Republic of the Philippines

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

TECHNOLOGY AND LIVELIHOOD EDUCATION

Shielded Metal Arc Welding

Grade 10

Essentials of Welding

QUARTER 1
Module 1

(NOT FOR SALE)

 HOW DO YOU USE THIS MODULE?

Before starting the module, I want you to set aside other tasks that will disturb you while
enjoying the lessons. Read the simple instructions below to successfully enjoy the objectives of
this kit. Have fun!

1. Follow carefully all the contents and instructions indicated in every page of this module.

2. Write on your notebook the concepts about the lessons. Writing enhances learning that is
important to develop and keep in mind.

3. Perform all the provided activities in the module.

4. Let your facilitator/guardian assess your answers using the answer keycard. 5. Analyze
conceptually the posttest and apply what you have learned.

6. Enjoy studying!

PARTS OF THE MODULE

 Expectations - These are what you will be able to know after completing the lessons in the
module.
 Pre-test - This will measure your prior knowledge and the concepts to be mastered throughout
the lesson.
 Looking Back to your Lesson - This section will measure what learnings and skills did you
understand from the previous lesson.
 Brief Introduction- This section will give you an overview of the lesson.
 Activities - This is a set of activities you will perform with a partner.
 Remember - This section summarizes the concepts and applications of the lessons.
 Check your Understanding- It will verify how you learned from the lesson.
 Post-test - This will measure how much you have learned from the entire module.

1
 Essentials of Welding
LESSON 1 – WELD CARBON STEEL PLATES IN FLAT POSITION (1F)

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

EXPECTATION:

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

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

PRE-TEST:

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

1. Steel where the main alloying constituent is carbon.

a. Carbon steel
b. Alloy steel
c. Steel plate
d. Hard steel

2. As the carbon content rises, the metal becomes

a. Softer
b. Harder
c. Brittle
d. Breakable

2
3. These plates are in high demand especially from oil and gas industry as they
require thick plates of extremely good quality; the steel used is certified because
a small lamellar tear can be fatal.

a. Boiler steel plate

b. Tank steel plate
c. Shipbuilding steel plate
d. Structural steel plate

4. Low carbon steel plate has a carbon content of_______?

a. 0.06% to 0.25%
b. 0.25% to 0.55%
c. 0.55% to 1.0%
d. None of the above

5. The most common standards of carbon steel plate.

a. ASTM A516 plate

b. ASTM A36 plate
c. ASTM A537 plate
d. ASTM A572 plate

6. This is a straightforward bead in which you either "drag" (pull) or push the
torch across the joint with minimal (if any) side-to-side movement.

a. Fillet beads
b. Weave beads
c. Stringer beads
d. All of the above

3
7. A surfacing operation that helps extend the life of scoops, fenders, plows and
other exterior metal parts on industrial equipment. Here the beads are not meant
to fuse with the base metal, however, but to create a protective surface over it.

a. Dragging operation
b. Hard facing operation
c. Fusion
d. Weaving

8. Welding produce smoke of various types, which in some cases can lead
to medical conditions like

a. Hypertension
b. Metal fume fever
c. Arthritis
d. Rheumatism

9. A type of welding which is also often used in underwater welding in the

construction and repair of ships.

a. Submerged Arc Welding

b. Shielded Metal Arc Welding
c. Gas Tungsten Arc Welding
d. Gas Metal Arc Welding

10. Which of the following is not a normal precautionary measure?

a. clean tools and machines after using them

b. keep flammable materials always when working
c. remove watches, bracelets while working
d. sharpen tools properly for work efficiency

4
LOOKING BACK TO YOUR LESSON

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

1. A machine that supplies the current in the arc welding process.

a. welding machine
b. pressing machine
c. washing machine
d. hydraulic machine

2. An ideal electrode holder is one that is

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

5
3. Which of the following tools used to remove slag.

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

4. Which of the following tools is best for eye protection in welding?

a. hand shield
b. sun glasses
c. mirror
d. goggles

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

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

6. A machine designed for direct current is called

a. Motor generator
b. rectifier
c. transformer
d. brake

7. Which of the following indicates each layer of beads deposited in the base
metal?

a. crater
b. pass
c. ripple
d. bead

6
 8. A metal rod used to fill up joints in the base metal is referred as

a. electrode
b. steel rod
c. scriber
d. bulb wire

9. Which of the following refers to the amount of current in a circuit?

a. ampere
b. alternating current
c. polarity
d. direct current

10. Which of the following refers to the point where two or more parts meet?

a. crater
b. pass
c. slag
d. joint

BRIEF INTRODUCTION

Welding is a common process for joining metals using a large variety of

applications. Welding occurs in several locations, from outdoors settings on rural farms
and construction sites to inside locations, such as factories and job shops. Welding
processes are fairly simple to understand, and basic techniques can be learned quickly.
Welding is the joining of metals at a molecular level. A weld is a homogeneous bond
between two or more pieces of metal, where the strength of the welded joint exceeds
the strength of the base pieces of metal.
At the simplest level, welding involves the use of four components: the metals, a
heat source, filler metal, and some kind of shield from the air. The metals are heated to
their melting point while being shielded from the air, and then a filler metal is added to
the heated area to produce a single piece of metal. It can be performed with or without
filler metal and with or without pressure.

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 Carbon Steel Plate

Carbon steel plate usually been considered as the steel that does not contain much
alloy steel elements. Generally elements are C, Mn, P, S, Si, besides these there are
no minimum limits for elements of Al, Cr, Ni, Mo, V etc.

Carbon steel plates are available in different grades depending on the carbon content
and strength.

There are low, medium, and high carbon steel plates. The more carbon content, the
more durable and stronger the plate becomes. There are further sub-categories
depending on thickness and usage as well as the formation process. Usually carbon
steel plates vary from 0.4 mm to 80 mm in thickness and 1000 mm to 45000 mm width,
and they can be of length up to 18 meters. But the length is customizable which helps
the customers to put them into various applications. One can also make cold rolled steel
coils from them.

Carbon content levels for each of carbon steel plate

Low carbon steel plate: For carbon content 0.06% to 0.25%, also we call it mild steel
plate.

Medium carbon steel plate: C content from 0.25% to 0.55%.

High carbon steel plate: 0.55% to 1.0%, also called hard steel plate.
As the content of Carbon increase, the steel plate hardness increases.

8
What Are The Different Types Of Carbon Steel Plates Available?

Carbon steel plates have versatile applications in different industries. It is classified

according to the carbon content from low to high. It is also classified according to their
usage and application. Different types of carbon steel plates are used in machinery and
production companies as the base material for component construction. Its durable
property makes it ideal for various manufacturing parts. Apart from carbon steel plate,
there are vessel steel plate, shipbuilding or construction steel plate, structural steel
plate, pipeline and stainless steel plate.

Carbon Structural Steel Plate

It is mostly used in construction industry and hence, the quality, durability, and
performance have to be of highest standard. They have to withstand overweight load
and pressure and must be corrosion resistant. It is known by the name construction
steel plate.

Boiler Steel Plate

These are high-pressure plates generally used in designing vessels, boilers, and heat
containers. Carbon boiler steel plates have low corrosive property and can withstand
low heat. Several layers of either chromium or nickel are added to make it suitable for
usage in various environments.

Tanks Steel Plate

These plates are used for building of oil and gas tanks, storage tanks, water tanks, and
tanks for storage other all kinds of stuffs.

Carbon Shipbuilding Steel Plate

Shipbuilding Steel Plate – These plates are in high demand especially from oil and
gas industry as they require thick plates of extremely good quality. Most of these are
made according to the specifications of the customers and the steel used is certified
because a small lamellar tear can be fatal.

9
What standards referred to carbon steel plate

Carbon steel plate almost includes all the common standards of steel plate/sheet.

1. ASTM A36 plates – The most common standards of carbon steel plate
2. ASTM A283 Grade A, B, C – Also most common material in carbon
structural.
3. ASTM A516 – For boiler, vessel steel plate.
4. ASTM A537 – For heat treated carbon steel plate in fusion welded
pressure vessels and structural steel plates.
5. ASTM A573 – A kind of structural steel plate with carbon-manganese-
silicon.
6. ASTM A572 – ASTM A572 plate mechanical strength is higher
than A36. Where with lower weight.
7. ASTM A737 – For boiler, pressure vessels steel plate of low alloy steel.

ESSENTIALS FOR PROPER WELDING PROCEDURES

1. Correct electrode size

2. Correct current
3. Correct arc length or voltage
4. Correct travel speed
5. Correct electrode angle

Besides the steady sizzling sound that a correct arc produces the shape of the molten
pool and the movement of the metal at the rear of the pool serve as a guide in checking
weld quality. In a correctly made deposit the ripples produced on the bead will be
uniform and the bead will be smooth no overlaps or undercuts.

1. CORRECT ELECTRODE SIZE

The correct choice of electrode size involves consideration of a variety of factors,
such as the type, position, preparation of the joint, the ability of the electrode to
carry high current values without injury to the weld metal or loss of deposition
efficiency, the mass of work metal and its ability to maintain its original properties
after welding, the characteristics of the assembly with reference to effect stresses
set up by heat application, the practicability to heat treatment before and / or after
welding, the specific requirement before and / or after welding, the specific
requirements as to welding quality and cost of achieving the desired results.

10
2. CORRECT CURRENT
If current on equipment is too high or too low, you are certain to be disappointed
in your weld. If too high, the electrode melts too fast and your molten pool is large
and irregular, if too low, there is nor will enough heat to melt the base metal and
your molten pool be small, will pile up, look irregular.

3. CORRECT ARC LENGTH

If the arc is too long or voltage too high the metal melts off the electrode is large
globules which wobble from side to side as the arc wavers, giving a wide,
spattered and irregular bead-with poor fusion between original metal and
deposited metal.

4. If the arc is too short, or voltage too low, there is not enough heat to melt
the base metal properly and the electrode quite often sticks to the work,
giving a high, uneven bead, having irregular ripples with poor fusion.

5. CORRECTTRAVEL SPEED
When your speed is too fast your pool does not last long enough, impurities a
gas locked in. The bead in narrow and ripples pointed. When speed is too slow
the metal piles up, the bead is high and wide with a rather straight ripple.

6. CORRECT ELECTRODE ANGLE

The electrode angle is of particular

importance in fillet welding and deep groove
welding. Generally speaking, when making a
fillet weld, the electrode should be held so
that it bisects the angle between the plates
(as shown at right) and is perpendicular to
the line of weld, if undercut occurs in the
vertical member, lower the angle of the arc and direct the arc toward the vertical
member.

11
Welding Beads

Like sewing up a seam, there are several ways to run a weld bead along a joint. Yet
unlike tailors, welders frequently need to perform their work in an awkward position.
Gravity also plays a role in how molten metal gets deposited between metal plates or
pipe sections.
If you're welding overhead, for instance, you've got to move fast or the weld metal will
end up on your face shield, rather than in the joint. After preparing a joint for welding,
selecting the appropriate rod (if stick welding) and choosing the right machine settings,
a welder must use a certain kind of hand stroke (and the right speed) to get the bead
down properly.

Stringer beads
This is a straightforward bead in which you either "drag" (pull) or push the torch
across the joint with minimal (if any) side-to-side movement. Dragging means the
electrode is pointed back towards the puddle, leading it. This enables maximum
penetration and a robust-looking weld.

For heat-sensitive or thin metals, or when welding in the vertical-up position, welders
"push" the torch, which means pointing the electrode forward.
(See photo above.) When welding vertical-up, the molten metal wants to fall downward,
so directing the heat away from the puddle allows the weld to solidify quickly. The
drawback to pushing is that penetration into the base metal is much less than when
dragging (pulling) the torch.

Stringer beads are generally not very wide and can be used in any welding position.
Even though you're moving in a straight line, it's still important to make sure you get "tie
in" with the toe of the weld on either side.

12
Remember, the object of welding is not just to fill a joint with new metal. It's critical to get
fusion between the weld and the base metal. Sometimes, moving the torch along slowly
enough so the weld puddle flows over both sides of the joint is all it takes to achieve
good fusion. Other times a slight side-to-side manipulation is necessary.

Again, the side-to-side manipulation is slight. If you move too far from side to side, you'd
have a weave bead. (See below.) Stringer beads are also used in hard facing, a
surfacing operation that helps extend the life of scoops, fenders, plows and other
exterior metal parts on industrial equipment. Here the beads are not meant to fuse with
the base metal, however, but to create a protective surface over it.

Weave Beads
For wider welds, you can weave from side to side along a joint. For a fat joint, weaving
is the fastest way to knock off a welding assignment. This is especially true in the
case of groove welds on thick stock. Weaves are also common on fillet welds.

There are different types of weaves, of course, and every welder has his or her
favorite. Your hand can perform a zig-zag, crescent or curlycue technique. Besides
allowing a wider bead, weaving is used to control heat in the weld puddle.

Besides that, you'll usually want to pause on each side of the weld to achieve good tie in
and prevent undercutting of the edges. When you move across the center of the joint,
however, you'll want to hurry. Otherwise you may end up with a high crown (i.e. a bulge
in the middle). It's better to have a flat or just slightly convex weld face when you weave.

To keep the puddle from overheating or expanding, you can try a semi-circle weave,
with the center point or your stroke crossing the front of the puddle (or just ahead of it).
If you want more heat in the puddle, weave the semi-circle (or crescent) back through
the puddle, as shown in the previous drawing.

Weaving in the overhead position can be a challenge, since gravity tends to pull the
molten metal out of the weld. Even with practice, laying down an overhead weave bead
a half inch or wider can be a tall order. But welders learn to do it, since weaving saves
time when compared to stringer beads.

13
ACTIVITY 1
Direction: Read and answer the given questions. Write your answer on your
notebook.

1. What are the different types of carbon steel plates? How did it differ from
each other?
2. Enumerate the different types of weaving used in welding.
3. What are the essentials for proper welding procedures?

REMEMBER

1. The correct choice of electrode size involves consideration of a variety of

factors, such as the type, position, preparation of the joint, the ability of the
electrode to carry high current values
14 without injury to the weld metal or loss
of deposition efficiency, the mass of work metal and its ability to maintain its
original properties after welding, the characteristics of the assembly with
reference to effect stresses set up by heat application, the practicability to
heat treatment before and / or after welding, the specific requirement
before and / or after welding, the specific requirements as to welding quality
and cost of achieving the desired results.

14
CHECK YOUR UNDERSTANDING

DIRECTION. Write in your paper full word TRUE or FALSE in the statement below.
1. Carbon steel plates are available in different grades depending on the
carbon content and strength.

2. If current on equipment is too high or too low, you are certain to be

disappointed in your weld.

3. Dragging means the electrode is pointed back towards the puddle, leading
it. This enables maximum penetration and a robust-looking weld.

4. If the arc is too short, or voltage too low, there is not enough heat to melt
the base metal properly and the electrode quite often sticks to the work,
giving a high, uneven bead, having irregular ripples with poor fusion.

5. For heat-sensitive or thin metals, or when welding in the vertical-up position,

welders "push" the torch, which means pointing the electrode forward.

6. Weaves are also common on fillet welds.

7. If the arc is too short, or voltage too low, there is not enough heat to melt
the base metal properly and the electrode quite often sticks to the work,
giving a high, uneven bead, having irregular ripples with poor fusion.

8. Weaving in the overhead position can be a challenge, since gravity tends to

pull the molten metal out of the weld.

9. When your speed is too fast your pool does not last long enough, impurities a
gas locked in. The bead in narrow and ripples pointed. When speed is too
slow the metal piles up, the bead is high and wide with a rather straight ripple.

15
 POST TEST

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

1. Steel where the main alloying constituent is carbon.

a. Carbon steel
b. Alloy steel
c. Steel plate
d. Hard steel

2. As the carbon content rises, the metal becomes

a. Softer
b. Harder
c. Brittle
d. Breakable

3. These plates are in high demand especially from oil and gas industry as
they require thick plates of extremely good quality; the steel used is
certified because a small lamellar tear can be fatal.

a. Boiler steel plate

b. Tank steel plate
c. Shipbuilding steel plate
d. Structural steel plate

4. Low carbon steel plate has a carbon content of_______?

a. 0.06% to 0.25%
b. 0.25% to 0.55%
c. 0.55% to 1.0%
d. None of the above

16
6. The most common standards of carbon steel plate.

a. ASTM A516 plate

b. ASTM A36 plate
c. ASTM A537 plate
d. ASTM A572 plate

7. This is a straightforward bead in which you either "drag" (pull) or push the
torch across the joint with minimal (if any) side-to-side movement.

a. Fillet beads
b. Weave beads
c. Stringer beads
d. All of the above

8. A surfacing operation that helps extend the life of scoops, fenders, plows and
other exterior metal parts on industrial equipment. Here the beads are not meant
to fuse with the base metal, however, but to create a protective surface over it.

a. Dragging operation
b. Hard facing operation
c. Fusion
d. Weaving

9. Welding produce smoke of various types, which in some cases can lead
to medical conditions like

a. Hypertension
b. Metal fume fever
c. Arthritis
d. Rheumatism

17
 10.A A type of welding which is also often used in underwater welding in
the construction and repair of ships.

a. Submerged Arc Welding

b. Shielded Metal Arc Welding
c. Gas Tungsten Arc Welding
d. Gas Metal Arc Welding

11. Which of the following is not a normal precautionary measure?

a. clean tools and machines after using them

b. keep flammable materials always when working
c. remove watches, bracelets while working
d. sharpen tools properly for work efficiency

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

1. Welding is a common process for joining metals using a large variety

of applications.

2. Carbon steel plates are available in different grades depending on the

carbon content and strength.

3. If current on equipment is too high or too low, you are certain to be

disappointed in your weld.

4. Dragging means the electrode is pointed back towards the puddle, leading
it. This enables maximum penetration and a robust-looking weld.

5. If the arc is too short, or voltage too low, there is not enough heat to melt
the base metal properly and the electrode quite often sticks to the work,
giving a high, uneven bead, having irregular ripples with poor fusion.

6. For heat-sensitive or thin metals, or when welding in the vertical-up position,

welders "push" the torch, which means pointing the electrode forward.

18
7. Weaves are also common on fillet welds.

8. If the arc is too short, or voltage too low, there is not enough heat to melt
the base metal properly and the electrode quite often sticks to the work,
giving a high, uneven bead, having irregular ripples with poor fusion.

9. Weaving in the overhead position can be a challenge, since gravity tends to

pull the molten metal out of the weld.

10. When your speed is too fast your pool does not last long enough, impurities a
gas locked in. The bead in narrow and ripples pointed. When speed is too
slow the metal piles up, the bead is high and wide with a rather straight ripple.

19
References

1. ^ "American Welding Society - Technical". American Welding

Society. Retrieved 7 November 2011.
2. ^ "American Petroleum Institute Standards". American Petroleum
Institute. Retrieved 7 November 2011.
3. ^ "Standards Development". Standards Australia. Retrieved
7 November 2011.
4. ^ "About CSA". Canadian Standards Association. Archived from
the original on 29 October 2011. Retrieved 7 November 2011.
5. ^ "BSI Standards". BSI Standards. Retrieved 7 November 2011.
6. ^ "ISO Standards". International Organization for Standardization.
Retrieved 7 November 2011.
7. ^ "About us". European Committee for Standardization (CEN). Retrieved
7 November 2011.
8. ^ Davis, A.: "Welder Qualification Standards - Philosophy and
Feedback", AWS Welding Journal, July 2003, pp. 14–16. EN ISO 9606-1 was
finally published in November 2013 and is gradually introduced in Europe,
the deadline for complete replacement being October 2015.
9. ^ "EWF Guide to deal with the transition from EN 287-1 to EN ISO 9606-
1 as efficiently as possible (EWF-654-13)" (PDF) (PDF). European Federation
for Welding, Joining and Cutting (EWF). 2013. Archived from the original (PDF)
on 2013-12-12.
10. ^ "NA 092 Welding and allied processes Standards Committee" .
DIN. Retrieved 7 November 2011.

20
Acknowledgements

Writer: Elesio P. Tabacon Jr.

Head Teacher VI
Raja Soliman Science and Technology High School

Management Team: Maria Magdalena M. Lim

Schools Division Superintendent Manila

Aida H. Rondilla
Chief Education Supervisor

Dr. Ariel Tosio

Education Program Supervisor

21