggles
d. Apron
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
4
Shieded Metal Arc Welding

Shielded metal arc welding is defined as arc welding with covered
electrodes manually controlled by the welder, without automatic or semi-
automatic replacement of electrode. This process uses a length of flux coated
electrode which provided filler metal and atmospheric shielding.
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.
Strike an Arc
SELECTING ELECTRODE
Objectives: The student 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.
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
5. Welding Position. Some electrodes are preferable to others for off-
position welding
6. Specification and Service Condition. Job specifications may indicate

class of electrodes to be used: Otherwise the service requirements (e.g.
desired tensile strength, ductility, corrosion or abrasion resistance, etc.)
should be considered
7. Practicability of Heat Treatment. If shop facilities preclude the

employment of pre-heating or post-heating for critical job, the use of low
heat input electrodes is the only recourse.
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
Common ways of classifying electrode (by the covering on the electrode).

1. Bare-Electrode
2. Dusted Electrode
3. Flux-Dipped Electrode
4. Extended Electrodes and Covering
The common electrode width sizes are:

3/32”Ø
6
1/8”Ø
5/32”Ø
3/16”Ø
7/32”Ø
1/4 ”Ø
The common lengths of electrodes are:
14-inches
18-inches
Recommended Current Settings for E-6013 Electrode

Electrode Diameter Ampere Arc Volt
(in mm)
1.58 20-40 17-20
1.98 25-50 17-20
2.38 30-80 17-21
3.17 70-120 18-22
3.96 120-170 18-22
4.76 140-240 20-24
5.55 170-300 21-25
6.35 200-350 22-26
7.93 250-450 23-27
Table # 1 Current Setting for E-6013 Electrode
7
ELECTRODE CODING
Electrode End Color Spot Color Group Color
Classification
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
AMERICAN WELDING SOCIETY CLASSIFICATION NUMBER OF

ELECTRODE
Mild Steel and Low Alloy Electrode AWS-A5.1-89 and A5.1-89. All mild
steel electrode and low alloy electrode are classified with 4 and 5 digits number
prefixed by “E”
First two (or three) digits - tensile strength (Psi) stress relieved as welded.
Third of Fourth - position of welding.
1. All position (flat, horizontal, vertical, over head position)

Horizontal (flat position only)
8
Fourth Digit
Type of Coating Welding Current
1 Cellulose potassium AC, DCSP, DCRP
2 Titania sodium AC, DCSP
3 Titania potassium AC, DCSP, DCRP
4 Iron powder titania AC, DCSP, DCRP
5 Low hydrogen sodium DCRP
6 Low hydrogen potassium AC, DCRP
7 Iron powder oxide AC, DC
8 Iron powder, low hydrogen AC, DCRP, DCSP
0 Low hydrogen, iron powder DC reverse polarity
Table #3 Classification Number of Electrode
Example: E- 60- 1- 0
Electrode
Tensile strength
60,000 PSI Power Supply
AC or DC
Welding position
1= all position Flux Coating
2= horizontal & flat only cellulose
3= flat only titania
Bonding Silicate rutile
Sodium iron powder
Potassium
9
ELECTRODE CLASSIFICATION
Electrode Type of coating or Capable of Type of Current

Classification covering producing
Number satisfactory weld in
position
E-45 series-minimum tensile strength of deposited metal in non-stress relived condition

45,000 Psi
E-4510 Sulcoated F.V.OH.H not specified generally
E-4520 Light coated H. fillet F DCSP-electrode negative

E-60 series- minimum- tensile strength of deposited metal in non-stress relieved
condition 60,000 Psi
-6010 Hi. Cellulose sodium F.V.OH.H use DC reverve polarity
E-6011 Hi. Cellulose potassium F.V.OH.H use AC. DCRP
E-6012 Titania Sodium F.V.OH.H use AC or DCSP
E-6013 Titania Potassium F.V.OH.H use AC or DCSP
E-6015 Lo-hydro sodium F.V.OH.H use DCRP only
E-6030 Hi-iron oxide H. fillet F. use AC. DC both polarity
E-70 series-minimum strength of deposited metal in stress relieved condition 70,000 Psi
E-7010 Hi. Cellulose sodium F.V.OH.H use DCRP
E-7011 Hi.Cellulose potassium F.V.OH.H use AC. DCSP
E-7020 i-iron oxide . fillet F. use AC. DCSP
E-7030 Hi-iron oxide F use AC. DC both polarity
E-80 series-minimum tensile strength of deposited metal in stress relieved condition 80,
E-8010 Hi.Cellulose sodium F.V.OH.H Use DCRP
E-8011 Hi. Cellulose potassium F.V.OH.H Use AC. DCRP
E-8015 Lo-hydro sodium F.V.OH.H Use DCRP
E-8020 Hi-iron oxide F.V.OH.H use AC. DC both polarity
E-8030 Hi-iron oxide H. fillet F use AC. DC both polarity

Table #4 Electrode Classification
Note: Sod. – Sodium, Pot- potassium, Ox.-oxide
10
MILD STEEL ELECTRODE
E-6011
Best for all position, deep penetration, x-ray quality, light slag, medium
deposition rate.
SPECIFICATION AWS Class E-6011
USES: For pipe welding, and structural work, shipbuilding and repair joints
required deep penetration galvanized steel, small diameter wire on straight
polarity for sheet metal, and where quality welds and excellent ductility is
required.
PROCEDURE: For general use employ AC or DC straight or reverse polarity.

For short arc, stay ahead of the puddle and use slight whipping motion. For to
bottom use no whipping nor weaving technique.
CHARACTERISTICS: This has slight amount of iron powder as an arc

stabilizer. These decrease spatter and make the arc easier to control.
TIP COLOR: Blue

WELDING CURRENT: Both AC and DC (-), striking voltage ( ) 40V
MECHANICAL PROPERTIES: Tensile Strength. (60,000 – 71,000) Psi – pound
per square inch.
CHEMICAL PROCESS C – 0.10 % P – 0.015 %
Mn – 0.45 % S – 0.035 %
Si – 0.20 %
11
E-6012
All position except vertically downwards, moderate penetration, excellent
quality, and medium slag high deposition rate.
USES: For fabrication of structural work, storage tanks, railroad cars, poor fit
up and for joints not requirement deep penetration.
PROCEDURE: For general use, electrode negative work positive. Use AC or DC

straight polarity. For flat, angle electrode to 10º to 15º from the perpendicular.
For vertical, reduce heat from flat position. From bottom to top use whipping
motion. From top to bottom use fast travel speed staying below the puddle.
For overhead we employ slight whipping motion.
TIP COLOR: White

WELDING POSITION All except vertical down
WELDING CURRENT both AC and DC (-) striking v. ( ) 50V.
MECANICAL Tensile strength – (67,000 – 70,000) psi
PROCESS
CHEMICAL PROCESS C – 0.07 %
P – 0.02 %
Mn – 0.35 %
S – 0.02 %
Si – 0.20 %
APPROVALS American Welding Society

AWS, ASTM, ASME, Lloyd’s Register od Shipping
12
E-6013
All position, mild penetration, good quality, heavy slag.
USES: For fabrication of structural work, poor fit up and joint not requiring
deep penetration..
PROCEDURE: For general use. Employ AC or DC straight or reverse polarity.

For flat, electrode angle to 10O - 15O from the perpendicular. Average arc length
with higher heat than E-6011 electrodes. For vertical reduce the heat from flat
position. Starting from the bottom to top, use fast travel speed staying below
puddle.
CHARACTERISTICS: A slag shielded type electrode. Its quick solidifying slag

and quiet arc gives an outstanding performance in vertical and overhead
welding. T as a very shallow penetrating arc which suit galvanized steel, and
poorly fitted joints without tendency of burning through. The bead has a
smooth and finely ripple appearance which eliminate post welding. Easy slag.
TIP COLOR: Brown

WELDING POSITION: All position
WELDING CURRENT: -AC or DC (+) striking V ( ) 50V
MECHANICAL PROPERTIES: Tensile strength – (74,100 psi)
13
LOW HYDROGEN ELECTRODE
E – 7018
Low hydrogen type electrode for mild, low alloy, and problems steels. All
purpose electrode.
USES: For joining high sulphur, low alloy high carbon, and cold rolled steel.
Structural fabrications of flanges, angles, channels iron pipes lines, and
shipbuilding, pressure vessels, bridges, hot and cols cast iron welding.
PROCEDURE: Clean weld area, removing all dirt grease, rust. Rounded the
sharp corners. Keep a medium arc length. Keep (1” – 2”) long bead length must
not exceed twice electrode diameter. Cool each bead slightly before proceeding.
Keep base metal at lowest temperature. Chip off slag between passes.
CHARACTERITICS: Electrode a basic coating for build up work. High

deposition rate because of high efficiency. Procedure a strong, tough and
machinable. Can withstand 260-300 Brinell Hardness.
TIP COLOR: None

WELDING POSITION: All position including vertical down.
WELDING CURRENT: AC or DC (+), striking V ( ) 70V
MECHANICAL PROPERTIES: Tensile strength – (83,000 – 88,500) psi
CHEMICAL PROCESS
C – 0.09 %
P – 0.02 %
Mn – 1.10 %
S – 0.02 %
Si – 0.70 %
14
STAINLESS ELECTRODE
E-308 L-16
Electrode with extremely low carbon for welding steel of A.I.S.I. types 301 302,
304L and 308.
SPECIFICATION AWS CLASS E-308 L-16
PROCEDURE: Clean weld area, Section of 10 gauge or thinner can be square

but weld. Bevel heavier gauges to 60 degrees. For long seam utilize accurate fit
up. Tack of clamp at short intervals to minimize warping. Keep short arc
length. In filling groove, deposit several light beads only. To preheat warpage,
we skip or set back technique. Use fast travel speed because stainless steel
expand 50% more and conduct heat 50% slower than milder steel.
USES: For welding stainless steel of the 18/8 Cr Ni Extra low carbon type
Medium hard overlays on steel requiring complete corrosion resistance.
Applicable to brewery, dairy, chemical, oil refining and food product.
CHARACTERITICS: Electrode with extremely low carbon content which gives

the weld a very high resistance against inters crystalline corrosion. Produce
finely rippled weld which can be polish.
TIP COLOR: Yellow

WELDING POSITION: All position
WELDING CURRENT: AC or DC (+), striking V ( ) 70V
MECHANICAL PROPERTIES: Tensile strength – (78,000 – 81,000) psi
CHEMICAL PROCESS Cr – 0.17 % - 20% Ni – 10% - 12%
Mn – 1.10 % C – 0.02%
Si – 0.30 % P – 0.02%
S – 0.02%
15
Welding Flux
1. Relationships of arc, base metal, electrode and 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.
2. How flux covered electrode works
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
a) Determine the electrodes size and amperage range because this

are use to dictate the lens protection required.
b) 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
lease one number darker, or check the seal on your lens.
Electrode Amperage Shade #

Size
- 30 to 75 8
1/16 – 5/32 75 – 200 10
3/16 – 1/4 200 – 400 12
5/16 – 3/8 400 + 14
c) A rule of thumb is that the larger the diameter of the electrodes,

the higher the number required for a lens shade.
16
17
ASSESSMENT (SELF-CHECK) 1.2
Directions: Encircle the letter of the correct answer for each of the following:
Write your answer in a separate sheet.
1. The coating of electrode is sometimes called:
a. Flux
b. Shield
c. Covering
d. All of these
2. The electrode which has no coating is called:
a. Shielded
b. Bare
c. Dusted
d. Dipped
3. The symbol E-6013;60 means
a. Welding Position
b. Tensile Strength
c. Power Supply
d. Flux Coating
4. The third digit in the symbol E-6013; 1 stands for
a. Welding Position
b. Tensile Strength
c. Power Supply
d. Flux Coating
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
18
OPERATION SHEET 1.1
Procedures in striking an arc:
Objective: The student 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.
Equipment, Tools and Materials:
Welding machine on its accessories
 Electrode
 Safety gears
 10mm x 50mm x 100mm steel plate
 Chipping hammer
 Steel brush
Procedure:
1. Prepare the 10mm x 50mm x 100mm steel plate
2. Prepare the safety gears on welding area.
3. Inspect the connections of the welding machines.
4. Set the welding machines to the recommended current setting.
5. Strike the arc either tapping or scratching method.
6. When the spark appears withdraw the electrode quickly and maintain the
proper arc length approximately the same weight as the diameter of electrode.
7. Maintain the arc for at least 5-7 seconds.
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 5-7 seconds
19
ACTIVITY 1.4
TARGET:
To strike and maintain an arc for 30 seconds with an arc length not to
exceed 4mm at an angle of approximately 75.
MATERIALS/SUPPLIES
1. mild steel plate, 6mm x 75mm x 150mm

2. electrode E6013, 3.2mm. diameter
TOOLS AND EQUIPMENT
1. AC welding machine with accessories

2. chipping hammer
3. steel brush
4. welding helmet/shield
5. welding gloves
6. welding apron
WELDING PROCEDURE
1. Prepare the tools, equipment
and materials needed.
2. Set up the welding machine

and set the current to 100 amps.
3. Wear protective clothing and

equipment.
4. Clamp the bare end of the

electrode in the holder.
5. Position your body in such a

way that your head will be
cleared of the column of fumes
arising from the arc (Fig. 28)
6. Strike the arc by either of the

two methods.
20
6.1 SCRATCHING
6.1.1Point the electrode downwards at

an angle of approximately 75 and the
striking end about 30 mm above the start
position on the plate surface
6.1.2 Strike the end of the electrode

on the plate surface similar to
striking a match.
6.1.3 When a spark appears, withdraw the electrode quickly and draw an arc
of approximately 6 mm.
6.1.4 Move the electrode to the start position and then reduce the arc length to
a distance equal to the diameter of the electrode.
6.2 TAPPING
6.2.1 Point the electrode

downwards at an angle of
approximately 75 and the
striking end to about 15
mm above the start
position on the plate
surface.
6.2.2 Lower the electrode on

the plate surface.
21
6.2.3 When a spark appears,
withdraw the electrode
quickly to an arc length equal
to its diameter.
NOTE: If the electrode welds to the plate, quickly

snap the electrode to one side.
If the electrode does not release, switch off the

welding machine and detached the electrode
with a cold chisel.
22
In performing striking an arc you should be able to hold the arc for 30
seconds. The arc length should not be bigger than 4mm at angle of
approximately 75.
1. Perform the tapping method.

2. Perform the scratching method.
23
Unit of Competency Weld Carbon Steel Plates
Module WELDING CARBON STEEL PLATES
Learning Outcome 2: Deposit Straight Bead
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
REFERENCES:
Welding Technology
2nd Edition
Gower A. Kennedy
Welding Guide
Fabrication Shop
Ismael V. Palabrica
Metal Works 1
SEDP Series

National Training Center
for Technical Education and Staff Dev.
Welding
24
Learning Outcome No. 2: Deposit Straight Bead

sheets 2.1, activity sheets 2.2,
Deposit Straight Bead
2. Answer the self-check 2.1,

Deposit straight bead to test
your knowledge. o Answer the self-check
without looking at the
3. Compare your answer on the information sheet.
answer keys.
4. If you missed some of the items

go over this information on
sheets.
NOTE: At the end of this L.O.
answer the post test.
5. If you pass, then proceed to the

next LO.
25
Base Metal Preparation
Objectives/purpose:
1. Prepare the metal to be welded
2. Determine the requirements in base metal preparation
Requirements in base metal:

1. The base metal must be clear
2. The base metal must be free from oil, grease & paints
3. The plate must have been checked for its type.
DIRT
OIL
PRINT
GREASE
Poor Parent Metal Preparation
Well Prepared Metal Preparation
26
SELF CHECK 2.1
YES NO
1. Did you remove the foreign materials on the plate? ________ ________
2. Did you check types of metal? ________ ________
3. Did you wear safety gears in preparing the plate? ________ ________
4. Did you clean the area after preparing the plate? ________ ________
5. Did you use the right cleaning tools ? ________ ________
27
Weaving Motions
Objectives:
1. Identify the weaving motions.

2. Determine the weaving motion to be used.
3. Determine the electrode to be used
Requirements:
1. The plate must be prepared properly.

2. The composition of electrode must be the same as the base metal.
Weaving Motions:
Weaving is a method or technique used to increase the width and volume of

bead.
1. Crescent
2. Figure of 8
3. Rotary
28
29
ACTIVITY SHEET 2.1
STRINGER BEAD IN FLAT POSITION
TARGET
To weld stringer bead flat position. The bead should be straight, of even
height and width and with fine ripples.
MATERIALS/SUPPLIES
1. Mild steel plate, 6mm x 75mm x 150mm (1 pc)

2. Electrode E6013, 3.2 mm diameter
TOOLS AND EQUIPMENT

2. chipping hammer
3. steel brush
5. welding gloves
6. welding apron
7. welding goggles
PLAN/ILLUSTRATION
PROCEDURES:
1. Prepare the tools, equipment and materials needed.
2. Set up the welding machine.
30
NOTE: Check the electrical connections before switching on the
machine. Set current between 90-140 amperes.
3. Wear suitable protective clothing.
4. Lay the plate flat in a

welding table where you are
comfortable as possible
when welding commences.
5. Strike an arc on the first line of the plate.
NOTE: 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 75 travel angle
and 90 work angle.
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.
31
NOTE: Quickly withdraw the electrode if you want to stop or reach
the end of the line.
9. Clean the weld using a chipping hammer and steel brush.
NOTE: Use clear goggles when chipping.

The direction of chipping should be away from you.
10. Inspect the weld run.
NOTE: The weld should be straight, of even thickness and width

with fine ripples.
The thickness of the bead should be about one-half of the

electrode diameter.
11. Finish all the laid out lines.
NOTE: Avoid the same mistakes you did on your first try.
32
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.
THE PASSING MARK IS 10 POINTS
MARKING TABLE
CRITERIA MARKS SUBTRACTED
1. Straightness
2. Width of bead
3. Height of bead
4. Ripple
TOTAL MARKS SUBTRACTED
FINAL POINTS = 20 - Total Marks Subtracted
20 - ______________________
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.
33
ACTIVITY SHEET 2.2
WEAVE BEAD IN HORIZONTAL POSITION
TARGET
To weld weave bead in horizontal position. The bead should be straight,
of even height and width fine ripples.
MATERIALS/SUPPLIES
1. mild steel plates, 6 mm x 75 mm x150 mm (1 pc)

2. Electrode, E6013, 3.2 mm diameter
TOOLS AND EQUIPMENT

2. chipping hammer
3. steel brush
4. welding gloves
5. welding apron
PLAN/ ILLUSTRATION
34
WELDING PROCEDURES
1. Clamp the plate in

the positioner with
the edge of the plate
parallel to the ground
ground.
NOTE: Make sure that the
height of the plate is
just enough for you to
feel comfortable when
welding commences.
2. Strike an arc on the first line of the plates

(see the plan/illustration)
3. When the arc is established, position the

electrode at 75 - 85 travel angle and
95 work angle, and an arc length of 2-3
mm.
4. Deposit the weld bead by

manipulating the electrode using a
circular weaving motion.
NOTE: Maintain the width of bead at

8 mm and the arc length at 2-
3mm.
5. Continue welding until you
reach the end of the line.
6. Clean and inspect the weld.

7. Finish welding all the laid out lines.
35
ASSESSMENT (SELF-CHECK 2.2)
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.
THE PASSING MARK IS 15 POINTS
MARKING TABLE
CRITERIA MARKS SUBTRACTED
1. Straightness
2. Width of bead
3. Height of bead
4. Ripple
TOTAL MARKS SUBTRACTED
FINAL POINTS = 20 - Total Marks Subtracted
20 - ______________________
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.
36

Common Cause and Cure for weld defect
CAUSES CURE/REMEDIES
1. Arc Blow- is caused when magnetic  Reduce current or suitable
forces present in DC build up lines of polarity
magnetism around the arc and cause  Change current to AC
the arc to blow wildly forward or to
outside, and spatter badly.
- It can also be caused by high
amperage and the major problem
areas are thick plates, corners, deep
groove and the start and finish of
joints.
2. Pinholes and porosity  Use shorter arc length and
- Both pinholes and porosity can be keeping the puddle molter for a
caused when length is to long and longer period so that the gasses
travel is too fast. may boil out before the metal
- Other causes for pinholes and freezes.
porosity are faulty electrodes incorrect  Use dry electrode and clean the
polarity, surface conditions of the base surface of the base metal.
metal or high sulphur and other
impurities.
3. Undercutting  Reduce the current and
- It is usually caused by too high shortening the arc length.
current of too long arc length.  Use smaller diameter of
- It is also caused by improper electrode
electrode angle manipulation or too  Change the electrode angle
fast a welding speed.
4. Spatter  Reduce current
- Too high current  Shorten arc lenght
- To long arc lenght
5. Incomplete penetration  Check the joint carefully,
- Faulty jointdesign inducting the root opening, root
37
- Insuffucient welding current face dimension and the groove
- Large electrode used force angle.
- Too fast welding speed  Increase the weld current
 Reduce the welding speed
 Use smaller diameter of
electrode
38
PRE TEST/POST TEST ON LAYING OUT BEADS ON CARBON STEEL
PLATES
LOI: STRIKING AN ARC
1. What is the basis for identifying the recommended arc length to be

maintained when striking an arc?
a) diameter of filler metal
b) diameter of the flux
c) type of electrode
d) thickness of the base metal
2. This type of welding rod is used mostly in root penetration.

a) E6013
b) E6011
c) E7018
d) E7020
3. What is the recommended travel angle and work angle in striking an arc
in flat position?
a) 65° - 75°, 90°
b) 75° - 85°, 95°
c) 70°, 90°
d) 60°, 85°
4. What is the recommended welding position in the electrode E6011?
a) flat position only

b) horizontal position only
c) vertical and overhead position
d) all of the above
5. What is the recommended angle in striking an arc in horizontal position?
a) 65° - 75°, 90°

b) 75° - 85°, 95°
c) 70°, 90°
d) 60°, 85°
6. Below are examples of weaving motion except:
a) crescent motion
b) figure 8 motion
c) square motion
d) linear motion
39
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
9. Below is an example of a rutile electrode:
a) E6013
b) E6011
c) E6010
d) E7011
10.Below is an example of a cellulosic electrode :
a) E6013
b) E6011
c) E7018
d) E6012
11.The growing together or growth into one body of materials being welded is
called.
a) coalescence
b) spatter
c) fusion welding
d) bead
12.A joining process produces a coalescence of materials by heating to a

melting point, with or without the use of filler metal is called.
a) oxyacetylene gas cutting

b) sawing
c) grinding
d) welding
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
40
14.The function of flux in an electrode is:
a) stabilize the arc

b) forms a gaseous atmosphere which protect the weld pool
c) to provide a means of welding alloy to the weld metal
d) all of the above
15.The key to maintain a stable arc in welding is:
a) correct electrode size and electrode angle

b) correct current
c) correct arc length and travel speed
d) all of the above
LO 2: DEPOSIT STRINGER BEAD
16 – 20 Enumerate at least 5 weaving motion in welding.
Labeling: Identify the parts of a welding process (21 – 30)
41
ANSWER KEY
PRE TEST AND POST TEST: Key to correction for Module # 4 which is
Surface Welding on Carbon Steel Plates
LO 1 Striking an Arc
A. Multiple Choice
3. a
4. b
5. c
6. d
7. b
8. d
9. b
10. d
11. a
12. b
13. a
14. d
15. a
16. d
17. d
LO 2 Deposit Stringer Bead

A. Enumeration
18. circular weave

19. crescent weave
20. square weave
21. figure 8 weave
22. V weave
B. Labeling
1. base metal/parent metal

2. weld metal
3. slag
4. arc length
5. flux covering
6. filler/core metal
7. electrode
8. welding gases
9. penetration depth
10. molten pool
42
Self Check # 1.1
23. b
24. c
25. c
26. b
27. a
Self Check # 1.2
1. a
2. b
3. b
4. a
5. a
43
HIGH SCHOOLS
Unit of Competency: FIT UP WELD MATERIALS
Module No.: 5 Module Title: FITTING UP WELD MATERIALS

ACKNOWLEDGMENT

February 18-22, 2008.
Technology Teacher:
Benjie R. San Juan

Community Vocational High School
Masipit, Calapan City Oriental Mindoro
Resource Person:
TESDA Specialist

Principal III
RESPSCI
Contextual Teacher:
May L. Sangalang
(English)
Encoder:

Education.
ACKNOWLEDGMENT

MODULE WRITERS:
WELDING
JIMMY P. OCAMPO
(RESPSCI)
JIMMY P. DOMINGO
JEFFREY G. MORENOS
BENJIE R. SAN JUAN

SCIENCE
EDNA M. PASAMONTE
MATH
FRANCISCO M. JAVIER
ENGLISH

(RESPSCI)
FACILITATOR :
VICTORIO N. MEDRANO
Principal IV
EDITOR:

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


Education.
TABLE OF CONTENTS
Page

Introduction .................................................................................................... ii
Learning Outcome 1 Perform Tack Welding……………………….. ................... …1
 Learning Experiences/Activities…..……………………………………………….2
 Information Sheet 1.1…………………………………………… .................... 3-4
● Operation Sheet 1.2……………………………………………… ................... 5-6
 Self Check 1…………………………………………………………… .................. 7
Learning Outcome 2 Weld Butt Joint (Closed) in Flat & Horizontal Position…..8
 Learning Experiences/Activities…..……………………………………………….9
 Operation sheet 2.1..……………………………………………………………10-11
 Self-Check 2.1………………………………………………………………………..12
 Operation Sheet 2.2……………………………………………………………..13-14
 Self Check 2.2….……………………………………………………………………..15
Learning Outcome 3 Weld Butt Joint (Open) in Flat & Horizontal Position……16
 Learning Experiences/Activities…………………………………………………..17
● Information Sheet 3.1……………………………………………………………18-19
 Operation Sheet 3.2.…………………………………………………………….20-21
 Self Check 3.2…………………………………………………………………………22
 Operation Sheet 3.3.…………………………………………………………….23-24
 Self Check 3.3…………………………………………………………………………25
 Pre-Test/Post-Test……………………………………………………………….26-27
 Answer Keys…………………………………………………………………………..28
Welcome to the Module “FITTING UP WELD MATERIALS”. This module

contains training materials and activities for you to complete.
The unit of competency “FIT UP WELD MATERIALS” contains the

knowledge, skills and attitudes required for Shielded Metal Arc Welding
(SMAW) required to obtain the National Certificate (NC) level I.

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.
module.
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.
i
Unit of Competency Fit up weld materials
Module FITTING UP WELD MATERIALS
INTRODUCTION:
This module contains information and suggested learning activities

on Fitting up Weld Materials. It includes instructions and procedure on how
to Fit up Weld Materials.

succeeding module on Repairing Weld.

you perform the instructions, read the information sheets and answer the
self-check and activities provided to ascertain to yourself and your teacher
that you have acquired the knowledge necessary to perform the skill portion
of the particular learning outcome.
Upon completing this module, report to your 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.
LO1 Perform tack welding

LO2 Weld butt joint (closed) in flat and horizontal position
LO3 Weld butt joint (open) in flat and horizontal position
Refer to assessment criteria of learning outcomes # 1-2 of this module.
PREREQUISITES:
ii
TECHNICAL TERMS
Tack Weld a weld (generally short) made to hold parts of a

weldment in proper alignment until the final welds
are made.
Electrode is another name for welding rod
Correct Current is the amount of current used based on diameter

size of electrodes. Electrodes manufacturer
recommend current appropriate for the size of
electrodes.
Arc Strike is caused by striking the arc either scratching or

tapping method.
Single Pass pertain to one pass weld from the joint.
Layer Pass a multiple passes weld which applied to groove

and fillet weld.
Pass a single longitudinal progression of a welding

operation along a joint or weld deposit. The result
of a pass is a weld bead.
Backing are materials (metal, asbestos, carbon) place at the

root side of the weld to facilitate the welder in
obtaining a sound and good root penetration, maybe
strips, backing rings (for pipes) and etc.
Close Butt Joint joining two pieces of metal with no gap to its edges.
Open Butt Joint joining two pieces of metal having gap to its edges
equal to the diameter of the electrode you are using.
iii
iv
v
Learning Outcome 1:
Perform Tacking
1. Tack welding is performed in accordance with the welding procedures.

2. Metals are prepared for tacking based on acceptable welding
requirements.
REFERENCES::
Welding Technology
2nd Edition
Gower A. Kennedy
Welding Guide
Fabrication Shop
Ismael V. Palabrica
Metal Works 1
SEDP Series

National Training Center for Technical Education and Staff Dev.
Welding
1
Learning Outcome 1. Perform Tack Welding
Note: Answer the pre test before you

read this module.
1.) Read the attached Information
Sheet 1.1, Operation Sheet 1.2
in performing tack welding.
2.) Answer the self-check no. 1.1  Answer the self-check without
to test your knowledge on tack looking at the information sheet.
welding.
3.) Compare your answer on
answer keys.
4.) If you missed some items, go
over this enabling objective
again.
5.) When you are ready, you can
objective.
Note: Answer the post test after you
finish this module.
2
Perform Tacking
Identify the two kinds of tack weld
 Information Sheet
In carrying out some welding operation, very often the pieces have to
be tack welded. Tack welds are simply short sections of weld beads
measured ¼” to ½” long used to maintain the proper root opening between
the two sections of metals being welded (These tack welds are spaced along
the seam and must be firmly fused into the joints.)
TACK WELD
10 mm
3mm GAP
Tack welded plates with 3mm gap
KINDS OF TACKING
1. Permanent Tacking is a type of tack weld measured at about ¼” up

to ½” length. It is used fir up temporarily the two pieces of heavy
metal being joined.
2. Semi-permanent Tacking is a tack weld done only in a very short

bead. It is used to fit up temporarily the two light pieces of metal to be
joined.
3
3. Bridge Tacking is a method of tacking using stiffeners or backing
plate to keep both plates aligned.
In performing tacking weld you must consider the following:
 Correct Electrode. The choice of electrode involves such items; as

position of the weld properties of the base metal, diameter of electrode,
types of joint and current value without the right choice of electrode it is
almost impossible to get the results desired, regardless to the welding
technique used.
 Correct Arc Length. As a rule, the length of the arc should be

approximately equal to the diameter of the electrode. For example, an
electrode 1/8” in diameter should have arc length of about 1/8’
 Correct Electrode Angle and Speed of Travel. Upon tack welding, the
welder should maintain a stable/uniform speed on the portion of the
metal to be tacked weld together with proper travel angle and work angle.
 Correct Current. The welder must consider the current setting in order
to have a good performance. If the current is set too high, the electrodes
melt too fast and the molten pool is large and irregular on the other
hand. If the current is set too low, there is no enough heat to melt the
base metal and the molten pool will be small. The result fill up will be
irregular in shape. More current is required for thick and heavy pieces
than for light thin sections.
● Properties of the Base Metal. A top quality weld should be as strong as

the parent metal. This means that the electrode to be used must produce
a weld metal with approximately the same mechanical properties as the
parent metal.
4
OPERATION SHEET 1.1
Perform Tacking
TARGET: The student should perform tack welding in accordance with the
requirements of Welding Procedure Specification (WPS) and should be
visually and dimensionally acceptable.
Perform Tacking weld
Materials/Supplies
 Mild steel plates 6 mm x 75 mm x 150 mm (2 pcs)
 Electrode E6013, 3.2 mm diameter
Tools and Equipments:

 Welding machines with accessories
 Welding helmet
 Clear eye glasses
 Chipping hammer
 Steel brush
 Leather apron
 Leather gloves
 Working table
Procedures:
Welding Procedure:
1. Prepare all the

materials/equipment needed in
performing tacking weld.
2. Lay the plate to be welded in the Plates tack welded
working table.
3. Tack weld the plates 10mm up to 700
15mm from each end at the
middle, without gap between the
plates. 900
4. Lay the plate flat on the working

table with the side which is not
tacked on top.
3mm
5. Start welding the side which is not Electrode angle

tacked with the electrode at an 70°
travel angle and 90° work angle.
5
Note: Maintain an arc length of 2mm to 3mm
6. Using the chipping hammer, chip off

slag from the bead, and by using an
steel brush remove the remnants of
the beads.
Note: Always wear a clear eye glasses when chipping slags.
7. Inspect the bead if there is a

uniform width.
Note: Use steel brush to remove remnants
8. Weld the opposite side following the

same procedure.
9. Present the work piece to your

instructor.
6
( Marking Table 1.1)
Directions:
Rate the quality of welding output using the marking schedule provided
below and record the marks in the marking table. Subtract the marks from 40
points which is the highest rating.
The passing mark is 20 points
Marking Points
Criteria Marks (Subtracted)
1. Straightness
2. Width of bead
3. Height of bead
4. Ripple
5. Plate alignment
Total Marks Subtracted
Final points = 40 – total marks subtracted
Final points =
Marking Schedule:
1. Straightness
Subtract 2 marks for each degree of depletion from the line of weld.
2. Width of Bead
Subtract 4 marks for each 10mm length of bead, which is 1mm less, or more
than required 8mm bead width.
3. Height of Beads
Subtract 4 marks for each 10mm length of bead exceeds the height of 3mm.
4. Ripple
Subtract 4 marks for uneven and coarse ripple.
5. Plate Alignment
Subtract 3 marks for each 2 degrees of angular misalignment.
Subtract 3 marks for each millimeter of offset between plates.
7
Learning Outcome 2:
WELD BUTT JOINT (CLOSED) IN FLAT AND HORIZONTAL POSITION
1. Uniformity of bead ripples are checked in accordance with welding

standards.
2. Stringer beads are performed in accordance with welding standards.
3. Finished weldment is performed based on acceptable standard for:
 Spatter
 Slag
 Uniformity of beads
REFERENCES::
Welding Technology
2nd Edition
Gower A. Kennedy
Welding Guide
Fabrication Shop
Ismael V. Palabrica
Metal Works 1
SEDP Series

Welding
7
Learning Outcome 2. Weld Butt Joint (Closed) in Flat and Horizontal Position
1.) Read the attached Operation

Sheets 2.1, 2.2, in welding
butt joint (closed) in flat and
horizontal positions.
2.) Answer self-check Nos. a. Answer the self-check without
2.1/2.2 to test your knowledge looking at the information sheet.
on Weld flat and horizontal
positions.
answer keys.
again.
objective.
8
OPERATION SHEET 2.1
SQUARE EDGE (CLOSE) BUTT WELD IN FLAT POSITION
TARGET: To weld a square edge close butt-weld in flat position. The bead
should be straight in terms of height and width, with smooth ripples and the
welded plates aligned.
MATERIALS/SUPPLIES
1. mild steel plates , 3.2 mm x 75 mm x 150 mm (2pcs)

2. electrode, E6013, 3.2 mm diameter
TOOLS AND EQUIPMENT

2. chipping hammer
3. steel brush
5. leather gloves
6. leather apron
7. portable grinder
PLAN ILLUSTRATION
9
WELDING PROCEDURE
1. Tack weld the plates 10 mm from each end

and at the center with no gap between
plates
Plates tack welded
2. Preset the plates to allow for angular distortion .
2mm
Preseted plates
3. Lay the plate flat on the table with the side 700
Which is not tacked on top.
900
4. Weld first the side which is not tacked

With the electrode at 70º travel angle
3mm
and 90º work angle .
Note: Maintain an arc length of Electrode angle

2-3 mm.
5. Chip the slag and wire brush the bead.
Note: Wear safety glasses or the chipping shield in your welding

helmet.
6. Inspect the run for uniform width.
7. Turn the plate over and grind the tacks flush.
Note: Wire brush the plate to remove the scale.
8. Weld the reverse side following the same procedure.
10
(Marking Table 2.1)
SQUARE EDGE (CLOSE) BUTT WELD IN FLAT POSITION
Directions:
points, which is the highest rating.
Marking Points
1. Straightness
2. Width of bead
3. Height of bead
4. Ripple
5. Plate alignment
Final points =
Marking Schedule:
1. Straightness
2. Width of Bead
3. Height of Beads
4. Ripple
5. Plate Alignment
11
OPERATION SHEET 2.2
SQUARE EDGE CLOSE BUTT WELD IN HORIZONTAL POSITION
MATERIALS/SUPPLIES
1. mild steel plate, 3.2 mm x 75 mm x 150 mm (2pcs.)

TOOLS AND EQUIPMENT

2. chipping hammer
3. steel brush
5. welding gloves
6. welding apron
7. portable grinder
PLAIN/ILUSTRATION
3mm Tack Weld
12
WELDING PROCEDURE
1. Tack welds the plates 10 mm from each end and at the center with no gap
between the edges of the plate.
2. Preset the plate to allow for angular distortion.
3. Clamp the plate in the welding positioner with the edge of the plate
parallel to the ground.
NOTE: Position the joint line just below eye level to have a clear view
of the arc when welding commences.
4. Weld first the side, which is not tacked with the electrode at 75º - 85º
travel angle and 95º-work angle.
NOTE: Manipulate the electrode using a circular weaving motion.

Maintain the width of bead at 8 mm. and arc length at 2 – 3
mm.
5. Chip the slag and wire brush the bead.
NOTE: Wear safety glasses or chipping shield in your welding helmet.
6. Inspect the run for uniform width.
7. Turn the plate over and grind/remove the tackings.
NOTE: Wire brush the plate to remove the scale.
13
(Marking Table 2.2)
SQUARE EDGE (CLOSE) BUTT WELD IN HORIZONTAL POSITION
Directions:
Marking Points
6. Straightness
7. Width of bead
8. Height of bead
9. Ripple
10. Plate alignment
Final points =
Marking Schedule:
11. Straightness
12. Width of Bead

13. Height of Beads

14. Ripple
15. Plate Alignment

14
Unit of Competency Fit up Weld Materials
Learning Outcome 3:
WELD BUTT JOINT (OPEN) IN FLAT AND HORIZONTAL POSITION
1. Uniformity of bead ripples are checked in accordance with welding

standards.
2. Stringer beads are performed in accordance with welding standards.
3. Finished weldment is performed in accordance with welding standards
for:
● Spatters
● Slag
● Uniformity of Beads
REFERENCES:
Welding Technology
2nd Edition
Gower A. Kennedy
Welding Guide
Fabrication Shop
Ismael V. Palabrica
Metal Works 1
SEDP Series

Welding
15
Learning Outcome 3. Weld Butt Joint (Open) in Flat and Horizontal Position
1.) Read the attached Information

Sheet 3.1, Operation Sheet 3.2
and weld butt joint (open) in
flat and horizontal position.
2.) Answer the self-check no. 3.1
to test your knowledge on weld a. Answer the self-check without
butt joint (open) in flat and looking at the information sheet.
horizontal position.
answer keys.
again.
objective.
16
WELD BUTT JOINT (OPEN) IN FLAT AND HORIZONTAL POSITION
BUTT JOINTS (WITH GROOVE)
In a butt joint, the weld is made between the two edge surfaces of the two
sections to be fused. The joint maybe either square or grooved type.
ROOT FACE
1/32” TO 1/8”
1/8”
1/8”
1/8”
3/16”
To make a sound weld a correct root opening is A proper root face should be provided for quality welds.
important.
17
TYPES OF BUTT JOINTS DESIGN
●Square Butt Joint. It is intended primarily

for materials that are 3/16” or less in
thickness, with proper root opening, and
require full and complete fusion for maximum
strength. For submerged-arc welding,
materials up to 3/8” with minimum gap of
1/8” can be welded. The joint is reasonably
strong in static tension but it is not
recommended when it is subjected to fatigue
and impact loads, especially in a low
temperature. The preparation of the joint is
relatively simple since it requires only
matching the edges of the plates;
consequently the cost of making the joint is
low.
●Single-V butt joint. It is used in 3/8” or

larger than thickness, but more than ¾”.
The preparation of this joint is more costly
because more filler materials are needed
and special beveling is necessary.
●Double- V butt joint. It is best for all load

conditions. It is often specified for stock that
is heavier than metal used for single-V (up to
¾”). For optimum strength, the penetration
must be complete on both sides. The
preparation of this joint is more costly than
the single-V, but less filler materials is
required.
●Single-U butt joint. Its type readily meets

all ordinary load conditions and is used for
work requiring high quality. It has greatest
applications for joining plates ½” to ¾”. The
preparation of this joint is less rather than
both Single-V and Double-V groove and less
war page is likely to occur.
●Double-U butt joint. It is intended for

metals ¾” or more in thickness where
welding can readily be accomplished on
both sides. The joint meets all regular load
conditions although the preparation cost is
higher than the single-U butt joint.
18
OPERATION SHEET 3.2
SQUARE EDGE OPEN BUTT WELD

IN FLAT POSITION
To weld a square edge open butt-weld in flat position. The bead should be
straight, of even height and width, with fine ripples and the welded plates
aligned.
MATERIALS/ SUPPLIES
1. mild steel plates, 6 mm x 75 mm x 150 mm (2 pcs)

TOOLS AND EQUIPMENT

2. chipping hammer
3. steel brush
5. welding gloves
6. welding apron
7. portable grinder
PLAN/ILLUSTRATION
19
WELDING PROCEDURE
1. Tack weld the plates 10 mm from TACK WELD

each end with uniform gap of 3 mm
between the plates edges.
3mm GAP
Tack welded plates with 3mm gap
2. Preset the plates to allow for angular distortion.
3. Lay the plate flat on the table with the side, which is not tacked on top.
4. Weld first the side, which is not tacked with the electrode at 70º travel
angle and 90º work angle.

Maintain the width of bead at 8 mm.
5. At the end of the run, reverse the direction of travel for approximately
5 mm to fill the crater.
DIRECTION OF TRAVEL
NOTE: Maintain a very short arc

with an increased electrode angle
Filling up the crater
6. Clean the bead and inspect the penetration.
7. Grind a 6 mm width U-shape groove on the

reverse side until it reaches the clean
weld metal.
NOTE: Ensure that the groove is U-

Shaped and not V- shaped so that
the electrode can touch the
bottom of the groove.
20
SQUARE EDGE (OPEN) BUTT WELD IN FLAT POSITION
Directions:
below and record the marks in the marking table. Subtract the marks from
40 points which is the highest rating.
Marking Points
1. Straightness
2. Width of bead
3. Height of bead
4. Ripple
5. Plate alignment
Final points =
Marking Schedule:
1. Straightness
2. Width of Bead
3. Height of Beads
4. Ripple
5. Plate Alignment
21
OPERATION SHEET 3.3
SQUARE EDGE OPEN BUTT WELD IN HORIZONTAL POSITION
MATERIALS/SUPPLIES
1. mild steel plate, 6 mm x 75 mm x 150 mm (2pcs.)

TOOLS AND EQUIPMENT

2. chipping hammer
3. steel brush
5. welding gloves
6. welding apron
7. portable grinder
PLAIN/ILUSTRATION
3mm
22
WELDING PROCEDURE
1. Tack weld the plates 10 mm from each end with a uniform gap of 3 mm
between the edges of the plate.
2. Preset the plate to allow for angular distortion.
3. Clamp the plate in the positioner with the edge of the plate parallel to the
ground.
NOTE: Position the joint line just below eye level to have a clear view
of the arc when welding commences.
4. Weld first the side, which is not tacked with the electrode at 75º - 85º
travel angle and 95º work angle.

Maintain the width of bead at 8 mm.
5.At the end of the run, reverse the direction of travel for approximately 5
mm to fill the crater.
NOTE: Maintain a very short arc with an increase electrode angle
6. Clean the bead and inspect the penetration

7. Grind a 6 mm width U-shape groove on the reverse side until it reaches
the clean weld metal.
NOTE: Ensure that the groove is U-shape and not V-shape so that the
electrode can touch the bottom of the groove.
23
SQUARE EDGE (OPEN) BUTT WELD IN HORIZONTAL POSITION
Directions:
Marking Points
1. Straightness
2. Width of bead
3. Height of bead
4. Ripple
5. Plate alignment
Final points =
Marking Schedule:
1. Straightness
2. Width of Bead
3. Height of Beads
4. Ripple
5. Plate Alignment
24
Pre test/Post test for Fitting up Weld Materials
LO 1: Perform Tack Welding
1. What is the basis for recommending the required gap in performing open
butt joints?
a) amperage rating
b) thickness of metal
c) electrode diameter
d) flux composition
2. What is the recommended travel angle and work angle for welding flat
position?
a) 65°, 90°
b) 75°, 90°
c) 75° – 85°, 95°
d) 75°, 95°
3. What is the recommended travel angle and work angle for welding
horizontal position?
a) 65°, 90°
b) 75°, 90°
c) 75° – 85°, 95°
d) 75°, 95°
4. What is the acceptable width of bead in a weld metal?
a) 5 mm
b) 6 mm
c) 8 mm
d) 10 mm
5. What is the most applicable weave motion in horizontal position?
a) circular weave
b) square weave
c) figure 8 weave
d) none of the above
6. In tack welding, where is the exact point of tack welding to be placed?
a) in the middle of the edges of the base metal

b) in one side of plate edges
c) in the middle and on both ends of plate edges
25
7. A type of tack that uses stiffeners to keep both base metal aligned.
a) permanent tacking
b) semi permanent tacking
c) bridge tacking
8. The kind of tack weld that is done in a very short bead, it is use to fit up
welds temporarily.
c) bridge tacking
9. The kind of tack weld that measures at about ¼” to 1/2” length. It is

used to fit up heavy pieces of metal.
c) bridge tacking
10. After tack welding plates should be check for
a) angular plate alignment

b) correct root gap
c) distortion
d) all of the above
LO 2. Weld both open and close Butt Joint in flat and horizontal position
11 – 15 Enumerate at least 5 groove weld joints use for open butt welds.
26
ANSWER KEYS
PRE TEST AND POST TEST: Key to correction for Module # 5 which is
Fitting up Weld Materials
LO 1 Perform Tack Welding
1. c
2. b
3. c
4. c
5. a
6. c
7. c
8. b
9. a
10.d
LO 2 Weld both open and close Butt Joint in flat and horizontal position
A. Enumeration
11. bevel groove

12. U groove
13. groove
14. square groove
15. flare groove
27
HIGH SCHOOLS
Unit of Competency: REPAIR WELD
Module No.: 6 Module Title: REPAIRING WELD

ACKNOWLEDGMENTS

February 18-22, 2008.
Technology Teacher:
June L. Dimalibot
Bauan Technical High School
Poblacion II Bauan, Batangas
Resource Person:
TESDA Specialist

Principal III
RESPSCI
Contextual Teacher:
May L. Sangalang
(English)
Encoders:

Education.
ACKNOWLEDGMENT

MODULE WRITERS:
WELDING
JIMMY P. OCAMPO
(RESPSCI)
JIMMY P. DOMINGO
JEFFREY G. MORENOS
BENJIE R. SAN JUAN

SCIENCE
EDNA M. PASAMONTE
MATH
FRANCISCO M. JAVIER
ENGLISH

(RESPSCI)
FACILITATOR :
VICTORIO N. MEDRANO
Principal IV
EDITOR:

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


Education.
TABLE OF CONTENTS
Page

Introduction .................................................................................................... ii
Learning Outcome (LO) 1 Mark/Locate Weld Defects… ................................... 1
 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
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.

In this module, you will find the activities for you to complete and relevant
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
Unit of Competency Repair Weld
Module Title: REPAIRING WELD
INTRODUCTION:

Repair of Weld. It includes instruction and procedure on how to Repair Weld.

succeeding module on Interpreting Drawings and Symbols.
This module consists of four (4) learning outcomes. Each learning


completion.
SUMMARY OF LEARNING OUTCOMES (LO)
LO1 Mark/locate weld defects;

LO2 Prepare tools and equipment;
LO3 Remove weld defects;
LO4 Perform re-welding
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
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


1
Learning Outcome 1: Mark/locate weld defects
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
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


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.
answer key.
4. If you missed some items, go
over this module.
5. If you passed, then proceed to the
next L.O.
15
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
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
HIGH SCHOOLS
Unit of Competency: INTERPRET DRAWINGS AND SYMBOLS
Module No.: 7 Module Title: INTERPRETING DRAWINGS AND SYMBOLS

ACKNOWLEDGMENT

February 18-22, 2008.
Technology Teacher:
June L. Dimalibot
Bauan Technical High School
Poblacion II Bauan, Batangas
Resource Person:
TESDA Specialist

Principal III
RESPSCI
Contextual Teacher:
May L. Sangalang
(English)
Encoders:


Education.
ACKNOWLEDGMENT

MODULE WRITERS:
WELDING
JIMMY P. OCAMPO
(RESPSCI)
JIMMY P. DOMINGO
JEFFREY G. MORENOS
BENJIE R. SAN JUAN

SCIENCE
EDNA M. PASAMONTE
MATH
FRANCISCO M. JAVIER
ENGLISH

(RESPSCI)
FACILITATOR :
VICTORIO N. MEDRANO
Principal IV
EDITOR:

Principal II
Muntinlupa City NCR
ENCODERS :
MA. RIZA B. ZAMORA


Education.
TABLE OF CONTENTS
Page

Introduction .................................................................................................... ii
Learning Outcome 1 Identify Standard Alphabet of Lines………… ................... 1
 Information Sheet 1.1 ......................................................................... 3-6
 Self-Check 1.1 ....................................................................................... 7
Learning Outcome 2 Identify Orthographic/Isometric Views……... .................. 8
 Learning Experiences/Activities ............................................................ 9
 Information Sheet 2.1 ..................................................................... 10-11
 Operation Sheet 2.1 ............................................................................. 12
● Job sheet 2.1…………………………………………………………………………13
 Information Sheet 2.2 .......................................................................... 14
 Operation Sheet 2.2 ............................................................................. 15
● Job sheet 2.2…………………………………………………………………………16
 Self check 2.1………………………………….……………………………………. 17
Learning Outcome 3 Interpret Standard Drawing Symbols,
Dimensions, Tolerances and Notations…………………………………..……18
 Learning Experiences/Activities…………………………………………………..19
 Information sheet 3.1……………………………………………………………20-27
 Self check 2.1………………………………….………………………………………29
Answer Key…………..…………………………………………………………………….….30
Welcome to the Module “INTERPRETING DRAWING AND SYMBOLS”. This

module contains training materials and activities for you to complete.
The unit of competency “Interpret Drawing and Symbols” contains the

knowledge, skills and attitudes required for Shielded Metal Arc Welding
(SMAW) to obtain the National Certificate (NC) level I.

You may already have some or most of the knowledge and skills covered in
this module.
If you can demonstrate competence to your 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 may 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.
In this module, you will find the activities for you to complete the relevant
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.
Unit of Competency Interpret Drawing and Symbols
Module Title: INTERPRETING DRAWING AND SYMBOLS
INTRODUCTION:

Interpreting drawings and Symbols. It includes instruction and procedure on
how to Interpret Drawings and Symbols.

succeeding module on Contributing to Quality System.


completion.
LO1 Identify Standard Alphabet of Lines;

LO2 Identify Orthographic/Isometric Views; and
LO3 Interpret Standard Drawing Symbols, Dimensional Tolerances and
Notations
PREREQUISITE:
TECHNICAL TERMS
1. Welding Symbol is the location of elements in a weld symbol with

respect to each other
2. Weld Symbol it indicates the require type of weld and

supplemental implementation.
3. Tolerance is the total amount of variation permitted for the

design size of a part.
4. Symbol is a figure or character used in place of a word

or group of words.
5. Arrow Side is a weld symbol that is written above the

reference line.
6. Other Side is a weld symbol that is written above the

reference line.
7. Both Side is a weld symbol that is written above and

below the reference line.
8. Reference Line is written horizontally forming an obtuse

angle.
9. Concave is a curve inward (see contour symbol).
10. Convex is a curve outward (see contour symbol).
11. Tail is a part of an arrow symbol on a welding blue

print where specifications are placed .
Unit of Competency: INTERPRET DRAWING AND SYMBOLS
Learning Outcome 1:
Identify Standard Alphabet of Lines
1. Alphabet of lines are identified according to International Standard

Organization (ISO)
2. Alphabet of lines are clearly explained according to their uses.
References:
Welding Technology
Second Edition
Gower A. Kennedy


1
Learning Outcome No. 1: Identify Standard Alphabet of Lines

sheet 1.1 and identify standard
alphabet of lines.
2. Answer self check no. 1.1 to

test your knowledge on
identifying standard alphabet of  Answer the self-check without
lines. looking at the information
sheet.
answer keys
4. If you miss some of the items,

again.

objective
2
Alphabet of Lines
Lines are the bases of all drawing. They are used even from simple
drawing to the difficult ones. Practice, exercise and correct use of techniques
in the making of lines will give student experience in technical sketching.
Moreover, constant practice will help students develop skill in making lines
and use of pencils. It should be remembered that the basic requirement for
line construction is clarify of line produced.
In practice, the kind of line produced, depends on the hardness of the
pencil. For drawing using pencil, the medium and light lines are more
prepared.
There are conventional lines used in drawing. These lines are called
alphabet of line and each line serves a particular purpose. These lines may
either be drawn freehand or they may be drawn mechanically.
3
 Visible lines are lines which are seen on the edge of an object. When
drawn using ink, the lines are heavy and solid; when a pencil is used the
line produced is medium. The thickness of the lines depends on the size
of the drawing.
Example:
 Long break lines are lines which show that a line has been broken.
These lines have definite breaks and are medium in weight.
Example:
 Short break lines are lines drawn with a heavy freehand line.
Example:
 Hidden lines are also called, dotted lines. They are short medium weight
dashes measuring about 3-4 millimeter and gaps about 1-2 millimeters
wide. These kinds of lines are used to represent hidden views of an
object.
Example:
4
 A leader line is a fine broken line. It has an arrowhead at one end. The
broken line has a short horizontal and an inclined line to indicate either
a part or measurement of an object.
Example:
 A reference line is a curved line with an arrowhead at one end. This

kind of line is used to label the parts of an object. The leader line and
reference line arrowheads both point to parts being labeled or measured.
Example:
 Center lines are lines used to pinpoint centers of objects, arcs and
circles. They are drawn by using one long and one short dash
alternatively. The spaces between the dashes are like that of the hidden
lines.
Example:
 Section line is lines used to show sectional views. The spaces are placed
evenly so that a shaded effect may achieve.
Example:
5
 Dimension lines show the measurement of objects. It consists of
arrowheads, fine line and the measurement. The arrowheads are short
and are placed at both ends of the line. The measurement is placed at the
middle of the fine line.
Example:
 Dimensioning is measuring the objects’ height, width and depth.
Principal Dimension of an Object
a. Height is the perpendicular distance between two horizontal

planes.
b. Width is the perpendicular distance between two profile planes.
c. Depth is the perpendicular distance between two horizontal planes.
6
Answer the following questions briefly. Write your answer in a separate paper.
A. Identify the given alphabet of lines.
1. ___________________________
2. ____________________________
3. _____________________________
4. ______________________________
5. ______________________________
6. ______________________________
7. _____________________________
8. ______________________________
7
Learning Outcome 2:
Identify Orthographic and Isometric Views
1. Orthographic and isometric are clearly explained.

2. Orthographic and isometric drawings are identified based on plan.
References:
Welding Technology
Second Edition
Gower A. Kennedy


8
Learning Outcome No. 2: Identify Orthographic/Isometric Views

sheets, operation sheets and
job sheets and identify
orthographic/isometric views.
2. Answer in each self check to

test your knowledge on a. Answer the self-check without
identifying looking at the information
orthographic/isometric views sheet.

answer keys
4. If you miss some of the items,

again.

objective
9
Orthographic View Sketching
The term orthographic comes from the Greek words orthos and graphos
which mean to write and to draw. Orthographic sketching therefore is drawing
using lines only.
This kind of drawing is simple. Its purpose is to represent a shape using
two or more views.
 Orthographic Drawing
Figure can be viewed in three ways:

a. Frontal plane
b. Horizontal plane
c. Profile plane
 The frontal plane shows the shape of an object as seen from the front.
This is called FV.
10
 The horizontal plane shows the object as viewed from the top. This is
called the TV of an object.
 The profile plane shows the shape of the object as seen from the side,
the distance from bottom to top and front to back. This is called the SV of
an object.
11
OPERATION SHEET 2.1
Identify Orthographic and Isometric View
Orthographic Sketching
Sketching Orthographic Views
Procedure:
a. Know the dimensions of the object: the length, width and
thickness.
Study the proportions of the parts and that of the whole object.
b. Check on the kind of view you wish to use in the object. Be sure
that the main surfaces are represented. More importantly check on
the size of the views taking care that they are proportioned
properly.
c. Draw the object using light lines first to give easier time for
erasures. Later when the view drawn is acceptable, the lines will be
made darker.
Sample orthographic views:
12
JOB SHEET 2.1
Identify Orthographic and Isometric View
Orthographic Sketching
Materials:
a. Pencil
b. Eraser
c. Protractor
d. Compass
e. Drawing table
f. T-square
g. Triangle
8. A4 paper
Draw the orthographic views
Plate No. 1
Plate No. 2
13
Isometric Drawing
Isometric drawing is a drawing wherein objects is represented by three

skills and are seen at one time. The term isometric comes from ISO which
means equal and metric means measure. This means therefore that the
isometric view is in equal measure to its orthographic views. Isometric also
means that the measurements of the angles are equal as formed by their three
axes.
There are three axes of an isometric drawing: the vertical, the left 20
degrees cross axis and the right 30 degrees cross axes.
14
OPERATION SHEET 2.2
Isometric Drawing
Procedure:
1. Draw the vertical axis and then

lay the height.
2. Draw the left and right

degrees cross axis.
3. Measure the width and

depth of the object.
4. Draw parallel lines to the width

and depth to complete the three
faces of the object.
15
JOB SHEET 2.2
Isometric Drawing
Materials:
a. Pencil
b. Eraser
c. Drawing table
d. T-square
e. Compass
f. Protractor
g. Triangle
h. A4 paper
Draw the given working drawing following given measurements using 30

degrees isometric drawing. Note: Use mm. unit of measurement.
Plate No. 1
Plate No. 2
INFORMATION SHEET #4
16
SELF CHECK 2.1
LO 2.
Direction. Answer Set A and B test (Write your answer in a separate sheet of
paper).
A. Enumerate the 3 principal views in the orthographic drawing
1.
2.
3.
B. List down five tools and materials used in constructing orthographic

drawing
1.
2.
3.
4.
5.
17
Learning Outcome 3:
Interpret Standard drawing Symbols, Dimensional Tolerances and

Notations
1. Drawing symbols are interpreted according to drawing standards.

2. Dimensional tolerance, notations are interpreted according to
specifications.
References:
Welding Technology
Second Edition
Gower A. Kennedy


Larry Jeffers and Harold V. Johnson
18
Learning Outcome No. 3: Interpret Standard Drawing Symbols, Dimensional

Tolerances and Notations

sheet 3.1 and interpret
standard drawing symbols,
dimensional tolerances and
notations.
2. Answer self check no. 3.1 to a. Answer the self-check without

test your knowledge on looking at the information
identifying sheet.
orthographic/isometric views

answer key
4. If you missed some of the items,

again.

objective
19
Interpret Standard Drawing Symbols, Dimensional Tolerances and

Notations
Welding Symbol
Location of Elements: The elements of a welding symbol have standard

locations with respect to each other.
Location Significance of Arrow: The arrow element in a welding symbol in

conjunction with the reference line determines the arrow side and other side of
a weld.
The symbol depicting an arrow side weld is always placed below the reference
line. The arrow side is always closest to the reader when viewed from the
bottom of the drawing. The weld symbol depicting other side weld is placed
above the reference line, away from the reader. Welds on both side of a joint are
shown by placing weld symbols on both sides of the reference line.
Some weld symbols have no arrow or other side significance. However,

supplementary symbols used in conjunction with these weld symbols may have
such significance. For example, welding symbols for resistance spot and seam
welding have no side significance, but GTAW, EBW, or other spot and seam
welds may have arrow and other side.
References: When a specification, process, test, or other references is needed to

clarify a welding symbol, the reference is placed in a tail on the welding symbol.
The letters CJP may be used in the tail of the arrow to indicate that a complete
joint penetration groove weld is required, regardless of the type of weld or joint
preparation. The tail may be omitted when no specification, process, or other
reference is required with a welding symbol.
Dimensions: Dimensions of a weld are shown on the same side of the reference
line as the weld symbol. The size of the weld is shown to the left of the weld
symbol, and the length of the weld is placed on the right. If a length is not
given, the weld symbol applies to that portion of the joint between abrupt
changes in the direction of welding or between specified dimension lines. If a
weld symbol is shown on each side of the reference line, dimensions are
required to be given for each weld even though both welds are identical.
Either US Customary or SI units may be used when specifying dimensions.

However, only one of the two should be used for a product or project.
If a weld in a joint is to be intermittent, the length of the increments and the

pitch (center-to-center spacing) are placed to the right of the weld symbol.
20
The term weld symbol and welding symbol have different meanings. A
weld symbol indicates the required type of weld. The welding symbol includes
the weld symbol and supplementary information. A complete welding symbol
consists of the following elements:
 Reference line
 Arrow
 Basic weld symbol
 Dimensions and other data
 Supplementary symbol
 Finish symbol
 Tail
 Specification, process and other references
21
22
23
24
25
Weld Symbols
Weld symbols are intended to be based in conveying the information among the
designer, shop and fabrication personnel.
 Type of joint
 Type of joint preparation
 Side of groove preparation and welding
 Type of weld
 Size of weld
a. Type of Joint
A joint is a junction of members or the edges of members that are to be
joined or have been joined. The five basic joints used in welding are:
26
Welding Positions
 Flat Position
The position of welding wherein the welding is performed from the upper
side of the joint in the face of the weld which is approximately
horizontal.
 Horizontal Position
The position of welding wherein the axis of the weld lies in

approximately horizontal plane and the face of the weld lies
approximately in vertical plane.
 Vertical Position
The position of welding wherein the axis of the weld is approximately

vertical.
 Overhead Position
The position of welding wherein welding is performed from the

underside of the joint.
27
SELF CHECK 3.1
Interpret Standard Drawing Symbols, Dimensional Tolerances and

Notations
Welding Symbol
I. Identify the following welding symbols. Write your answer in a separate sheet.
a. ________________________
b. ________________________
c. ________________________
d. ________________________
e. ________________________
28
II. Draw the different types of joint preparation.
a. Single J __________________
b. Double Bevel __________________
c. Single U __________________
d. Single V __________________
e. Double J __________________
f. Single Bevel __________________
g. Double V __________________
h. Double U ___________________
29
ANSWER KEY
LO 1.
SELF CHECK 1.1
1. Leader line
2. Dimension Line
3. Short break line
4. Reference line
5. Long break line
6. Visible line
7. Section line
8. Hidden line
LO 2.
SELF CHECK 2.1
A.
1. Front View
2. Top View
3. Side View
B.
1. Compass
2. T-Square
3. A4 Paper
4. Drawing Table
5. Eraser, Pencil or Protractor
LO 3.
SELF CHECK 3.1
a. Fillet Weld
b. Half U-Groove Weld
c. Groove Weld
d. Flare Butt Weld
e. Square Butt Weld
30

Welding Y2

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Welding Y2

Uploaded by

Copyright:

Available Formats

Republic of the Philippines

Unit of Competency: USE BASIC HAND TOOLS

Module No.: 1 Module Title: USING BASIC HAND TOOLS

First Published JUNE 2008

This draft was prepared at the Competency-Based Learning

This learning instrument was developed by the following personnel:

Jose D. Gonzales Jr.

This work was produced with funding provided by the Department

The Department of Education (DepED), Central Office through

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

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

● Self Check 2.2 ………………………………………………………33

Learning Outcome 3 Maintain Hand Tools……………………….34

● Information Sheet 3.1.………………………………………….36-39

● Self Check 3.1 …………………………………………………..40-41

● Answer Keys ………………………………………………………….42

The unit of competency “Using Basic Hand Tools” contains

You are required to go through a series of learning activities

If you have questions, don’t hesitate to ask your facilitator

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and

If you can demonstrate to your trainer that you are

After completing this module ask your trainer to assess your

Unit of Competency Use of Basic Hand Tools

Module USING BASIC HAND TOOLS

This module contains information and suggested learning activities in

Completion of this module will help you better understand the

This module consists of three (3) learning outcomes. Each learning

Upon completing this module, report to your instructor for

SUMMARY OF LEARNING OUTCOMES:

Upon completion of the module you should be able to:

LO1 Select and classify hand tools;

Refer to assessment criteria of learning outcomes # 1-3 of this

1. Hand Tools are tools operated and manipulated by

Learning Outcome # LO1:

(LO title) Select hand tools

1. Hand tools were selected and classified according to the job

Welding Inspection Technology

Welding Principles and Application

Learning Outcome #1: Select Hand Tools

Learning Activities Special

1) Read the attached information sheet No. 1.1/1.2  Answer

Select and Classify Hand tools

A list of common hand tools and their uses is thereby provided

Hand tools are classified into four:

(1) measuring tools;

Each classification has different types and uses.

 Steel tape. Is similar to a steel tape rule but differs in that it is

 Combination Square. It is an instrument combined with 45°, 90°

 Hacksaw. Is a tooth cutting tool usually with a solid and

a. Fixed or solid frame. It is intended to hold only one size of

b. Adjustable frame. Its frame can be adjusted to hold blades of

o Blade. It is made of thin, high grade steel usually 1.27 mm

Kinds and uses of files:

1. Mill File. It is a single-cut file used for filing and finishing

2. Flat File. It is rectangular in shape and tapered slightly in

4. Round File. It is used primarily for enlarging holes. It as

5. Half-round File. It is used for filing curved or concave

6. Triangular File. It is used for filing surfaces that meet at

 Cold Chisel. A wedge-shape tool used to shear, cut and chip