Technology

Vocational Livelihood 11
Shielded Metal Arc Welding

Quarter 1
Self-Learning Module 7
TITLE : CLEANING SURFACES AND EDGES OF MATERIALS
Writer : Rubener P. Tacsay
Reviewer : Orlando A. Joven Jr (Validator)
Emmanuel B. Penetrante (Technical)
 EXPECTATIONS

At the end of this module, the learners will be able to:

 define the meaning of work piece;
 select materials, metal to be as work piece; and
 explain the important of cleaning surfaces and edges of materials

PRETEST

Directions: Write the letter of the correct answer in every items. Provide separate
answer sheet.

1. Why is cleaning the surface and edges of metal so important?

a. It Provide good appearance of the cut metal
b. It is given in the instruction
c. Dirt and other substances are detrimental to weld quality
d. It makes it easy to fit-up joint.
2. What tool is used to easily clean metal scale, old paints and rust.
a. Grinder
b. Scrapper
c. Chipping hammer
d. Metal sand paper
3. What is an air tight fit-up necessary for Tee-joint preparation?
a. Dirt or contaminant will not stick
b. Gas pocket associated with unfit fit-up are avoided
c. None of the above
4. Beveled Joint is considered “critical” in the category of weld. This mean
that:
a. Weld joints are necessary for radiography
b. Weld joint is for visual
c. Weld joint needs no inspection
d. All of the above
5. Root face of beveled joint will not exceed a maximum of ___________
a. 3 mm
b. 5mm
c. 4mm
d. 6 mm
 RECAP

What are the different examples of Cutting tools and Equipment?

__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________

LESSON

CLEANING SURFACES AND EDGES MATERIALS

INTRODUCTION:

One of the basic needs to prepared in welding job is preparing the work piece that
suited for the job. Work piece refer to a piece of metal which will be weld to do a
certain task, in welding industry it is necessary to identify the particular metal as
work piece which is the Carbon steel, it is a steel with carbon content from about
0.05% up to 2.1% by weight. The definition of carbon steel from the American Iron
and Steel Institute

The term carbon steel may also be used in reference to steel which is not stainless
steel; in this use carbon steel may include alloy steels. High carbon steel has many
different uses such as milling machines, cutting tools (such as chisels) and high
strength wires. These applications require a much finer microstructure, which
improves the toughness.
As the carbon percentage content rises, steel has the ability to
become harder and stronger through heat treating; however, it becomes less ductile.
Regardless of the heat treatment, a higher carbon content reduces weldability. In
carbon steels, the higher carbon content lowers the melting point.
CLASSIFICATION OF CARBON STEEL
Mild or low-carbon steel
Mild steel (iron containing a small percentage of carbon, strong and tough but not
readily tempered), also known as plain-carbon steel and low-carbon steel, is now the
most common form of steel because its price is relatively low while it provides
material properties that are acceptable for many applications.
High-tensile steel
High-tensile steels are low-carbon, or steels at the lower end of the medium-carbon
range
Higher-carbon steels sulfur in particular make the steel red-short, that is, brittle
and crumbly at working temperatures

CARBON STEEL IS BROKEN DOWN INTO FOUR CLASSES BASED ON CARBON

CONTENT:
Low-carbon steel
0.05 to 0.25% carbon (plain carbon steel) content.
Medium-carbon steel
Balances ductility and strength and has good wear resistance; used for large parts,
forging and automotive components.
High-carbon steel
Approximately 0.6 to 1.0% carbon content. Very strong, used for springs, edged tools,
and high-strength wires.
Ultra-high-carbon steel
Steels that can be tempered to great hardness. Used for special purposes like (non-
industrial-purpose) knives, axles or punches

Proper cleaning of metal surfaces and edges must be in mind before any fit – up and
tacking take places. There must be an acceptable cleaning procedure applied in the
surface of the plates and pipe before welding joints. The cleaning of surface and edges
is considered one step for achieving quality in the preparation of materials.

Below are acceptable practices in the preparation of surfaces and edges of the
materials

Edge A needs to grind smooth 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 place together to see to it that no gasps are found.
Then are tightly assembled. The contaminants that are
found in the fit-up must be cleaned and removed for
welding safety

Source:https://www.the
fabricator.com/thefabric
ator/article/cadcamsoft
ware/the-art-of-bevel-
Picture A cutting#gallery-3
Source:https://www.thefabricator.com/thefabrica
tor/article/cadcamsoftware/the-art-of-bevel-
cutting#gallery-3
Common tools use in cleaning surfaces and Edges on Materials

Wire brush is a tool consisting of

a brush whose bristles are made
of wire, most often steel wire.
The steel used is generally a
medium- to high-carbon

Angle grinder, also known as a side

grinder or disc grinder, is a handheld power
tool used for grinding (abrasive cutting)
and polishing. Although developed originally as
tools for rigid abrasive discs, the availability of
an interchangeable power source has
encouraged their use with a wide variety of
cutters and attachments.
Angle grinders can be powered by an electric motor, petrol engine or compressed
air. The motor drives a geared head at a right-angle on which is mounted
an abrasive disc or a thinner cut-off disc, either of which can be replaced when worn.
Angle grinders typically have an adjustable guard and a side-handle for two-handed
operation. Certain angle grinders, depending on their speed range, can be used
as sanders, employing a sanding disc with a backing pad or disc. The backing system
is typically made of hard plastic, phenolic resin, or medium-hard rubber depending
on the amount of flexibility desired.

PICTURE B

SAFETY MEASURES:

Before tacking, air tight fit-up must be check so as to avoid pockets in the
fitted edge or surfaces.

Original edge of cut

 Picture A

The picture 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 grinder until such
appearance is accepted, Dirt and contaminants such as oil, grease, scale, water and
old paints must be removed from the surfaces using appropriate tools and solution.

600

1/8” (3mm)
max

Source: https://www.wikihow.com/Weld-With-a-%22Buzz-Box%22
1/8” (3mm)
max
After root face is made and smoothened on the beveled surface, the two plates
are place together facing each other with approximate gap before tacking may be
done. This kind of preparation is applicable for plates and pipes of different types of
materials. The root face must not exceed the maximum of 3mm thick from wall
thickness of 6mm to 20 mm.

ACTIVITIES

ACTIVITY NO.1: Label the parts of portable grinder. Choose the label from the box
Lock nut Flex wheel Plastic pad Inner flange Shaft lock Lock
nut wrench

Source: https://www.manualslib.com/manual/98200/Makita-Angle-Grinder.html?page=7#manual
ACTIVITY NO.2
Make a short write up on “What are the different factors needed to consider when
using the flow cutting machine?
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________

WRAP–UP

OTHER CUTTING MACHINE

Use the checklist below as basis for judging whether you meet the required
competency. Mark check in the space provided.

Performance Indicators YES NO

1. Can identify the different parts of angle grinder
2.Can installed or removed the wheel guard
3.Can check all the precaution before using the flow cutting.
4 Can installed or removed the depressed center grinding
wheel/Multi-disc
5. Can installed or removed the depressed abrasive disc
6.Can replaced the carbon brush
7. Can operate the angle grinder confidently
8. Can repair the angle grinder safety fuse

Note: Have learners assess their performance. For criteria needing assistance, provide
the appropriate intervention

VALUING
What is the best way to clean the surface and edges of materials?
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
 POSTTEST

Directions: Encircle the letter of the correct answer in every items.

_____1. What is a piece of metal which will be weld to do a certain task?

a. Electrode
b. Grinder
c. wire brush
d. workpiece
_____2. This is a tool consisting of a brush whose bristles are made of wire, it is
generally a medium- to high-carbon
a. Electrode
b. Grinder
c. Steel brush
d. Workpiece
_____3. This is a handheld power tool used for grinding (abrasive cutting) and
polishing.
a. Electrode
b. Portable Angle Grinder
c. Steel brush
d. Workpiece
_____4. Root face of beveled joint will not exceed a maximum of ___________
a. 3 mm
b. 5mm
c. 4mm
d. 6 mm
_____5. This is iron containing a small percentage of carbon, strong and tough but
not readily tempered
a. High-tensile steel
b. Higher-carbon steels
c. Medium Carbon steel
d. Mild or low-carbon steel
 KEY TO CORRECTION
D 5. 5. A
D 4. 4. D
B 3. 3. Inner flange 3. B
C 2. 2. Shaft lock 2. Flex wheel 2. A

References
D 1. 1. Lock nut wrench 1. Lock nut 1. C
POST TEST ACTIVITY 1 PRETEST

References

Government of the Philippines. DepEd-NCR Shielded Metal Arc Welding Module 1

series 2019

^ Jump up to:a b c d "What is CNC Plasma Cutting?". www.manufacturingnetwork.com. Retrieved 2015-11-

17.

^ "The life and times of plasma cutting". www.thefabricator.com.

^ "Making plasma cutting easier". www.thefabricator.com.

^ "Eye and face protection. - 1910.133". www.osha.gov. Retrieved 2015-09-27.

^ "How To Use A Plasma Cutter - A Comprehensive Beginners Guide".

^ Sacks, Raymond; Bohnart, E. (2005). "17". Welding Principles and Practices (Third ed.). New York:
McGraw_Hill. p. 597. ISBN 978-0-07-825060-6.^ see the online seller Amazon, for example

https://www.youtube.com/watch?v=GhDwwmtqH-Y

https://www.millerwelds.com/resources/article-library/tech-tips-for-better-plasma-cutting

http://www.cvosupply.com/upload/images/Document/%E0%B9%80%E0%B8%84%E0%B8%A3%E0%
B8%B7%E0%B9%88%E0%B8%AD%E0%B8%87%E0%B8%95%E0%B8%B1%E0%B8%94%E0%B9%81%E
0%B8%81%E0%B9%8A%E0%B8%AA/koike/manual/Koike%20IK-12%20Beetle.pdf

https://www.youtube.com/watch?v=GhDwwmtqH-Y

https://www.google.com.ph/search?hl=en&tbm=isch&sxsrf=ALeKk01E0r5RTtR2mwCvP_noVntoLBB
6pg%3A1595814913293&source=hp&biw=1366&bih=625&ei=ATQeX4zbD8zVm

https://www.ganpatind.com/carbon-steel-plates-supplier-exporter/
https://www.thefabricator.com/thefabricator/article/cadcamsoftware/the-art-of-bevel-
cutting#gallery-3

https://www.thefabricator.com/thefabricator/article/plasmacutting/better-bevels-with-plasma-arc-
cutting

1. "Classification of Carbon and Low-Alloy Steels"

2. ^ Knowles, Peter Reginald (1987), Design of structural steelwork (2nd ed.), Taylor & Francis,
p. 1, ISBN 978-0-903384-59-9.
3. ^ Engineering fundamentals page on low-carbon steel
4. ^ Elert, Glenn, Density of Steel, retrieved 23 April 2009.