Department of Education

Region V
Naga City Division
District 1

CAMARINES SUR NATIONAL HIGH SCHOOL

TLE- SMAW 9
LEARNING ACTIVITY SHEET
Quarter 2, Week 1-3

Name: _______________________________________ Grade & Section: __________________

Subject: _______________________________________Date: ___________________________

I. Introductory Concept

Shielded metal arc welding (SMAW) is often referred to as stick welding. The welding process
can use either alternating current (AC) or direct current (DC). This unit covers the skills,
knowledge and attitudes in preparing equipment for welding.

II. Learning Competency

 SET-UP WELDING EQUIPMENT
 CONTENT STANDARDS
The learner demonstrates understanding of basic concepts and underlying
theories in setting-up welding equipment.
PERFORMANCE STANDARDS
The learner independently demonstrates competency in setting-up welding
equipment needed for the job.
Reference:
o Technology & Livelihood Education – Grade 9 Industrial Arts:
Shielded Metal Arc Welding - (Set-up Welding Equipment) Learner’s
Material First Edition, 2014
o Welding Technology, Second Edition by Gower A. Kennedy
o Welding Inspection Technology, Education Department, American
welding Society

 Specific Objectives:
1. Identify the set-up of welding machine/ equipment
2. Discuss the importance of Welding power source/ welding machine set-up
3. Draw the parts and write function of Welding Machine

INFORMATION / FACT SHEET

LET US STUDY

WORDS TO STUDY

 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 in one second.
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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
 Information Sheet

Set-up Welding Machine

SMAW safety

Welding is a dangerous profession, not because of the welding itself, but because of the
environments which the work is often performed.

Primary safety concerns involve the following:

 Moving welding equipment

 Electrical hazards
 Lifting hazards
 Working heights
 Welding hazards
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.

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• 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 provide electrode holder cable and return cable connections to the welding
machine.

Step 1: Plug in the Machine

This is the most dangerous part of setting up the stick

welding machine. First of all, make sure that the power switch on
the front of the machine is set to OFF. Then, make sure the safety
switch on the wall is set to OFF. Now it is safe to plug in the
machine. After all leads are plugged in, flip the safety switch to
the ON position

Step 2: Turn on and Grounding the Machine

Before you turn the machine on, you are going to want to put your ground
clamp in position. You can ground to the table that you will be welding on, or you
can ground directly to your piece.

After your ground clamp is in place, you can turn the machine on. Be
careful when you turn the machine on, the electrode holder (torch) is now HOT.

Step 3: Filler Rod Selection, Amperage Selection

We currently have two kinds of electrodes, 6011(fast freeze) and

6013(fast fill). If you need deep penetration with a thin yet tough layer of slag, go with the 6011. If you
prefer a better weld appearance and thick easily removed slag, use the 6013 electrode. If you are welding
out of position, use the 6013 for vertical down welding and 6011 for vertical up welding.

If you are new to stick welding I recommend you start practicing with the 6013 electrode on thick
steel.
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 Once you have chosen your electrode kind and size, you will need to set the amperage on the
machine. The chart (the link above) will tell you the proper amperage range for each kind of electrode. Set
the machine accordingly.

Proper selection and set up of equipment is necessary in order to achieve a reliable weld while maintaining
a safe work environment. Shielded metal arc welding is often referred to as stick welding and remaining
one of the most widely used forms of welding in the industry because of its simplicity and low cost.

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.

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 INFORMATION SHEET

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

INFORMATION SHEET

WELDING POSITIONERS

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 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 are designed so that the holes are placed properly.

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 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.

III. ACTIVITY 1 (10 points)

A. MULTIPLE CHOICE
Direction: Choose the correct answer and write the letter that correspond to your choice on the answer
sheet provided. Use separate answer sheet (tablet paper/long bond paper).

1. The duty cycle of a welding machine is based on a

a. ten-minute period
b. five-minute period
c. six-minute period
d. four-minute period
2. Which of the following is a measurement of the electric current flowing in a circuit?
a. Amperage
b. Resistance
c. Ohms
d. Voltage
3. Which of the following provides a smaller, lighter power source?
a. Inverter
b. Conventional welding
c. Engine driven generator
d. Alternator machine
4. Which part of welding machine establish the connection between the workpiece and the welding
lead?
a. Workpiece ground clamps
b. Electrode holder

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 c. Lever operated jaw
d. Collet- type electrode holder
5. Most sites will have a preventive maintenance schedule based on ____ the engine operates.
a. Minutes
b. Hours
c. Days
d. Years
B. TRUE OR FALSE
Direction: Read each statement below carefully. White TRUE if the statement is correct and FALSE if the
statement is not correct.

____________1. A welding spark could cause the battery to explode.

____________2. The type of welding current- AC or DC

____________3. The conductors inside the cable are made of fine strands of copper wire.

____________4. If the amperage is set below the rated amperage, the duty cycle will increase.

____________5. Polarity only applies to DC Current.

ACTIVITY 2 (15 points)

Briefly answer the following questions. Use separate answer sheet (tablet paper/long bond paper).

1. What is the main function of the welding power source?

Describe the following power sources.

A. AC Transformer

B. DC Generator

C. Transformer Rectifier

2. What is the main function welding fixtures?

3. What is the purpose of welding positioner?

ACTIVITY 3- Performance Task (15 points)

Draw and label the Major parts of the welding power source/ Welding machine
and write each function.

IV. Scoring Rubric

Criteria 5 4 3 2

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 Accuracy Drawing of parts Drawing of most Drawing of some No evidence
are done parts are done parts are done
correctly and are correctly and are correctly and are
easy to see. easy to see easy to see.

Labeling Parts Drawing has a Drawing of most Drawing of some No evidence

set of clear, neat parts have a set parts have a set
labels that of clear, neat of clear, neat
describe the labels that labels that
parts. describe the describe the
parts. parts.

Neatness Exceptionally Neat and Appears messy No evidence

well draw, neat relatively and in a hurry.
and attractive. attractive.

V. References:

Welding Principles and Application

By Larry Jeffus and Harold Johnson

Welding Technology 2nd Ed.

By Gower A. Kennedy

Technology & Livelihood Education – Grade 9 Industrial Arts: Shielded Metal Arc
Welding - (Set- up Welding Equipment) Learner’s Material First Edition, 2014

Prepared by:

DARYL R. TESORO
Teacher I, TLE Department
Camarines Sur National High School

Noted:

ALMIRA S. PADUA
HTVI- TLE/TVE Department
Camarines Sur National High School

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