Professional Documents
Culture Documents
Department of Education
National Capital Region
Division of City Schools – Manila
QUARTER 1
Week 5 Module 5
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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.
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!
•
throughout the lesson.
METAL
Looking Back to your Lesson - This section will measure what learnings and skills did
•
ARC
you understand from the previous lesson.
Brief Introduction- This section will give you an overview of the lesson.
•
•
WE MODULE
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)
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LESSON 4 - LO 4. Prepare Welding Consumables
EXPECTATION
Grade 1
4.1 Identify welding electrodes according to classification and specifications
SHIELDE
4.2 Maintain and keep electrodes in electrode oven based on prescribed temperature
4.3 Prepare specified consumable gases based on job requirements
ME
4.4 Select correct materials in accordance with job requirements
PRE - TEST
Multiple Choices:
1. These are low hydrogen electrodes usually used in welding high sulfur and high
carbon steel.
a. E – 6030
b. E – 7016
c. E – 60 11
d. E – 70 11
2. This electrode has a thick coating which is made of 30% iron powder used in
welding mild and low alloy steel.
a. E – 7012
b. E – 7016
c. E – 7014
d. E – 7011
3. This is type of electrode is primarily use for the construction of ships, buildings,
bridges tanks and piping systems.
a. E – 6010
b. E – 6011
c. E – 6020
d. E – 6013
3
4. An electrode particularly suited for sheet metals.
a. E – 6010
b. E – 6011
c. E – 6020
d. E – 6013
5. An electrode useful in welding higher strength, free machining, cold rolled, alloy,
high carbon and high sulfate steel.
a. E – 6010
b. E – 6011
c. E – 6015
d. E - 6013
a. E – 6010
b. E – 6011
c. E – 6020
d. E – 6013
4
9. This is made of cast iron and used for welding cast iron.
10. This electrode is suited for flat horizontal, vertical and overhead positions of
welding.
A. E – 6020
b. E – 6013
c. E – 7024
d. E – 6030
BRIEF INTRODUCTION
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LESSON 4 - LO 4. Prepare Welding Consumables
Objectives:
Types of Consumables
As you’ll learn in a welding program, the type of consumable used can vary
between a cored wire, solid wire, or rod electrode depending on the job. Electrodes
draw the necessary energy in order to perform welding applications.
The American Welding Society has designated filler material specifications and
listed which welding processes each material can be used for. As you can see from
the chart, some of the filler materials should only be used in one welding process, such
as iron and steel gas welding rods for Oxy-Acetylene (OA) welding. Below are a few
different types of electrodes used for some of the most common welding processes.
• Shielded metal arc welding uses a powder-coated electrode (flux). When it burns
off, the coating shields the weld from oxygen.
• Filler metal is often added to the coating to speed up the process.
• Gas-tungsten arc welding uses a non-consumable tungsten rod to heat the metal
and filler metal. The rod just heats the metal and doesn’t add to the filler material.
• Gas metal arc welding is a process that uses a wire consumable with a wire
spool feeding the wire into the weld joint.
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“Matching” Strength of Consumables to Metals
Along with ensuring the consumable has the same melting point as the base
metal, it’s also critical to match the strength of the filler to the strength of the metals
being welded to get the best results.
However, “matching” the strength of the base metal with the filler material isn’t as
simple as matching the strength classifications of metals using a chart because base
and filler metals have different minimum yield and tensile strengths. The yield strength
is the amount of stress a material can handle before it starts to deform plastically, while
the tensile strength is the amount of stress a material can take before it breaks.
Electrodes for Shielded Metal Arc Welding (SMAW) or stick electrodes must be
properly stored in order to deposit quality welds. When stick electrodes absorb moisture
from the atmosphere, they must be dried in order to restore their ability to deposit
quality welds. Electrodes with too much moisture may lead to cracking or porosity.
Operational characteristics may be affected as well. If you've experienced unexplained
weld cracking problems, or if the stick electrode arc performance has deteriorated, it
may be due to your storage methods or re-drying procedures.
Follow these simple storage, exposure and re-drying techniques to ensure the
highest quality welds, as well as the best operational characteristics from your stick
electrodes.
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Storing Low Hydrogen Stick Electrodes
Low hydrogen stick electrodes must be dry to perform properly.
Low hydrogen stick electrode coatings that have picked up moisture may result in
hydrogen induced cracking, particularly in steels with a yield strength of 80,000 psi (550
MPa) and higher.
Moisture resistant electrodes with an "R" suffix in their AWS classification have a high
resistance to moisture pickup coating and, if properly stored, will be less susceptible to
this problem, regardless of the yield strength of the steel being welded. Specific code
requirements may indicate exposure limits different from these guidelines.
All low hydrogen stick electrodes should be stored properly, even those with an "R"
suffix. Standard EXX18 electrodes should be supplied to welders twice per shift.
Moisture resistant types may be exposed for up to 9 hours.
When containers are punctured or opened, low hydrogen electrodes may pick up
moisture. Depending upon the amount of moisture, it will damage weld quality in the
following ways:
3. Severe moisture pickup can cause weld cracks in addition to under-bead cracking,
severe porosity, poor appearance and slag problems.
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Re-drying Low Hydrogen Stick Electrodes
Re-drying, when done correctly, restores the electrodes' ability to deposit quality welds.
Proper re-drying temperature depends upon the electrode type and its condition.
One hour at the listed final temperature is satisfactory. DO NOT dry electrodes at higher
temperatures. Several hours at lower temperatures is not equivalent to using the
specified requirements.
Electrodes of the E8018 and higher strength classifications should be given no more
than three one-hour re-dries in the 700 to 800°F (370 to 430°C) range. This minimizes
the possibility of oxidation of alloys in the coating resulting in lower than normal tensile
or impact properties.
Any low hydrogen electrode should be discarded if excessive re-drying causes the
coating to become fragile and flake or break off while welding, or if there is a noticeable
difference in handling or arc characteristics, such as insufficient arc force.
Electrodes to be re-dried should be removed from the can and spread out in the oven
because each electrode must reach the drying temperature.
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Re-drying Conditions - Low Hydrogen Stick Electrodes
Final Redrying
Temperature
E7018, E7028 E8018,
E9018,
Condition Pre-drying E10018,
Temperature(1) E11018
Electrodes exposed to air for less than one week; N/A 650 to 750°F 700 to
no direct contact with water. (340 to 400°C) 800°F (370
to 430°C)
Electrodes which have come in direct contact 180 to 220°F (80 to 650 to 750°F 700 to
with water or which have been exposed to high 105°C) (340 to 400°C) 800°F (370
humidity. to 430°C)
(1) Pre-dry for 1 to 2 hours. This will minimize the tendency for coating cracks or
oxidation of the alloys in the coating.
If exposed to humid air for long periods of time, stick electrodes from opened containers
may pick up enough moisture to affect operating characteristics or weld quality. If
moisture appears to be a problem, store electrodes from the opened containers in
heated cabinets at 100 to 120°F (40 to 50°C). DO NOT use higher temperatures,
particularly for electrodes from the "Fast Freeze" group.
Some electrodes from wet containers or long exposure to high humidity can be re-dried.
Adhere to the procedures in the following table for each type.
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Stick Electrode Electrode Group Final Re-drying Time
Temperature
E6010: Fleet weld 5P, Fast Freeze - excessive moisture is Not Recommended N/A
5P+ indicated by a noisy arc and high spatter,
E6011: Fleet weld 35, rusty core wire at the holder end or
35LS, 180 objectionable coating blisters while
E7010-A1: SA-85(1) welding.
E7010-G: SA-HYP+(1)
E8010-G: SA-70+(1), Re-baking of this group of stick
SA-80(1) electrodes is not recommended.
E9010-G: SA-90(1)
E7024: Jet weld 1, 3 Fast Fill - excessive moisture is indicated 400 to 500°F (200to 30 - 45
E6027: Jet weld 2 by a noisy or "digging" arc, high spatter, 260°C) minutes
tight slag, or undercut. Pre-dry unusually
damp electrodes for 30 - 45 minutes at
200°F to 230°F (90 - 110°C) before final
drying to minimize cracking of the coating.
(11)
E6012: Fleet weld 7 Fill Freeze - Excessive moisture is 300 to 350°F (150 to 20 - 30
E6013: Fleet weld 37 indicated by a noisy or "digging" arc, high 180°C) minutes
E7014: Fleet weld 47 spatter, tight slag or undercut. Pre-dry
E6022: Fleet weld 22 unusually damp electrodes for 30 - 45
minutes at 200° - 230°F (90° - 110°C)
before final drying to minimize cracking of
the coating
(1) Pre-dry for 1 to 2 hours. This will minimize the tendency for coating cracks or
oxidation of the alloys in the coating.
Using longer drying times or higher temperatures can easily damage the
electrodes. For drying, remove the electrodes from the container and spread
them out in the furnace because each stick electrode must reach the drying
temperature.
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AWS Classifications
The American Welding Society (AWS) numbering system can tell a welder quite a bit
about a specific stick electrode including what application it works best in and how it
should be used to maximize performance. With that in mind, let's take a look at the
system and how it works.
The prefix "E" designates an arc welding electrode. The first two digits of a 4-digit
number and the first three digits of 5-digit number indicate minimum tensile strength.
For example, E6010 is a 60,000 psi tensile strength electrode while E10018 designates
a 100,000 psi tensile strength electrode.
E 60 1 10
Electrode Tensile Position Type of Coating and
Strength Current
The next to last digit indicates position. The "1" designates an all position electrode, "2"
is for flat and horizontal positions only; while "4" indicates an electrode that can be used
for flat, horizontal, vertical down and overhead. The last 2 digits taken together indicate
the type of coating and the correct polarity or current to use. See chart below:
As a welder, there are certain electrodes that you will most likely see and use time and
time again as you go about your daily operations. A DC machine produces a smoother
arc. DC rated electrodes will only run on a DC welding machine. Electrodes which are
rated for AC welding are more forgiving and can also be used with a DC machine.
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Here are some of the most common electrodes and how they are typically used:
E6010
DC only and designed for putting the root bead on the inside of a piece of pipe, this is
the most penetrating arc of all. It is tops to dig through rust, oil, paint or dirt. It is an all-
position electrode that beginning welders usually find extremely difficult, but is loved by
pipeline welders worldwide. Lincoln Fleet weld® 5P+ sets the standard in this category.
E6011
This electrode is used for all-position AC welding or for welding on rusty, dirty, less-
than-new metal. It has a deep, penetrating arc and is often the first choice for repair or
maintenance work when DC is unavailable. The most common Lincoln product is Fleet
weld® 180 for hobby and novice users. Industrial users typically prefer Fleet weld® 35.
E6013
This all-position, AC electrode is used for welding clean, new sheet metal. Its soft arc
has minimal spatter, moderate penetration and an easy-to-clean slag. Lincoln Fleet
weld® 37 is most common of this type.
E7018
A low-hydrogen, usually DC, all-position electrode used when quality is an issue or for
hard-to-weld metals. It has the capability of producing more uniform weld metal, which
has better impact properties at temperatures below zero. The Lincoln products are
typically Jet weld® LH-78 or our new Excalibur® 7018.
E7024
Typically used to make a large weld down hand with AC in plate that is at least ¼" thick,
but more commonly used for plate that is ½" and up. Lincoln has several electrodes in
this category that are called Jet weld® 1 or 2.
Other Electrodes
Although not nearly as common, an electrode may have additional numbers after it such
as E8018-B2H4R. In this case, the "B2" indicates chemical composition of the weld
metal deposit. The "H4" is the diffusible hydrogen designator, which indicates the
maximum diffusible hydrogen level obtained with the product. And "R" stands for the
moisture resistant designator to indicate the electrode's ability to meet specific low
moisture pickup limits under controlled humidification tests.
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Electrode Coding and Applications of Mild Steel and Alloy Steel Electrodes -
Some of the applications of mild steel and alloy (medium to high tensile) steel
electrodes are given below:
Electrode
Applications
coding
AWS : E 6010 Pipe lines, pressure vessels, storage tanks and field work
BS : E 100
IS : M 100264
AWS: E6012 Steel furniture, storage tanks, truck and bus bodies, shaft build up,
BS : E 206, trusses, chimneys, gates and grills, repair jobs
216
IS : M 206253
M216251
AWS : E 6013 Pipe lines, truck bodies, steel window frame, farm machinery,
BS : E bridges, railway wagon, ships, trailers, boilers, tanks and coaches,
307,316,317 building construction.
IS : M 307264
M 316263
M 317274
AWS: E 6015 For welding high carbon or low alloy steels, high sulphur bearing
IS : E 6102XX steels and armor plate.
AWS: E 6020 Bridges, cranes, locomotive fire boxes, truck chassis frame, boilers
BS : E 422, and pressure vessels, fabricated plate girders, columns etc.
426 Produce radiographic quality welds.
IS : M 422275
M 426274
AWS: E 6027 A deep penetration electrode, used for welding heavy deck plates,
BS : E 922P plate girders for bridge work, loco fire box, rotary kilns and driers.
IS : M
922411P
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AWS: E 7010, High pressure boiler plates or tubes containing 1% Cr, 0.5% Mo,
7014 carbon moly. Piping, pipelines for oil and gas transmission.
BS: E 100,
E317
IS: E 100411
E 307512
AWS: E 7013 Bridges, dams, ships, tanks and wagons, cranes, railway bogies
BS: E 317
IS: M 317375
AWS: E 7016 Concrete reinforcement rods, rails, wagons, crank shaft rebuilding,
BS: E 616H earth moving machinery, buffer layer prior to hard facing, pressure
IS: M 616479H vessels, butt welding of rail ends.
AWS: E 7016 High carbon steel to mild steel, high carbon steel parts, cast steel,
BS: E601H steel rich in sulphur, steel of unknown composition.
IS: M 601279H
AWS: E 7018 Bridges, penstocks, pressure vessels, atomic reactor shell and pipe
BS : E 601JH work, blast furnace steel work, earth moving machinery.
IS : M 601389
JH
AWS: E 7018 Pressure vessels, air receivers, boilers, bridges and, penstocks,
BS: E 614HJ buffer layer prior to hard facing. Produce radiographic quality welds.
IS : M 614479
AWS: E For welding steels; ASTM: 1/2 Cr, 1/2 Mo; 1(1/4) Cr, 1/2 Mo, IS
8013B2 steel: 07 Cr 90 Mo 55, German steels: 13 Cr Mo 44, 13 Cr Mo V 42
BS : E etc.
1CrMoR
IS: E 31432C
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AWS: E 8016 Loco butt welding, buffer layer before hard facing.
BS: E 614
IS : E
614512H
BS : E 611H High temperature high pressure boiler plates and tubes operating
IS : E up to 575°C.
611512H
AWS: E High tensile steel machinery parts, cold worked alloy steel, fine
8018G grained steel containing Cu-Ni or Ni.
BS : E 611JH
IS : M
611469JH
AWS: E 9016 Chemical plants, superheated steam boilers, and refinery parts
BS : E 611 operating up to 610°C.
IS : E
611512H
AWS : E 9018- For welding steels containing Cr and Mo and being used in boilers,
B3 oil refineries, chemical plants, and in power plants as structures and
BS : E2Cr pipes operating up to 610°C.
MoBH
IS : E 61131D
AWS: E 11018 Bridge and penstock construction, surfacing .and repair of road
BS : E 601JH building machinery and ore dressing plants, concrete reinforcement
IS : M rods, earth moving machinery.
601XXXJH
AWS : E High tensile steel, penstocks, earth moving equipment, heavy steel
13018G fabrications.
BS : E 601JH
IS : 601XXXJH
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ACTIVITY 1
Direction: Read and answer the given questions. Write your answer on your notebook.
REMEMBER:
• Shielded metal arc welding uses a powder-coated electrode (flux). When it burns off,
the coating shields the weld from oxygen. Filler metal is often added to the coating to
speed up the process.
• Gas-tungsten arc welding uses a non-consumable tungsten rod to heat the metal
and filler metal. The rod just heats the metal and doesn’t add to the filler material.
• Gas metal arc welding is a process that uses a wire consumable with a wire spool
feeding the wire into the weld joint.
(19)
CHECK YOUR UNDERSTANDING
1. AWS –
2. GTAW –
3. FCAW –
4. GMAW –
5. OA –
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POST TEST
1. These are low hydrogen electrodes usually used in welding high sulfur and high
carbon steel.
a. E – 6030
b. E – 7016
c. E – 60 11
d. E – 70 11
2. This electrode has a thick coating which is made of 30% iron powder used in
welding mild and low alloy steel.
a. E – 7012
b. E – 7016
c. E – 7014
d. E – 7011
3. This is type of electrode is primarily use for the construction of ships, buildings,
bridges tanks and piping systems.
a. E – 6010
b. E – 6011
c. E – 6020
d. E – 6013
4. An electrode particularly suited for sheet metals.
a. E – 6010
b. E – 6011
c. E – 6020
d. E – 6013
5. An electrode useful in welding higher strength, free machining, cold rolled, alloy,
high carbon and high sulfate steel.
a. E – 6010
b. E – 6011
c. E – 6015
d. E - 6013
6. An electrode intended to weld pressure vessels, heavy machines bases and
steel structures.
a. E – 6010
b. E – 6011
c. E – 6020
d. E – 6013
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7. An electrode is considered ideal if it meets the criteria:
a. It gives minimum weld strength.
b. It has slow deposition
c. It gives bad arc stability.
d. It produces minimum spatter.
8. This is recommended for metal such as copper, brass and aluminum.
A. non – ferrous electrode
b. high carbon steel electrode
c. mild steel electrode
d. special alloy steel electrode
9. This is made of cast iron and used for welding cast iron.
a. non – ferrous electrode
b. alloy steel electrode
c. cast iron electrode
d. mild steel electrode
10. This electrode is suited for flat horizontal, vertical and overhead positions of
welding.
A. E – 6020
b. E – 6013
c. E – 7024
d. E – 6030
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REFERENCE PUBLICATIONS
Published by the American Welding Society550 N.W. LeJuene Road, Miami, Florida
33126
Safety in Welding and CuttingANSI Z49.1Recommended Safe Practices for the
Preparation for Welding andCutting of Containers and Piping That Have Held
Hazardous SubstancesAWS F4-1Standard Methods for Mechanical Testing of
WeldsAWS B4.0Terms and DefinitionsAWS 3 .0Welding SymbolsAWS 2.0Operator’s
Manual for Oxyfuel Gas CuttingAWS
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REFERENCES:
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ACKNOWLEDGEMENT
This module was outlined based on the Most Essential Learning Competencies (MELC) for
S.Y. 2020-2021, the K to 12 Basic Education Curriculum Guide, Learning Continuity Plan
(LCP) for Shielded Metal Arc Welding (SMAW) and Training Regulation of TESDA for
Shielded Metal Arc Welding (SMAW) NC I.
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