Module Metal Works Edu

HOW TO USE THIS MODULE
Welcome to the Module on Metal Works. This module contains

training materials and activities for you to complete.
The unit of competency “Perform Metal Works” contains the

knowledge, skills and attitudes required for a student. The module
itself focused in two competencies that includes, welding works
and introduction to machine shop practice. Upon completion of this
module you can move on to the next unit of competency and eventually
complete the competency requirements needed in the course.
In connection, this module contains a topic that focused on

welding works particularly, shielded metal arc welding and a little
topic on gas metal arc welding such metal inert gas welding and
tungsten inert gas welding. It also includes a topic that describes an
overview to introduction to machineshop work.
You are also required to answer the Pretest before you 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. Answer the Posttest before you
proceed to the next Module.
If you have questions, do not hesitate to ask your facilitator for

assistance.
Date Developed: Document No.

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Table of Contents
Page
How to use this Module…………………………………………………..............1
Introduction…………………………………………………………….…………2
Technical Terms………………………………………………………………..…3
Covered Competencies and Assessment Criteria………………………………....4
Reference……………………………………………………………………….….8
Learning Experiences/Activities…………………………………….…………….9
Information Sheet 1………………………………………………………………13
Self-Check 1.1…………………………………………………………………...17
Answer Key 1.2……………………………………………………………….....17
Information Sheet 2………………………………………………………………18
Self-Check 2.1…………………………………………………………………...27
Answer Key 2.2………………………………………………………………….28
Information Sheet 3……………………………………………………………...29
Self-Check 3.1…………………………………………………………………...37
Answer Key 3.2………………………………………………………………….39

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Self-Check 4.1…………………………………………………………………....49
Answer Key 4.2…………………………………………………………………..49
Self-Check 5.1…………………………………………………………………...54
Answer Key 5.2………………………………………………………………….54
Information Sheet 6………………………….......................................................55
Learning Experiences/Activities………………………………………………...66
Job Sheet 1……………………………………………………………………….68
Job Sheet 2……………………………………………….....................................69
Job Sheet 3……….................................................................................................70
Job Sheet 4……………………………………………………………………….71
Self-Assessment…………………………………………………………………72

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Unit of Competency: WELD ON CARBON STEEL PLATES
Module Title: WELDING GROOVE WELD ON CARBON STEEL

PLATES (1G, 2G, 3G AND 4G)
INTRODUCTION:
This module contains information and suggested learning activities on

Welding Groove. It includes instruction and procedure on how to Weld Groove
on Carbon Steel Plates. Completion of this module will help you better
understand it for future reference.
This module consists of three (4) 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 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.
SUMMARY OF LEARNING OUTCOMES:
Upon completion of the module the students should be able to:

LO1 Weld Carbon Steel Plates in Flat Position (1G)
LO2 Weld Carbon Steel Plates in Horizontal Position (2G)
LO3 Weld Carbon Steel Plates in Vertical Position (3G)
LO4 Weld Carbon Steel Plates in Overhead Position (4G)
ASSESSMENT CRITERIA:
Refer to assessment criteria of learning outcomes of this module.

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TECHNICAL TERMS
Angular distortion -is shifting of metal parts so they are out of alignment, caused by weld
shrinkage.
Bevel angle- is the angle at which a bevel is cut.
Butt joint- is a joint between two members lying approximately in the same plane.
Complete fusion- is where fusion has occurred over the entire base metal surfaces exposed for
welding between all layers and passes.
Flat welding- is a welding done on the upper side of the joint with the face of the weld parallel
to the ground, also called down hand welding.
Groove angle -is the total included angle of the groove.
Groove weld- is a weld made in the groove between two pieces to be joined.
Horizontal welding- it is a welding position with the axis of the weld parallel to the ground
and the face perpendicular to the ground.
Root crack- is a crack in the weld or heat-affected zone at the root of the weld.
Tack weld -is a small, temporary weld used to hold strongly the parts of a weldment in
alignment until the final welds are made.
V-groove- is a straight angular groove on both metal pieces to be joined.
Root penetration -is the depth that a groove weld extends into the root of a joint, measured at
the center of the root cross-section.
Root opening- is the area between the pieces to be joined at the root of the joint also called
root gap.
Stringer bead -is a type of weld bead made with little side- to-side movement.

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PROGRAM/ COURSE : SMAW NCII
UNIT OF COMPETENCY : WELD CARBON STEEL PLATES
MODULE TITLE : PERFORMING GROOVE WELDING ON CARBON

STEEL PLATES
LearningOutcome#1 : Weld carbon steel plates in flat position (1G)
1. Root penetration not exceeding allowable tolerances specified by welding

codes/ standards on
 concavity
 convexity
 undercut
 excess penetration
 lack of fusion
 burn-through
 cracks
2. Weld capping/ final pass not exceeding allowable tolerances specified by
welding codes/ standards on
 height of reinforcement
 underfill
 porosities
 undercut
 cracks
 cold laps
3. Uniformity of bead ripples must be in accordance with welding standards
4. Stringer or layered beads deposited in accordance with welding standards
5. Finish weldment visually acceptable in accordance with welding standards
for:
 spatters
 arc strikes
 slag
 uniformity of beads

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STEEL PLATES
LearningOutcome#2 : Weld carbon steel plates in Horizontal position (2G)

codes/ standards on
 concavity
 convexity
 undercut
 lack of fusion
 burn-through
 cracks
 underfill
 porosities
 undercut
 cracks
 cold laps
9. Stringer or layered beads deposited in accordance with welding standards
10. Finish weldment visually acceptable in accordance with welding
standards for:
 spatters
 arc strikes
 slag

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STEEL PLATES
LearningOutcome#3 : Weld carbon steel plates in Vertical Position (3G)

codes/ standards on
 concavity
 convexity
 undercut
 lack of fusion
 burn-through
 cracks
 underfill
 porosities
 undercut
 cracks
 cold laps
14. Stringer or layered beads deposited in accordance with welding
standards
standards for:
 spatters
 arc strikes
 slag

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STEEL PLATES
LearningOutcome#4 : Weld carbon steel plates in Over Head Position (4G)

codes/ standards on
 concavity
 convexity
 undercut
 lack of fusion
 burn-through
 cracks
 underfill
 porosities
 undercut
 cracks
 cold laps
19. Stringer or layered beads deposited in accordance with welding
standards
standards for:
 spatters
 arc strikes
 slag

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References
Resources: References, Tools/Equipment,etc.–Should conform with the

Contextual Learning Matrix
 ANSI Z87.1, Practice for Occupational and Educational Eye and Face Protection,
American National Standards Institute, 11 West 42nd Street, New York, NY 10036.
 Arc Welding and Your Health: A Handbook of Health Information for Welding.
Published by The American Industrial Hygiene Association, 2700 Prosperity Avenue,
Suite 250, Fairfax, VA 22031-4319.
 NFPA Standard 51B, Cutting and Welding Processes, National Fire Protection
Association, 1 Batterymarch Park, P.O. Box 9146, Quincy, MA 02269-9959.
 OSHA General Industry Standard 29 CFR 1910 Subpart Q. OSHA Hazard
Communication Standard 29 CFR 1910.1200. Available from the Occupational Safety
and Health Administration at http://www.osha.org or contact your local OSHA office.
 The following publications are published by The American Welding Society, P.O. Box
351040, Miami, Florida 33135. AWS publications may be purchased from the
American
 Welding society at http://www.aws.org or by contacting the AWS at 800-854-7149.

 ANSI, Standard Z49.1, Safety in Welding, Cutting and Allied Processes. Z49.1 is now
available for download at no charge at
 http://www.lincolnelectric.com/community/safety/ or at the AWS website
http://www.aws.org.
 AWS F1.1, Method for Sampling Airborne Particulates Generated by Welding and
Allied Processes.
 AWS F1.2, Laboratory Method for Measuring Fume Generation Rates and Total Fume
Emission of Welding and Allied Processes.
 AWS F1.3, Evaluating Contaminants in the Welding Environment: A Strategic
Sampling Guide.
 AWS F1.5, Methods for Sampling and Analyzing Gases from Welding and Allied
Processes.
 AWS F3.2, Ventilation Guide for Welding Fume Control
 AWS F4.1, Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers and Piping That Have Held Hazardous Substances.
 AWS SHF, Safety and Health Facts Sheets. Available free of charge from the AWS

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LEARNING EXPERIENCES/ACTIVITIES
Learning Outcome No. 1 : Weld Carbon Steel Plates in Flat Position (1G)
Learning Activities Special Instructions
1. Read info. Sheet no. 1-6

2. Answer self- check for every o In case of doubt
info. Sheet always ask your
3. Refer your answers in answer teacher.
key o If possible
4. Proceed to activity 1 welding in
answer all the
1G position after answering all
self-check. self-check in
5. Read the procedure in activity shortest time.
1 for welding carbon steel
plates in flat position (1G).
6. Perform step-by-step o Try to pass the
procedure with caution. self -check for
7. Rate the quality of your weld welding carbon
using the marking schedule.
steel plates in
8. If you did not pass the
marking points, repeat the flat position (1G)
activity for welding carbon
steel plates in flat position
(1G).
9. 5. When you are ready, you
can proceed to the next LO

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Learning Outcome No. 2 : Weld Carbon Steel Plates in Horizontal Position (2G)

key o If possible
answer all the
2G position after passing
activity 1 self-check in
plates in Horizontal position
(2G). o Try to pass the
6. Perform step-by-step self -check for
procedure with caution. welding carbon
7. Rate the quality of your weld
steel plates in
8. If you did not pass the vertical position
marking points, repeat the (2G)
steel plates in Horizontal
position (2G).
9. When you are ready, you can
proceed to the next LO

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Learning Outcome No. 3 : Weld Carbon Steel Plates in Vertical Position (3G)

key o If possible
answer all the
activity 1 and 2. self-check in
plates in Vertical position (3G).
6. Perform step-by-step o Try to pass the
procedure with caution. self -check for
7. Rate the quality of your weld welding carbon
steel plates in
8. If you did not pass the
marking points, repeat the Vertical position
activity for welding carbon (3G)
steel plates in Vertical position
(3G).
9. When you are ready, you can
proceed to the next LO

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Learning Outcome No. 4 : Weld Carbon Steel Plates in Overhead Position (4G)

key o If possible
answer all the
activity 1,2 and 3. self-check in
plates in Overhead position
(4G). o Try to pass the
6. Perform step-by-step self -check for
procedure with caution. welding carbon
7. Rate the quality of your weld
steel plates in
8. If you did not pass the Vertical position
marking points, repeat the (4G)
steel plates in Overhead
position (4G).
9. Evaluate all your
performances.

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INFORMATION SHEET 1
Learning Objectives: After reading this information sheet, you must be able to give some of the examples of
safety measures inside the shop and its importance.
SAFETY PRACTICES IN WELDING
INTRODUCTION
Arc welding is a safe occupation when sufficient measures are taken

to protect the welder from potential hazards. When these measures are
overlooked or ignored, however, welders can encounter such dangers as
electric shock, overexposure to fumes and gases, arc radiation, and fire and
explosion; which
may result in serious, or even fatal injuries.
• ‘SMAW Safety’ is supplemental and does not replace the information

found in ‘Arc Welding Basics’
• Understand and follow all safety precautions listed in ‘Safety in
Welding, Cutting, and Allied Processes’ (ANSI Z49.1) and Arc Welding
Safety (E205)
• Understand and follow all warning labels found:
The Department of Labor and Employment (DOLE) and the Occupational

Health and Safety Standards (OSHS) issued D.O. 13, ss 1998, known as the
Guidelines Governing Occupational Safety and Health in the Industry. It
requires employers and establishments to use a safety sign where there is a
significant risk to health and safety that has not been avoided or controlled
by the methods required under other relevant law, provided the use of a sign
can help reduce the risk. Safety signs are not a substitute for those other
methods of controlling risks such as engineering controls and safe systems of
work.

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INFORMATION SHEET NO. 1
SAFETY COMES FIRST and is everyone’s concern. An accident in the

machine shop can be messy and painful experience. Most accidents in the shop
are the results of carelessness. The victim knows at the time that he should not
do what he is about; he takes a chance. Sometimes he is lucky to get away from
it. Accident statistics prove that he who takes a chance often loses.
It takes time and experience to develop a skilled machinist. A skilled machinist
is seldom involved in accidents. He knows that he cannot take chances with the
certainty of the machines timing, or with the power of its movement. There are
basic rules for the development of safe working habits.
Your safety and well-being is of vital importance to your teacher. Always
remember this every time safe work practices are emphasized when performing
any shop activities.
SAFETY MEASURES IN ARC WELDING
● Insulate welder from work piece and ground using dry insulation. Rubber
mat dry wood.
● Wear dry, hole-free gloves (Change as necessary to keep dry).
● Do not touch electrically “ hot: parts of electrode with bare skin or wet
clothing.
● If the area is wet and the welder cannot be insulated from work piece with
dry insulation, use a semi-automatic, constant-voltage or stick welder with
voltage reducing device.
● Keep electrode holder and cable insulation in good condition. Do not use if
insulation is damaged or missing.
● Use ventilation or exhaust to keep air breathing zone clear, and comfortable.
● Use welding helmet and positioning of head to minimize fume in breathing
zone.

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● Read warnings on electrode container and material safety data sheets for
electrode.
● Provide additional ventilation/exhaust were special ventilation
requirements exist.
● Use special care when welding in contained area.
● Do not weld unless ventilation is adequate.
● Do not weld on containers which have held combustible materials. Check
before welding.
● Remove flammable materials from welding area or shield from sparks, heat.
● Keep a fire extinguisher in the welding area.
● Wear fire retardant clothing and hat. Use earplugs when welding overhead
●Always be sure the work cable makes a good electrical connection with the
metal being welded. The connection should be as close as possible to the area
being weld.
●Ground the work or metal to be welded to a good electrical (earth) ground.
●Maintain the electrode holder, work clamp, welding cable and welding
machine in good, safe operating condition. Replace damaged insulation.
●Never dip the electrode in water for cooling.
●Never simultaneously touch “ hot” parts of electrode holders connected to two welders
because voltage between the two can be the total of the open circuit voltage of both
welders.
‘’Safety Is No Accident’’

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UNDERSTAND AND FOLLOW ALL WARNING LABELS FOUND:
• Fumes and gases can be

hazardous to your health
• Keep your head out of the
fumes
Use enough ventilation
• Electric shock can kill

• Do not touch live electrical
parts

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SELF CHECK 1.1
Direction: Enumerate the following being asked in the question.
1. Give at least five examples of welding precautionary measures.
1.
2.
3.
4.
5.
2. Explain how important is the safety a measure in the shop is especially in

welding works. (5 pts.)
3. In your own point of view how do you elaborate the saying “Safety is no
Accident”? Kindly provide a comprehensive explanation. (5 pts.)
4. Site an example that best describes an accident occurrence in the

workplace or in your own resident. Kindly provide further explanation that
what do you think will be the cause and what do you think could be the
best way to address it. (5 pts.)

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INFORMATION SHEET 2
Learning Objectives : After reading this information sheet, you must be able to explain the
importance of using PPE and the 5S in welding works including housekeeping in the shop.
Personal Protective Equipment (PPE)
Student trainees in the shop will be provided personal protective

equipment (PPE) and will use them all throughout the duration of the activities
in the shop. This will reduce the occurrence of an injury and/or illness. PPE is
not a substitute for engineering or teacher’s administrative controls, or good work
practices, but should be used in conjunction with safety standard practices.
Responsibilities
Instructors have the primary responsibility for implementation of the PPE
in their respective work area. This includes:
1. Conducting a hazard assessment in their work area.
2. Determining what type of PPE is required.

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3. Ordering the necessary equipment.
4. Ensuring the employees are trained on the proper use, care and cleaning of
PPE.
5. Ensuring the employees are wearing the PPE.
6. Seeking assistance from the appropriate authorities to evaluate hazards.
7. Maintaining records on hazard assessments.
8. Replacing defective or damaged equipment immediately.
As a student you have the primary responsibility for wearing and

cleaning and maintaining the assigned PPE in accordance with the instruction
from you shop instructor.
Hazard Assessment and PPE Selection
As you perform shop works, your teacher will conduct a walk-through

survey of each work area to identify potential hazards. The hazard assessment
should be dated and signed as the written certification and maintained for
inspection and training.
Protective Devices
All PPE will be appropriate for the work to be performed and maintained in a
clean condition. Equipment must meet OHS standards as assessed by your
instructor.

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Eye and Face Protection
All trainees must use appropriate eye or face protection when exposed to hazards
from flying particles, liquid chemicals, acids or caustics, chemical gases or
vapors, or injurious light radiation. Eyewear shall comply with Occupational
Health Safety (OHS) standards as indicated by labels on the PPE. When there is
a hazard from flying objects, side protectors must be used. Those trainees
wearing prescription glasses need to wear approved safety glasses that
incorporate the prescription into the glasses or wear goggles over the prescription
glasses.
Head Protection
Worker must wear a hard hat when there is a danger from impact and/or
penetration from falling objects in any work location. Where there is a
possibility of hitting the head on protruding objects or pipes, a bump hat may
be worn.
Hand Protection
Trainees must use appropriate hand protection when exposed to
hazards from skin absorption of harmful substances, severe cuts or
lacerations, abrasions, punctures, chemical burns, or temperature extremes.
A careful evaluation of the hazard must be made due to the enormous variety
of gloves on the market. Glove selection will be based on performance
characteristics of the gloves, conditions, duration of use, and hazards present.
One type of gloves will not work in all situations. No glove will protect the
wearer from all hazards. Even if glove protect the wearer, it will not last forever
and must be changed regularly, as chemicals eventually permeate them.
Once gloves are removed, hands should be washed thoroughly. Gloves
should not be worn out of the lab or when shared lab equipment is handled.
Additional PPE
Guidelines for the selection and use of respirators and hearing protectors
should also be made available. Cool vests and cooling scarves may be
indicated when performing heat treatment process.
Occupational Foot Protection

Trainees working in areas where there is a possible danger of foot injuries due
to falling or rolling objects or objects that may be piercing the sole shall wear
protective footwear.
Cleaning and Maintenance

It is the student‟s responsibility to ensure that their PPE is clean and properly
maintained. Cleaning is particularly important for eye and face protection where
dirty or fogged lenses could impair vision. PPE should be inspected, cleaned and
maintained at regular intervals as instructed by the supervisor.
It is also important to ensure that contaminated PPE which cannot be
decontaminated, is disposed of in a manner that protects employees from
exposure to hazard.

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Welding - Personal Protective Equipment
Body Part Equipment Illustration Reason
Eyes and face Welding Protects from:

helmet, hand
shield, or  radiation
goggles  hot slag, sparks
 intense light
 irritation and
chemical burns
Wear fire resistant

head coverings under
the helmet where
appropriate
Lungs Respirators Protects against:

(breathing)
 fumes and oxides
Exposed skin Fire/Flame Protects against:

(other than resistant
feet, hands, and clothing and  heat, fires
head) aprons  burns
Notes: pants should

not have cuffs, shirts
should have flaps over
pockets or be taped
closed
Ears - hearing Ear muffs, ear Protects against:

plugs
 noise
Use fire resistant ear

plugs where sparks or
splatter may enter the
ear.

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Feet and hands Boots, gloves Protects against:
 electric shock
 heat
 burns
 fires
WELDING GLOVES AND MASK
PROTECTIVE CLOTHING
WELDERS MUST WEAR PROTECTIVE CLOTHING FOR
– PROTECTION FROM SPARKS, SPATTER AND UV RADIATION
– INSULATION FROM ELECTRIC SHOCK
– PROTECTIVE CLOTHING INCLUDES …
– FIRE-PROOF CLOTHING WITHOUT ROLLED SLEEVES, CUFFS OR FRAYS
– WORK BOOTS

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– WELDING GLOVES, JACKETS, BIBS, AND FIRE-PROOF PANTS
– WELDING CAP, HELMET AND SAFETY GLASSES
– EAR PROTECTION – EAR PLUGS AND MUFFS
CORRECT CLOTHING IN WELDING OPERATION

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HOUSE KEEPING INSIDE THE WELDING LABORATORY
CLEANLINESS IS NEXT TO GODLINESS.
This popular saying may sound overused but it guides us all to be clean in
all aspects of our lives clean in thoughts and in deeds. When one is clean
everything just seems to be fine otherwise, everything will be in chaos. Worst
scenario- accident is most likely to happen. It is then true that one’s line of
thinking is affected by the things which surround him. So to avoid these things
to happen, cleanliness must be our foremost priority. Cleanliness may occur in
our home, school, office, canteen, restaurants or even in our workplace or shop.
Consider this: Let us say a learner comes to the school shop and is usually
very aggressive and energetic in doing things. He wants to start at once so he
could finish it on time. However, this would deter him because his time is limited.
Before he could finish his work, the bell rings and consequently shifting of classes
start. What will he do? Will he continue and hasten his work? Will he stop
cleaning because he will be late? How does this affect safety practices? Are these
all true because he is determined to finish is work at all cost? If yes, then the
learner is at risk.
The saying HASTE MAKES WASTE is true under these circumstances.

Such procedure and practice must be discouraged. The student must be taught
safe practices and good HOUSEKEEPING. Housekeeping is a term in the industry
to mean the safe storage of tools, parts, and all the rest of the items used in
manufacturing in its proper place or tool crib. REMEMBER THAT A SIGN OF SAFE
SHOP IS A CLEAN AND ORDERLY SHOP
JAPANESE 5S
Why employ 5S?
In order to have a better workplace, it is a must that everybody must

becomes responsible for the cleanliness and orderliness of the shop to avoid
untoward incidents. One good idea is through the implementation of the
Japanese S-5. The SEIRE (sort), SEITON (systematic), SEISO (sweep), SEIKETSU
(standardize), SHITSUKE (self discipline).
WHAT IS 5S?
It is a systematized approach to organize work areas, keep rules and

standards, and maintain discipline needed to do a good job.
It utilizes workplace organization and work simplification techniques to

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make work easier, faster, cheaper, safer and more effective.
SEIRI (SORT)
Sort out unnecessary items and dispose them properly

Make work easy by eliminating obstacles
Provide no chance of being disturbed with unnecessary item
Eliminate the need to take care of unnecessary items
Prevent accumulation of unnecessary items
SEITON (Systematize)
Arrange necessary items in good order so that they can be easily picked up
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 material at the defined positions to ensure “First-In, First-Out”, as
well as to make work easy
Store dies and molds together with the specific tools necessary for their 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 is no dust on floor, machinery

and equipment To make workplace clean, safe and comfortable
To make it easy to produce quality products
To check whether machinery and equipment are in good condition or not.
SEIKETSU (Standardize)
Maintain high standards of workplace organization and housekeeping at all

times
To prevent the deterioration of Seiri, Seiton and Seiso activities.

To minimize causes that make the workplace dirty and uncomfortable
protect workers from dangerous conditions
To make workers happy and vivid giving them a chance to present their
talent and creativity.
SHITSUKE ( Self-discipline )
Do things spontaneously without being told or ordered

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The Seiri, Seiton, Seiso, Shitsuke, these 4S’s are techniques and actions to
make workplace well organized
Shitsukeis a condition in which all members practice these 4S’s
continuously, spontaneously and willingly.
Shitsukeis the creation of strong cooperative culture filled with a spirit of
high productivity through implementation of these 4S’s, as well as motivation,
education and training to all members
Management should give good example
BENEFITS OF 5S
A clean and well-organized workplace is high in PRODUCTIVITY
A clean and well-organized workplace produces QUALITY products and

services
A clean and well-organized workplace reduces COST to a minimum

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Self-Check 2.1
I-MULTIPLE CHOICE TEST
Direction: Choose only the letter of your answer.
1. A systematized approach to organize work areas, keep rules and standards,

and maintain discipline needed to do a good job is the.
a) 5S Housekeeping c) 5S House
b) 5S Assignment d) 5S Safety Assignment
2. ____ or Sort out unnecessary items and dispose them properly is the first
S assignment.
a) Seiton b) Seiri c) Shitsuke d) Seiso
3. ____ or Systematize is to arrange necessary items in good order so that they

can be easily picked up for use. This is the second in 5S Assignment.
a) Shitsuke b) Seiri c) Seiton d) Seiketsu
4. ____ or Sweep is to clean your workplace completely so that there is no dust

on floor, machinery and equipment.
a) Seiton b) Seiri c) Shitsuke d) Seiso
5. ____ or Standardize is maintaining high standards sanitize workplace

organization and housekeeping at all times.
a. Shitsuke b) Seiri c) Seiton d) Seiketsu
II- ENUMERATION
Direction: Enumerate the following being asked in the question.
1. Give at least five examples of personal protective gears in welding

works.
2. Explain each uses in the operation. (5 pts.)

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INFORMATION SHEET 3
Learning Objectives : After reading this information sheet, you must be able to give the parts
of accessories of welding equipment and the basic of welding.
INTRODUCTION TO ARC WELDING

Arc Welding
In Electric Arc Welding a sustained arc provides the heat required for
melting the parent as well as filler material.
The workpiece and the electrode are connected to the two materials of
the power source. The arc is started by momentarily touching the electrode
on to the workpiece and then withdrawing it to a short distance (a few mm)
from the workpiece.
About 70% of the heat liberated due to striking of electrons at anode

raises the anode temperature to very high values (5,000 to 30,000oC). This
heat melts the base metal as well as tip of the electrode in the area
surrounding the arc.
A weld is formed when the mixture of molten base and electrode metal
solidifies in the weld area. Since 70% heat is generated at anode a workpiece
connected to anode will melt 50% faster as compared to if connected with
cathode.
This is why work piece is usually made positive and electrode as

negative and is termed as straight polarity.

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Shielded Arc Welding
The slag therefore rises to the surface and on solidification forms a

protective covering over the hot metal.
This also slows down the rate of cooling of the weld. The slag layer can be
removed by light chipping.
Electric arc welding of this type is known as Shielded Metal Arc Welding.
More than 50% industrial arc welding is done by this method.

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WELDING EQUIPMENT AND ACCESSORIES
1. WELDING MACHINE- a machine that comprises of controllers of

amperage to be use and terminals to adapt the positive and ground
cables.
2. ELECTRODE HOLDER- An accessory of a welding machine that is used
for holding the electrode. It has a groove wherein it serves as a guide for
the electrode to be on its correct angle for the work.
3. ELECTRODE- A stick like metal core coated with various elements that
acts as a sparker and later melts down for connecting metals.
4. CLIP GROUND- The one that holds the parent metal to make the
complete flows of electricity needed for welding.
5. PARENT METAL- a materials to be weld either ferrous or non ferrous.
6. WELDING CABLES- A two colored cables that serves as the path for
current to be flows. Commonly black and red in color.

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SMAW Equipment Set Up
1. Turn power supply on

2. Connect work clamp
3. Select electrode
a. Type
b. Diameter
4. Adjust output
a. Polarity
b. Amperage
5. Insert electrode into electrode holder
SMAW Process Variables
• Settings on the machine
– Polarity : AC, DC+, DC-
– Amperage Output
• Operator Controlled Variables
– Work Angle
– Travel Angle
– Arc Length
– Travel Speed

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Basic Steps of Arc Welding
• Prepare the base materials: remove paint and rust
• Choose the right welding process
• Choose the right filler material
• Assess and comply with safety requirements
• Use proper welding techniques and be sure to protect the molten puddle
from contaminants in the air
• Inspect the weld
Striking an Arc and Making a Weld
• To begin the SMAW Process, you must first strike an arc. This can be
done using one of the following techniques:
– Scratch start – scratch the electrode on the base metal like a match
– Tap Start – tap the rod against the base metal

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• The work angle is the angle between the electrode and the work as
depicted on the left
• Work angles can vary depending on the position the weld is being made
in
• Also commonly called Lead Angle
• The travel (lead) angle is the angle between the electrode and the plane
perpendicular to the weld axis.
• After striking the arc, maintain a 1/8” distance between the electrode
and the workpiece

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– If the arc length becomes too short, the electrode will get stuck to
the workpiece or ‘short out’
– If the arc length becomes too long; spatter, undercut, and porosity
can occur
• The travel speed is the speed at which the electrode moves along the
base material while welding
– Too fast of a travel speed results in a ropey or convex weld
– Too slow of a travel speed results in a wide weld with an excessive

metal deposit.

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• ‘crater’
• Use a short pause or slight back step at the end of the weld to fill the
crater
• Large craters can cause weld cracking
• Here is the proper technique for restarting a weld:

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SELF-CHECK 3.1
I-FILL IN THE BLANKS
Direction: Answer the following being asked in the questions. Write your
answer on the space provided for before or after the question.
1. ___________ a sustained arc provides the heat required for melting the
parent as well as filler material.
2. A weld is formed when the mixture of _______ and electrode metal
solidifies in the weld area.
3. This also slows down the rate of cooling of the weld. The slag layer can
be removed by light chipping. Electric arc welding of this type is known as
___________
4. ____________A two colored cables that serves as the path for current to
be flows. Commonly black and red in color.
5. ____________ A machine that comprises of controllers of amperage to be
use and terminals to adapt the positive and ground cables.
6. ____________ An accessory of a welding machine that is used for holding
the electrode. It has a groove wherein it serves as a guide for the
electrode to be on its correct angle for the work.
7. ____________A stick like metal core coated with various elements that
acts as a sparker and later melts down for connecting metals.
8. ____________ The one that holds the parent metal to make the complete
flows of electricity needed for welding.
9. ____________ A materials to be weld either ferrous or non ferrous.
10. ___________ scratch the electrode on the base metal like a match.
II- ENUMERATION
Direction: Enumerate the following being asked in the questions.
1. Give the four SMAW Operated Controlled Variables. Then site its
function in the welding process. (5 pts.)
2. What are the six basic Steps of Arc Welding and explain it
comprehensively? (5 pts.)

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INFORMATION SHEET 4
Learning Objectives: After reading this information sheet, you must be able to explain the
essentials of welding.
THE FIVE ESSENTIAL VARIABLES OF SMAW (STICK) WELDING
INTRODUCTION
Welding is a practical skill that requires continual practice and careful

attention to the variables that the welder controls to improve. The old golden
rule “practice makes perfect” applies to welding in that the more you do, as
long as you or someone evaluates your welds, the better you become. The
term variable as used in this text means something the welder has control of
either before welding or during welding.
Review the following five essential variables and the weld discontinuities that
may result if control is not maintained.
KEY POINT: An easy way to remember the variables is by remembering

the first letter in each one spells the word CLASS.
1. CURRENT SETTING.
2. LENGTH OF ARC.
3. ANGLE OF ELECTRODE.
4. SPEED OF TRAVEL.
5. SELECTION OF ELECTRODE.
1. CURRENT SETTING.
The welding current or amperage is essential to producing welds with

good appearance and the required strength characteristics. The welder
controls the amperage variable by setting the amperage on the welding
machine prior to welding.
The amperage is set from recommended ranges according to the size of the
electrode, the type of electrode, and the type of current AC, DCEN or DCEP
you are using.
KEY POINT: AC means Alternating Current, DC means direct current and can be set
for Direct Current Electrode Negative (Straight Polarity) or Direct Current Electrode
Positive (Reverse Polarity).
Some electrodes are designed to work best on a given Current and Polarity, for example
an E-6010 should be used with DCEP (direct current electrode positive).

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The chart below shows typical amperage ranges
Amperage may be referred to as the heat by some welders. An excellent place

to find amperage ranges, recommended current and polarity and information
on electrode applications are the Electrode Selection Guidebooks available at
any welding supply store.
The amperage range is fine tuned by the welder to the correct

amperage before welding on an actual workpiece or testpiece by running
practice welds on a piece of scrap metal in the position of welding as follows;
1. Run a practice weld at the lower recommended range setting.

2. Run a second practice weld at the higher recommended setting.
3. Compare the two welds for evidence of a well formed bead, good fusion,
lack of defects, and a smooth transition into the base metal.
4. If necessary reduce the amperage from lower to highest amperage until
a satisfactory weld bead is produced.
5. It is important to try different setting to avoid wasting time with a
setting that is to low or to high and will need to be changed later.
The chart below gives an idea of the evaluation process;

In example A the E-6010 weld made with the correct amperage appears
properly formed with the appropriate width and consistency.
In example B the weld made with amperage setting too low appears thin and
stringy.
In example C the weld made with amperage setting too high appears wide and
flat with excessive spatter and evidence of undercut.
A B C
A) Amperage correct
B) Amperage too low
C) Amperage too high

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KEY POINT: Remember conditions may change for example; if you are
welding multiple passes in the vertical position and using a weave
technique you may need to increase the amperage when weaving over a
prior weld bead.
You may want to use higher setting for welding flat and horizontal than for
welding in other positions.A setting used on one machine may need to be
adjusted when using another machine, if the machines are not calibrated the
same.
One welder (operator) may prefer to use a slightly higher setting and travel
faster than you, so set the amperage for your technique.
The correct amperage is one that provides a good weld and is not based on
a specific number on the machine.
2. LENGTH OF ARC
When electricity is made to jump across a gap it is said to arc across

the gap. In Shielded Metal Arc Welding (Stick) it is this arcing effect that
creates the intense heat required for melting the electrode and the base
metal together.
The Arc is the term used to describe the distance from the tip of the
electrode to the base metal and can be varied from lightly touching the
metal at an angle sufficient to maintain an arc to a distance far enough
from the base metal to extinguish the arc.
If the electrode is held in contact with the work using the slight angle to
maintain the arc it is referred to as the drag technique. This technique is
often used to weld in the flat and horizontal positions, especially with larger
or iron powder electrodes. If contact with the base metal is made too
quickly however; the electrode will stick or freeze to the metal.
Another method to employ is to allow a slight gap between the electrode
tip and the base metal. The length of the arc gap affects the appearance of
the weld.

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If the voltage is increased too much the arc may become unstable and result in a poor
quality weld.
The correct arc length may vary according to the type of electrode and the position of
welding.When production welding flat or horizontal the drag method is often used for ease in
welding and faster travel speeds.
When a slight gap is maintained the force of the arc provides a weld bead with a slightly flatter
appearance with less chance of slag inclusions and better joint penetration.
KEY POINT: make sure you are maintaining a proper arc length before adjusting the
amperage on the welding machine. If the arc length is too long and the voltage increases
it may seem as though the amperage is too high or the sticking caused by too low an arc
length with some electrodes may seem as though the amperage is too low.
3. ANGLE OF ELECTRODE
In the Shielded Metal Arc Welding (STICK) process there are two electrode angles that
the welder must control. The first angle is the one formed between the electrode and the base
metal, called the work angle. The second angle is the angle the electrode is held at relative to
the direction of travel, called the travel angle. The travel angle for the flat, horizontal and
overhead can be either pulled or pushed and the travel angle for the vertical can be either
upward or downward.

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Note: The direction of travel across the plate for both drag and push methods:
The work angle should be one that places the weld metal between the members to be
welded in the manner desired. The weld metal will be deposited in a relatively straight line
from the tip of the electrode to the work. The decision to push or pull is largely one of
experience and practicality.
A flatter somewhat less rounded weld can be achieved with a slight push
angle when welding flat and horizontal. When welding in the vertical upward
position a more extreme angle using the side of the electrode seems to produce
a flatter weld with tighter ripples.
KEY POINT: because of the high deposition rat of an E-7018 electrode it

is more difficult to weld vertical downward.
3. SPEED OF TRAVEL
The rate of travel across the joint is controlled by the welder during
welding and greatly affects the appearance and strength characteristics of the
weld.
The amount of weld metal deposited (weld deposition rate) and the
travel speed may vary with the type and size of electrode being used. The
correct weld speed will result in a well formed weld bead that shows good
fusion, penetration and a gradual transition of weld metal into the corners of
the joint.
Since the travel speed is not timed in stick welding, the welder must be

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able to read the molten weld pool as the electrode is manipulated across the
joint. A weld speed that is too fast results in a thin stringy weld with poor
strength. A weld bead that is too slow a speed will result in a heavy weld that
has too much convexity.
4. SELECTION OF ELECTRODE
There are a variety of electrodes available for welding a wide range of

metals. The electrode for a given application must be selected carefully to
provide the strength characteristics required for the weld joint. One of the
most useful tools for electrode selection is the Electrode Handbooks available
from welding supply outlets. These handbooks provide information from
electrode classification to application and usability.
In general the electrode weld metal must be matched to the type and
composition of the base metal being welded. Further some electrodes within
the available scope are designed for specific purposes.
Some of the most widely used Electrodes are those used for welding
carbon Steel.
The following is a brief description of the most commonly used electrodes

for welding Carbon Steel.
The electrodes are classified by a letter and numbering system as

follows:

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The tensile strength is defined as the ability of the weld metal to
withstand forces acting to pull it apart.
The last digit indicates the type of flux or electrode covering and in turn
determines the type of current, penetration and appearance of the weld.
The following are some commonly used electrodes and their

characteristics.
KEY POINTS:
The E-6010 and E-6011 Electrodes are similar with only a slight
change in the electrode covering to enable the E-6011 to be used with
AC current.
These electrodes have a deep penetrating and forceful arc with
quickly solidifying weld metal. They may be used in all positions
including Vertical Downward. Because of the arc characteristics they
may be used on dirty or rusty metals and for root passes in open root
grooves and pipe.
These electrodes have a certain amount of moisture content to enable

the forceful arc and should not be stored in ovens.
The E-6012 and E-6013 electrodes are also similar with some variations
in the electrode covering. These electrodes have shallow to medium
penetration making them useful for welding thinner sections, sheet metal and

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for welding gaps due to poor joint fit up. Trapping slag may be a problem when
using E-6013 at lower amperages or on dirty metal surfaces.Both the E-7018
and E-7028 electrodes are Iron powder Low hydrogen electrodes. The E-7028
is used for flat and horizontal position only and may be used with a drag
technique to produce a smooth weld with good appearance.
The addition of Iron powder to these electrodes covering adds to the

available weld metal resulting in heavier convex welds.
These electrodes are classified as low hydrogen meaning they are low in
moisture content and should be stored in ovens or moisture free environment
once the container is opened.Because these electrodes are low hydrogen they
are the choice for welding higher carbon steels.
A short arc length should be maintained especially when striking the arc to
avoid surface porosity (tiny holes).
1. WELDING DISCONTINUITIES
If control of these variables are not properly maintained the result may be
a weld with one or more discontinuities or defects.
KEY POINT: A discontinuity is defined as; an irregularity or imperfection

in the appearance of the weld or surrounding base metal. A defect is
defined as; a single or group of discontinuities severe enough to cause
rejection or rework of the weld or assembly. When the five essential
variables are properly controlled the weld profile should be properly formed
and free of discontinuities.

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Note: In the above diagrams the size of the fillet weld is shown in dotted lines and the
throat is from the root of the joint to the face of the weld.

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CHART SHOWING DISCONTINUITIES IN SMAW AND THEIR CAUSES
DISCONTINUITY POSSIBLE CAUSES

Excessive Convexity Slow travel speed that allows weld metal to build up
Welding currents too low
Insufficient Throat A combination of Travel speed to fast and current too high
Improper placement of weld beads when multiple pass welding
Undercut Amperage too high
Arc length too long increasing the force of the arc so that it cuts
into corners
Improper weld technique causing the corners to be left unfilled
or cut into
Groove joint not completely filled and overlapped
Insufficient Leg Size Using the wrong electrode angle causing the weld to be
deposited to heavily on one side
Using the wrong angle on multiple pas welds Causing the welds
to overlap incorrectly
Poor Penetration Amperage too low
Travel speeds too fast
Using too large an electrode for the root of the joint
Improper electrode angle at the root of the joint
Improper weave technique
Using the wrong electrode for the desired joint penetration:
(using E-6013 instead of E-6010)
Poor Fusion Amperage too low
Travel speeds too fast
Improper electrode angle at the sides of the joint
Improper weave technique that does not allow enough time at
the sides of the joint
Using the wrong electrode for the application
Overlap Amperage too low and /or travel speed too slow
Electrode too large with low currents
Porosity Dirty base metal painted or galvanized surfaces
Arc length too long especially with E-7018 Electrodes
Moisture in low hydrogen electrodes
Wind or fans strong enough to break down the shielding gas
Slag Inclusions Improper manipulation of the electrode especially with E-6013
Improper cleaning and slag removal between multiple pass
welds
Cracks Using the wrong Electrode for the application
Using Excessively high amperage on some metals
Excessive Spatter Amperage too high
Electrode angle too extreme
Arc length too long

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SELF–CHECK 4.1
DIRECTION: Answer the following questions.
1. What does the acronym CLASS in the essentials of welding stands for?
2. Is the term used to describe the distance from the tip of the electrode
to the base metal and can be varied from lightly touching the metal at
an angle sufficient to maintain an arc to a distance far enough from
the base metal to extinguish the arc.
3. E-6012 is commonly found in electrode, what does the second digit

imply?
4. Give at least five examples of discontinuities in SMAW.
5. The rate of travel across the joint is controlled by the welder during
welding and greatly affects the appearance and strength
characteristics of the weld.
Questions
Direction: Answer the questions comprehensively.
1. What causes welding deformity? How will you address the observed
deformity during welding process? (5 pts.)
2. In what way or particular reasons that welding must be anchored

from welding standards? If you agree, then support your reason and if
disagree site an examples and provide reasons. (5 pts.)

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INFORMATION SHEET 5
Learning Objectives : After reading this information sheet, you must be

able to give some of the examples of safety measures inside the shop and
its importance.

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Fillet and Groove Welds
• Groove and fillet welds can be made on many types of joints
Welding Symbols
• Welding symbols give the welder specific instructions about the weld
including:
– Placement
– Size
– Length
– Process
WELDING SYMBOLS

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– Any other special notes
– Universally used
– Governed by the AWS
– Found on engineering drawings
• Welding symbols contain information about the weld to be made
– S – leg dimension of the weld
– Triangle – the weld is to be made on the arrow side of this joint
– Tail – any additional information required (i.e. position the weld is

to be made)
– Arrow - the joint the welding symbol applies to

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Welding Position
There are various positions that a weld can be made in:

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SELF CHECK 5.1
ENUMERATION:
Direction: Enumerate the following.
1. What are the types of joints in welding?
2. What are the types of Welding Positions?
QUESTIONS
1. Is learning the basic of welding joint important? Why? Provided

comprehensive reasoning on your claim. You may also site an
example to give additional problem on your postulated claim.
Direction: Answer the questions comprehensively. (5pts)
2. Provide further, reasons why do we have to anchor our welding

routine on the standard of welding positions? In what way it will
give a good quality output as you expected after performing the
welding process? Discuss and elaborate it. (5pts)

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INFORMATION SHEET 6
Learning Objectives : After reading this information sheet, you must be able to PERFORM THE 3
POSITIONS in welding.
FLAT POSITION WELDING
Flat Position. A butt joint is used to join two plates having surfaces in
approximately the same plane. Several forms of joints are used to make butt
welds in the flat position. The most important of these forms are described in
the following subparagraphs
(a) Plates 1/8 inch thick can be welded in one pass without any special edge
preparation being necessary. Plates from 1/8 to3/16 inch thickness can be
welded with no special edge preparation by making a bead weld on both sides
of the joint. Tack welds should be used to keep the plates aligned for welding.
The electrode motion is the same as that used in making a bead weld.
(b) When welding 1/4 inch or heavier plates, the edges of the plates should
be prepared by beveling or by "J," "U," or "V"grooving, whichever is the most
applicable. Single or double bevels or grooves may be used depending on the
thickness of the plate being welded. The first bead should be deposited to seal
the space between the two plates and to weld the root of the joint.
This bead (also referred to as a layer or weld metal) must be thoroughly

cleaned to remove all slag before the second layer of metal is deposited. When
making multipass welds on the second, third, and fourth layers of weld metal
are deposited using any of the weaving motions of the electrode, as shown in
figure 16, view B. Each layer of metal must be cleaned before depositing the
succeeding layers.
(c) When using any of the weaving motions, the electrode shouldbe oscillated
or moved uniformly from side to side with slighthesitation at the end of each
oscillation and, as in beadwelding, the electrode should be inclined 5 to 15
degrees in thedirection of welding. If the weaving motion is not properly
performed, undercutting will occur at the joint as Excessive welding speed will
also cause undercutting and poor fusion at the edges of the weave bead.
d) Backup or backing strips are used when welding 3/16 inchplate or heavier
to obtain complete fusion at the root of theweld and to provide better control
of the arc and the weld metal.

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The edge of the plates to be welded are prepared in the samemanner as
required for welding without backing strips. Thebacking strips, 1 inch wide
and 3/16 inch thick for plates up to3/8 inch thick, 1 1/2 inch side, and 1/4
inch thick for platesover 1/8 inch thick, are tack welded to the base of the
joint.The backing strip will act as a cushion for the first bead or layer
deposited in the joint.
(e) The joint should be completed by adding additional layers

of metals.
(f) After the joint is completed, the backup strip may bewashed off or cut away
with a cutting torch and, if necessary, a sealing bead may then be applied
along the root of the joint.

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HORIZONTAL POSITION WELDING.
In the horizontal position the two plates are located approximately at

right angles to each other in the form of an inverted T. The edge of the vertical
plate may be tack welded to the surface of the horizontal plate.
(a) A fillet weld is used in making the joint by using a short arc to
provide good fusion at the root and along the legs of the weld. The electrode
should be held at an angle of 45 degrees to the two plate surfaces and inclined
approximately 15 degrees in the direction of welding.
b) Light plates can be fillet welded in one pass with little or no weaving
of the electrode. Welding of heavier plates may require two or more passes
with the second pass or layer made using a semicircular motion. A slight
pause is made at the end of each weave to obtain good fusion between the
weld and base metal without any under cutting.
(c) A fillet-welded tee joint on 1/2 inch or thicker plate can be made by
depositing string beads in the sequence. Fillet welds of these types are used
where high weld strength is not required; however, the short welds are so
arranged that the finished joint is equal in strength to a fillet weld along the
entire length of a joint from one side only. Also, the war page and distortion
of the welded parts are held to a minimum within termittent welds.
The procedure for making this weld is similar to that used for making
fillet welds in tee joints. The electrode should be held so as to form an angle
approximately 30 degrees from the vertical and tilted 15 degrees in the
direction of welding.
The weaving notion is the same as that used for tee joints, except that the
pause at the edge of the top plate is sufficiently long to ensure good fusion
and no undercut. Lap the joint by depositing a series of overlapping beads on
top of each other.

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VERTICAL POSITION WELDING.
In the fabrication of many structures such as steel buildings, bridges,

tanks, pipelines, ships, and machinery, the operator must frequently make
vertical weld is one with a seam or line of weld running up and down.
One of the problems of vertical welding position is that gravity has a

tendency to sag the molten puddle from the electrode and plates being welded.
To prevent this from happening, fast-freeze types of electrodes should be used.
Puddle control can also be achieved by proper electrode manipulation and
selecting electrodes specifically designed for vertical position welding.
POSITION AND MOVEMENT OF THE ELECTRODE.
Vertical welding is done by depositing beads either in an upward or

downward direction, (sometimes referred to as uphill and downhill).
Downward welding is very practical for welding light page metal because
penetration is shallow, thereby forming an adequate weld without burning
through the metal. Moreover, downward welding can be performed much
more rapidly, which is important in production work. Although it is generally
recommended for welding lighter materials, it can be used for most metal
thickness.
100 to 150 AND 150 to300
Position of the electrode for downward (left) and upward (right) vertical
welding On heavy plates of ¼ “ or more in thickness, upward welding is often
more practical, since deeper penetration can be obtained. Welding upward
also makes it possible to create a shelf for successive layers of beads. For
downward welding, tip the electrode at about 60° travel angle and 90° work
angle. Start at the top of the seam and move downward with little or no
weaving motion. If a slight weave is necessary, swing the electrode so the
crescent is at the top.
For upward welding, start with the electrode at right angles to the
plates. Then, lower the rear of the electrode, keeping the tip in place, until the
electrode forms an angle of 10-15 with the horizontal.

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Laying Straight Beads in Vertical–Downhill Method
Set up a practice piece in vertical position with a series of straight lines

drawn on it. Start at the top of the plate with the electrode pointed upward
about from the vertical plate. Keep the arc short and draw the electrode
downward to form the bead. Travel just fast enough to keep the molten metal
and slag from running ahead of the crater. Do not use any weaving motion to
start with. Once this technique is mastered try weaving the electrode but very
slightly with the crest at the top of the craters.

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Laying Straight Beads in a Vertical Position-Uphill Method
1. Obtain a ½ “ plate and draw a series of straight lines. Then fasten the
piece so the lines are in a vertical position.
2. Strike the arc on the bottom of the plate. As the metal is deposited, move
the tip of the electrode upward in a rocking motion as shown in the picture
below.
This is often called a whipping motion. In rocking the electrode, do not

break the arc but simply pivot it with a wrist movement so the arc is moved.

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up ahead of the weld long enough for the bead to solidify. Then return it to
the crater and repeat the operation, working up along the line to the top of
the plate. Remember; do not break the arc while moving the electrode upward.
Withdraw it just long enough to permit the deposited metal to solidify and
form a shelf so additional metal can be deposited. Continue to lay beads from
bottom to top until each line is smooth and uniform in width.
Laying Vertical Beads with a Weaving Motion
On many vertical seams in uphill welding, it is necessary to form beads

of various widths. The width of the bead can control by using one of the
weaving patterns. Each pattern will produce a bead approximately twice the
diameter of the electrode. Notice that each weave is shaped so the electrode
can dig into the metal at the bottom of the stroke, and the upward motion
momentarily removes the heat until the metal can solidify. When a smooth
weld is required on the final pass of a wide joint, the wash bead should be
used.
Before applying these weaving motions on the actual joints, practice
running them on a vertical plate. Continue this practice until a smooth bead
of uniform width can be deposited.

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Overhead welding is similar to flat except gravity is now working against you! Make
sure you wear some kind of welding leathers to protect your arms and chest from the
sparks.
Start away from you and weld back towards your body so you always see what the
puddle is doing and you have a clear line of sight of the joint. Keep the rod tight to the
joint but don't bury it in the puddle. A slight weave side to side will help too.
Biggest thing is to make sure you're comfortable. If you have to, tack an angle or
something in a spot you can rest one of your elbows on and still make the weld.
Hope this helped a little more.
Overhead welds (AWS position 4G) are welded as a series of straight beads
using a slight circulation motion. A whipping technique is used when Fleetweld 5P+
(E6010) and Fleetweld 180 (E6011) electrodes are used. Weaving techniques cannot
be used because the weld puddle becomes too fluid and will spill from the joint.
Full welding jacket and a good set of gloves to protect yourself from falling
hotstuff, button your jacket to the neck if you can stand it. Position yourself and brace
yourself as the fellas have recommended, try to get a hip and shoulder against
something even if you have to tack it up yourself. Expect your arms to tire and to be
sore in the shoulders and neck the next couple of days; no big deal cause repitition
will build up the muscles you need.
Keep your rod close into the weld or you will get a lot of spatter and drips and
make a mess of it. Put your ground clamp as close to the work as you can get it. If this
is v'd plate with a backing strip and gap make sure if you do the fitup that you pay
close attention to an evenly spaced joint, and more importantly getting the backing
plate flat to the back of the plates when tacking. If you find there is a gap, gouge out
the tacs and start over. You'll thank yourself for doing so when you watch the other guy
with poor fitup blowing his root apart. Mount your work HORIZONTAL, not on some
angle.
It can be done, but why make your life harder. And stringers only, no weaving.
Keep your rod perpindicular to work. When you are laying the beads that tie in to the
plate angle your elctrode into the corner. Clean your slag thoroughly, scrape in the
grooves with a pick and wire brush (did I say?) thoroughly. A light source will be
valuable for you to better see the work; shop light doesn't point the way that you will
be looking when welding overhead. Invest in a cheap reflector lamp and the brightest
rough service bulbs you can find. Cover the bulb with a piece of plexi or acrylic to
protect it from dropping hotstuff or it will blow. I used a clear mask lens and spaced it
off the bulb so it wouldn't melt from the heat, secured it with duct tape. Ugliest thing I
ever saw, and invaluable.

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Anyway, Aside from keeping your beads even, if you are welding a closed
root or slightly open root with a backing plate, then run your first bead down
the middle, rod Pointed straight up and tilted 10 degrees toward the forming
puddle (drag technique), and working from the far end of the joint towards
yourself. If the root requires 2 passes then angle your electrode 30 degrees
into the corner of the joint where the plate meets the backing, 10 degree back
angle a before.
If youv'e done this right you should still have the other side of the joint
exposed and clear of weld.
Clean your 1st bead thoroughly and apply the 2nd bead opposite the 1st; 30
degrees into the corner of the joint and allowing the bead to overlap your
other. Clean your bead, then it is repetition, increasing the number of
stringers by 1 with every layer of bead you put down. (The 1-2-3-4-5
mentioned in the first post.)
Travel speed is a matter of practice. Too slow and you will see your
beads begin to lump up and drip, to fast and you will undercut and leave
wagon tracks. When running adjacent stringers, run your elctrode directly
along the edge of the previous bead. As far as capping, I was taught to step
your electrode down 1 size from what you used to fill the joint, and yes,
stringers just like before. Ovelap the edge of the plate 1/8", making sure there
are no low spots that are below the level of the plate surface.

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Overhead fillet welds on lap joints and tee joints are made in a similar
manner. Weld overhead as a series of stringer (straight) beads using a slight
circular motion. Weave beads are too fluid and will spill. The term stringer
bead applies to any bead made in a straight line (no weave) regardless of
electrode or technique being used.

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SELF-CHECK 6
QUESTIONS
Direction: Answer the questions briefly and comprehensively. You may site
an example including explaining the sequential procedures in performing the
various welding positions in welding. Each welding position is equivalent to
10 pts if you explain and detailed it properly.
1. How do we strike F1 or flat POSITION WELDING?
2. How do we strike F2 or horizontal POSITION WELDING?
3. How do we strike F3 or vertical POSITION WELDING?
4. How do we strike F1 or overhead POSITION WELDING?

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Learning Outcome No. 1-4: Weld carbon Steel Plates in 1G, 2G, 3G AND 4G
POSITIONS.
Learning Activities
1. Read the procedure in activity for welding carbon steel plates in all
positions (1G, 2G, 3G and 4G).
2. Perform step-by-step procedure with caution.
3. Rate the quality of your weld using the marking schedule.
4. If you did not pass the marking points, repeat the activity for welding
carbon steel plates in flat position (1G and the rest)
5. When you are ready, you can proceed to the next LO
MATERIALS
1. Mild steel plates 6.0mm x 100mm x 150mm (2pcs)
2. Electrode, E-6013, 3.2mm diameter.
Tools and Equipment
1. AC welding machine with accessories
2. chipping hammer
3. steel brush
4. welding helmet/shield
5. gloves
6.portable grinder.

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BLUEPRINT OF ACTIVITY

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JOB SHEET NO. 1
PERFORMING WHIPPING METHOD IN FLAT POSITION (1G)
Run a bead with a whipping technique to keep the puddle “hot”.
1. Clean the base metal and position flat.
2. Set the polarity and amperage: DC+ at 70-110A for 1/8” E6010 electrode.
3. Hold electrode upright, inclined 65 to 70 degrees in the direction of travel.
4. Assume a position that permits you to see behind and ahead of the arc so
that corrections can be made while welding.
5. Strike the arc and carry the bead with a normal arc length during the entire
whipping motion. The whipping motion to keep the puddle “hot” or fluid
should be about 5/16” forward and 1/8” to 1/4” back toward the crater,
depending upon the size of the bead desired. When the backward motion is
completed, hesitate in the electrode motion. Penetration is obtained on the
“hesitation” of the backward motion. The longer the hesitation, the larger the
weld deposit. The length of the backward motion controls the ripple
appearance of the weld. With the exception of the hesitation, the motion is
rapid.
6. Practice the motion using different length of return strokes, until you can
build up a heavy or light bead.
7. Visually inspect

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JOB SHEET NO. 2
PERFORMING WHIPPING METHOD IN HORIZONTAL POSITION (2G)
Make a horizontal weld on a tee joint.
1. Clean the base metal and position plates.
2. Set polarity and amperage: DC+ at 65-130 A for a 1/8” E7018 electrode.
3. Tack-weld each end of the joint in position with a good fit up. After each
tack with E7018 electrode, take the electrode out of the holder and gently tap
the electrode to remove crystallized end. This will improve the re-strike of this
electrode on the next tack or bead.
4. Hold electrode lightly against both plates with the arc directed into the
corner.
5. Observe the bead carefully as it forms under the arc. There may be some
tendency to undercut the vertical plate. Vary the electrode angle specified
above to get the correct bead shape. If travel speed and electrode angle are
correct, the bead will not undercut.
6. Clean the bead and examine it for signs of overlap and undercut.
7. Visually inspect.
8. Break the weld to see if penetration is equal into both plates and completely
into the corner. Heavier horizontal fillet welds require more than one bead or
pass.

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JOB SHEET NO. 3
PERFORMING WHIPPING METHOD IN VERTICAL POSITION (3G)
Make a weld on a tee joint in the vertical position welding down.
1. Clean the base material.
2. Set the polarity and amperage: DC+ at 110-120 amps for 1/8” E6010
electrode. Tack-weld two plates together in a lap joint and secure in vertical
position.
3. Hold the electrode directly pointing upward 60 degrees from the vertical
plate and directly into the corner, 45 degrees from the plate surface.
4. Strike the arc at the top and weld down keeping a short arc length.
5. Use a straight bead. Travel downward should be at such a rate that the
slag does not run ahead of the crater.
6. Clean slag
7. For a three pass weld - Repeat placing the bead on the toe of the first weld.
This will result in a slightly heavier bead. Using a slightly longer arc length
will let the bead wash out better at the toes. Repeat again, clean the bead well,
and lay a second bead over the initial bead. Make certain you are getting
penetration into the corner and evenly into each plate.
8. Visually Inspect

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JOB SHEET NO. 4
PERFORMING WHIPPING METHOD IN OVER HEAD POSITION (4G)
Make a weld on a lap joint in overhead position
1. Clean the base material
2. Set the polarity and amperage: DC+ at 85-100A for 1/8” E6010 electrode.
3. Tack-weld plates for lap joint, and secure in the overhead position so that
the underside may be easily reached with the electrode.
4. Hold electrode 40 to 45 degrees out from the vertical plate and inclined 85
degrees in the direction of travel.
5. Strike an arc and establish a puddle evenly on both pieces. Place a single
bead in the corner using a whipping motion.
6. Visually Inspect
7. Break the plates apart and inspect for complete penetration into the corner.
There should be no undercutting on the horizontal plate or overlapping on the
vertical plate.

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ASSESSMENT CRITERIA
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. 5 points per component. 5 is the highest and
1 is the lowest.
THE PASSING MARK IS 40 POINTS
CRITERIA POINTS
1. Straightness
2. Width of bead
3. Height of bead
4. Ripple

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INFORMATION SHEET 7
Overview on the Introduction to Machine shop Practice
This page content an overview to machine shop practice as part of the few
content of the subject metal works. These includes topic such, safety in
machineshop, symbols and sign, machineshop equipment and tools with their
respective uses and maintenance. Safety measures and routine in
machineshop work.
Safety Signs, Symbols and Alarms
I. Safety Signs
The different safety signs you may have seen in several

establishments, factories, shops and even along the roads and highways
may include some of those listed below:
1. Circular Label Safety Signs
2. Fire Safety Signs
3. Fire Exit Signs
4. Mandatory Safety Signs
5. Health and Safety Signs
6. Prohibition Signs
7. Tactile Braille Safety Signs
8. Pocket Safety Guides
9. Warning Signs
10. No Entry Signs
11. No Smoking Signs
12. No Parking Signs
The Department of Labor and Employment (DOLE) and the

Occupational Health and Safety Standards (OSHS) issued D.O. 13, ss
1998, known as the Guidelines Governing Occupational Safety and Health
in the Industry. It requires employers and establishments to use a safety
sign where there is a significant risk to health and safety that has not

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been avoided or controlled by the methods required under other relevant
law, provided the use of a sign can help reduce the risk. Safety signs are
not a substitute for those other methods of controlling risks such as
engineering controls and safe systems of work.
This table summarizes some of the different kinds of signs and

symbols you have to follow at all times while doing your works in the shop.
Example Classification Meaning/ Usage
SAFE
Hazard emergency escape route or first aid. It shows
avoidance the way to medical assistance, area of safety,
and a course of safe action to take.
Do not use in any specified places. It may

Prohibition interfere in the operations of other electronics
gadgets in the vicinity
BE CAREFUL
Hazard alerting Warning. It warns everybody of potential
dangers around the workplace.
NOT ALLOWED
Prohibition Danger, alarm. This prohibition reduces risks
of fire and prevents personal injury.

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This sign clearly indicates that there is a need
Hazard alerting for a hearing protection device in the
workplace.
This is very prominent in workplaces where

radioactive substances are handled. Do not
Hazard alerting
enter such area unless you are provided with
protective clothing or device.
This is very prominent in workplaces where

radioactive substances are handled. Do not
Hazard alerting
enter such area unless you are provided with
protective clothings or devices.
When you see this symbol, picking, smoking,

Prohibition
or touching is prohibited
Do not engage in any activity in the workshop

Hazard
with gloves and other protective clothing and
Avoidance
device.

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Be careful in handling, touching, and
Hazard alerting
operating machines, specifically, gears.
Do not touch the area where it is located, it is

Hazard alerting understood that the moving parts where that
point is placed is dangerous.
Do not perform any activity when your eyes are

Hazard alerting
unprotected.
Danger of electrocution. Do not ignore this sign in the

Hazard alerting
workplace.
Avoid getting into contact to places, equipment or tools

Hazard alerting
with this sign.

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In some work places or shop, be cautious with high
Hazard avoidance intensity ultraviolet rays. It is highly dangerous to your
eyes.
In the machine shop, working with milling, grinding, and

bench works sometimes noise cannot be controlled.
Hazard alerting
Wear the necessary ear protection device to avoid
damaging your eardrum.
Hazard High voltage is dangerous and fatal. Keep out

alerting of areas where you see signs like this.
In all offices, workplaces, and establishments,

it is mandatory to have this sign for first aid
Safety
displayed on conspicuous places. This is where
you should run to if accidents happen.
For good house keeping, these symbols

Hazard indicate “recycling” materials. This means that
avoidance/ the material is recyclable or where you should
safety place recyclable objects/wastes in the work
area.

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Hazard
Be careful in working with gears.
Avoidance
Hazard Be careful in rolling objects, cylinders and

Avoidance other objects while working with machines
Hazard
Avoidance Be careful with falling objects and from being
pressed from lathe and other moving machines
Hazard Do not touch when the gears or wheels of

Avoidance machines are moving.
Hazard Be careful in handling objects specifically hot

Avoidance cylinders or tubes.

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Safe Use of Signs
The Code of Practice for escape route signing states:

1. That a fire exit/exit sign with an arrow should be used where
the escape route from a building is not conspicuous or
confusion could occur.
2. All changes in direction in corridors, stairways and open
spaces forming part of the escape route should be marked with
additional signs.
Safety, hazard and warning signs ensure that machine shop

students, employees, visitors, building occupants, and emergency
personnel have adequate information concerning dangers in the
workplace. Employers, establishments and schools are usually
required by law to post and maintain these kinds of signs in
appropriate areas.
Occupational Health and Safety Standards requires the use of Safety

Signs to indicate and to define specific hazards that without
identification, may lead to accidental injury to workers. The public or
may also cause property damage.

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INFORMATION SHEET 7.1
Safety Precautionary Measures in the Shop
SAFETY COMES FIRST and is everyone‟s concern. An accident in

the machine shop can be messy and painful experience. Most accidents
in the shop are the results of carelessness. The victim knows at the time
that he should not do what he is about; he takes a chance. Sometimes he
is lucky to get away from it. Accident statistics prove that he who takes a
chance often loses.
It takes time and experience to develop a skilled machinist. A skilled

machinist is seldom involved in accidents. He knows that he cannot take
chances with the certainty of the machine‟s timing, or with the power of
its movement. There are basic rules for the development of safe working
habits.
Your safety and well-being is of vital importance to your teacher.

Always remember this every time safe work practices are emphasized
when performing any shop activities.
Each machine has individual hazard. (In the next learning

outcomes, the proper ways of handling machines to be used in your
respective areas will specifically be discussed). The careful operator
however, quickly observes each potential danger and sets a pattern of
work habit that will keep him clear of involvement with any dangerous
practice.
What are the good working habits of a skilled machinist?

1. The skilled machinist dresses safely.
2. He does not wear anything that can be caught by the moving
job or machine.
3. He is aware of the danger of the flying chips and minute
particles from abrasive wheels and of the horrible damage
that flying particles from drills and cutting tools can do.
4. He wears his safety glasses from the time he enters the shop
until he leaves.
5. He handles sharp cutting tools with care.
6. He keeps the floor around his workplace free of oil and short
pieces of stock.

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7. He stacks rough casting and finished workpieces separately
and neatly because stacked material may interfere with his
movement around the machine.
8. When a workpiece or a machine attachment is too heavy or
cumbersome for one to handle, he asks for assistance.
The wise machining student is the one who observes and profits from
the skilled shop teacher‟s examples. You must be aware of the dangers
around you in the shop. It is also expected that “presence of mind” in all
your shop activities is highly practiced. This will lead to the development
of your own awareness of the importance of avoiding accidents and your
own awareness of hazards to safety in the workplace. Thus, your own safe
working techniques, and alertness to possible dangers will not happen
when you observe and obey what your teacher tell you.
Finally, always remember these four (4) important reminders in the

shop:
1. SAFETY COMES FIRST
2. IT HURTS TO GET HURT
3. SAFETY IS A TEAM EFFORT
4. THINK BEFORE ACTING

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Title: Safety Precautionary Measures (Equipment & Tools)

I. EQUIPMENT
1. Shapers a. Be sure that ram, tool head, tool,
work, table-support clamping
screws, and vise are properly
secured in place, or in position, and
in that the tool head and tool clear
the work before starting the shaper.
b. Place a metal shield or heavy, close-

mesh wire screen over the tool
catch and the chips.
c. After setting the stroke length and

position, check to see that adjusting
nuts are tight.
d. Remove all wrenches from machine

after completing the set up. If
magnetic chuck is used, be sure that
the current is “on” before starting
machine.
e. Stand parallel to direction of stroke

of machine when it is running and
never reach across the table
between strokes of the ram.
f. Never remove chips while ram is in
motion.
2. Planers a. After work is fastened, check to see
that it clears cross rails.

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b. See that stop pegs are in proper
places and safety dogs are secured
in position.
c. See that feed rod and its

attachment are properly located
and in proper working order.
d. Have planer idle when adjusting
length of bed stroke and speed of
machine to suit work.
e. Do not reach over a moving job and
never ride the bed or platen.
f. Do not leave any tools of any kind

between the ways.
g. When loosening tool holders, hold
tool with one hand or place a
wooden
support under it.
3. Milling a. Make sure that the cutter and arbor

Machine are secured and that cutter and
s arbor support clears the work.
b. Use only cutters that are correctly

ground and in a good condition.

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c. To avoid striking hands on cutter
while setting up, move table with
work as far away from cutter as
possible.
d. When using cutters in a vertical

milling machines, do not take an
excessively heavy cuts or feed.
e. Such feed or cut could break the
cutter and injure the operator.
f. Do not try either to tighten or take

off arbor nut by applying power to
machine.
g. Make sure that the motor is “Off.”
Check speeds and feeds, and feed
work against direction in which
cutter is rotating.
h. Keep hands away from work when

machining.
i. Never reach over a revolving cutter,
especially the side cutter which
cuts into the work. Use a brush not
hands to remove chips.
a. Use drills
4. Drill Press properly sharpened to cut to the
right size and see that the drill is
running true.

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b. Small drills should revolve at high
speeds, large drills at low speeds.
c. Reduce speed at about 50% when

drilling cast iron.
d. Chuck wrenches must be removed
from drill chucks before starting the
machine.
e. Never attempt to hold work under
the drill by hand.
f. Always clamp work to table. Run
drill only at proper speed; forcing or
feeding too fast may result in
broken or splintered drills and
serious injuries.
g. Change belt for speed regulation

only when power is “Off” and
machine has come to dead stop.
h. If work should slip from clamp,
never attempt to stop it with the
hands. Stop the machine and make
adjustments.
i. If drill stops in work, shut off the
motor and start drill by hand.
j. File or scrape all burrs from drilled

holes. Do not reach around or in
back or a revolving drill.

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k. Keep your head back and well away
from any moving part of the drill
press.
5. Lathes a. Before turning on the power, check
to see that the tailstock, tool
holder, and job are properly
clamped.
b. Use hand power only when putting
on or removing chuck or faceplate.
Do not use the power that operates
the lathe.
c. When assembling or removing the

chuck, place board on ways to
prevent damage to machine and
possibly to operator in case the
chuck falls. Have a firm grip on
chuck as it nears the end of the
thread. Do not leave chuck wrench
or any other tool in the chuck.
d. If machine is turned on, wrench may
fly out and injure the operator or
any other person.
e. Do not use wrench on revolving

work or parts.
f. Never try to measure work or feel
the edge, or adjust a cutting tool
when lathe is running. Do not take
heavy cuts on long slender work.
g. Doing so may cause the job to fly
out from the machine.

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h. When filing, be sure tang of file is
protected by a strong
wooden handle. Stand to
one side so that, if the file is forced
upward, it will go past the body
rather than against it.
i. As a general rule, do not shift or

change gears while lathe is running.
j. Stand erect. This keeps your head

away from flying chips.

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6. Metal Saw a. When turning on power, stand to one
side of saw frame and then adjust
speed to suit work.
b. When saw is operating, do not bend
over it.
c. Mount work only when the saw has
stopped.
d. Support protruding end of long work
so material cut of will not fall and
possibly injure any one. Be sure that
the protruding end is well guarded
against anyone coming in contact
with it.
e. When using the sliding stock guide,
do not allow fingers to project
beyond the end so that they could
come in contact with the saw teeth.
f. Be sure that the blades for both
circular and band saws are in good
condition before using. An indication
that the blade is cracked is a sharp,
regular clicking sound as the work is
fed. Change the blade at once if
these conditions arise.
g. Always inspect the blade before
using.
h. If blade does break in work, shut off
the power and do not attempt to
disengage the blade from work until
the machine has come to a complete
stop.

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7. Grinders: a. Stand on a side out of line of
Pedestal wheel when starting it up,
Type especially if wheel is new. The
face of the wheel must be flat
b.
and free from grooves.
c. Work should be fed slowly and

gradually. Using too much
pressure or striking the wheel
suddenly may cause it to break.
d. Make sure that the tool rest is

only 1/8 in. from the face of the
wheel. Check this distance. Too
much clearance may cause the
job to jam the wheel and break
it.
e. Do not set tool rest while

machine is in motion.
f. Use the face of the wheel only,
unless it is designed for grinding
on the side; otherwise, side
pressure may break the wheel.
Whenever possible, use entire
face of wheel to avoid grooving.
g. Never use a grinding wheel that

is loose on the shaft or if its rate
of speed is not safe for the
number of r.p.m. of the spindle.
Check with the
teacher for this information.

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h. Stop wheel if it chatters or
vibrates excessively. This may
be a danger signal that the
wheel is not properly balanced
or not attached securely to
spindle.
i. All wheels should be tested for
soundness.
The teacher does that.
j. Hold job against wheel firmly so
that it will not slip out of the
hand and cause hand and
fingers to come in contact with
the wheel.
k. Use clamp or other suitable

holding devices for grinding
short pieces.
l. Always use face shield or
goggle even if grinders is
provided with
protective glass shields
8. Surface

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Grinder a. Be sure that the magnetic
chuck is thoroughly cleaned.
b. Test the holding power of
chuck before starting the
machine.
c. Stand at one side of the
wheel before starting up.
d. Check to see that the wheel
properly clears work.
II. HAND TOOLS

1. Screw a. Select screw drivers to fit the screw
Drivers head being used.
b. Keep the screwdriver handles
smooth.
c. Do notuse a screw-diver handle as a
hammer.
d. Avoid holding the work in the hand
when using a
screw driver on it as it may slip
and cause stab wounds.
e. Never grind screw drivers to a chisel
edge.
2. Wrenches a. Discard wrenches that are

spread.

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b. Select open-ended wrenches
to fit in the job.
c. Where possible, avoid using an

adjustable or monkey wrench.
d. If a wrench has become burred,

grind off the rough spots to
avoid cutting the hands.
e. It is generally safer to pull a
wrench towards yourself than
to push it away from you.
f. Be sure that your knuckles will

clear obstructions when the
wrench turns.
3. Hammers
mmers that are chipped ould

i. Ha sh be discarded.
j. Nev er use hammer that has oose
a l or split handle.

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4. Chisels a. In hausing a chisel and
he mmer, keep the chisel
gri ad free from burring by nding it
if necessary.
b. Wh en chips may fly, use a p

chi screen.
c. Hold the chisel and hammer clean and
free from grease.
5. Scrapers a. Keep scrapers in a place away from

the rest of the tools.
b. Keep guard from handles on all

scrapers. Guard against scraping
towards the body.
c. Avoid holding work in one hand and

the scraper in the other. Stab
wounds are likely to result.

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d. Scrapers that must be carried in a
tool box should be guarded with a
wooden or leather sheath for their
own protection as well as yours.
6. Files a. Always use a file with a handle.
b. When filling in the lathe, learn to

file left handed.
c. Keep the file and your hand clear of
the jaws or dog.
d. Do not use the file as pry bar.
e. If filling in a lathe, do not use a pad

of cloth or waste under the thumb
on the end of the file.
f. Keep a firm a grip on the file at all
times.
g. Do not blow fillings so that they can
go into anyone‟s eyes.
7. Hacksaw a. Use the correct blade for the job.

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b. See that the blade is correctly
secured in the frame.
c. Went the saw breaks through the

work, ease up the pressure so that
the hand will not strike the work or
vise.
d. Be sure that the work is held
securely in the vise.
e. Do not force cut.
8. Taps and Dies a. Be sure that the work is firmly

mounted n vise.
b. Secure the proper size of tap
wrench.

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c. Avoid cutting the hands on a broken
tap end.
d. If a broken tap is removed by using

a punch and hammer, wear goggles.
e. If a long thread is cut with a hand

die, keep the arms and hands clear
of the sharp threads coming
through the die.

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Health and Safety Responsibilities
Key Point: Health and safety at work is everyone's responsibility.
You are responsible in looking after your own health and safety. You
must also take care not to put other people at risk.
You might put other people at risk by:
• acting in an unsafe manner,
• not following the agreed safe work practices,
• not acting to report a situation which may result in hurting someone.
To ensure the safety of yourself and others, make sure you are aware
of the correct safety procedures at your place of work. This means:
• listening very carefully to safety information provided by your

employer.
• asking for clarification, help or instructions if you're not sure about

how to perform any task safely.
There are three steps used to manage health and safety at work:
1. Spot the hazard (Hazard Identification)
2. Assess the risk (Risk Assessment)
3. Make the changes (Risk Control)
At work you can use these three Think Safe steps to help prevent
accidents.

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1. Spot the hazard
Key Point: A hazard is anything that could hurt you or

someone else.
Examples of workplace hazards include:
• frayed electrical cords (can result electrical shock)
• boxes stacked precariously (can fall on someone)
• noisy machinery (can result in damage to your hearing)

During work experience, you must remain alert to anything that
may be dangerous. If you see, hear or smell anything odd, take note. If
you think it could be a hazard, tell someone.
2. Assess the risk
Key Point: Assessing the risk means working out how

likely it is that a hazard will harm someone and how
serious the harm could be.
Whenever you spot a hazard, assess the risk by asking yourself two
questions:
• How likely is it that the hazard could harm me or someone else?
• How badly could I or someone else be harmed?
Always tell your instructor or your classmates about hazards you can
not fix yourself, especially if the hazard can cause serious harm to anyone.
For example:
• Ask your teacher for instructions and training before using an

equipment
• Ask for a help in moving or lifting heavy objects
• Tell your teacher if you think a work practice can be dangerous
If you are not sure of the safest way to do something on work

experience, always ask your work experience supervisor.
3. Make the changes

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Key Point: It is your employer's responsibility to fix
hazards. Sometimes you may be able to fix simple hazards
yourself, as long as you don't put yourself or others at risk.
For example, you can pick up things from the floor and put
them away to eliminate a trip hazard.
The best way to fix a hazard is to get rid of it altogether. This is not
always possible, but your shop teacher should try to make hazards less
dangerous by looking at the following options (in order from most effective
to least effective):
• Elimination - Sometimes hazards from equipment,

substances or work practices can be avoided entirely. (e.g.
Clean high windows from the ground with an extendable pole
cleaner, rather than by climbing a ladder and risking a fall.)
• Substitution - Sometimes a less hazardous thing, substance

or work practice can be used. (e.g. Use non-toxic glue instead
of toxic glue.)
• Isolation - Separate the hazard from people by marking the

hazardous area and fitting screens or putting up safety
barriers. (e.g. Welding screens can be used to isolate welding
operations from other workers. Barriers and/or boundary
lines can be used to separate areas where forklifts operate
near pedestrians in the workplace.)
• Safeguards - Safeguards can be added by modifying tools or

equipment, or fitting guards to machinery. These must never
be removed or disabled by workers using the equipment.
• Instructing workers in the safest way to do something -

This means developing and enforcing safe work procedures.
Students on work experience must be given information and
instruction and must follow agreed procedures to ensure
their safety.
• Using personal protective equipment and clothing (PPE) -

If risks remain after the options have been tried, it may be
necessary to use equipment such as safety glasses, gloves,
helmets and ear muffs. PPE can protect you from hazards
associated with jobs such as handling chemicals or working
in a noisy environment. Sometimes, it will require more than
one of the risk control measures above to effectively reduce
exposure to hazards.

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Hazardous Substances and Dangerous Goods
Identification and Control
Your workplace may use hazardous substances and dangerous

goods. Hazardous substances may be things you see every day such as
paint, glue, cleaning liquid and powders. Dangerous goods may be
corrosive, flammable, explosive, spontaneously combustible, toxic,
oxidizing, or waterreactive. They must be identified in the workplace (and
when being transported) by different colored 'diamond' symbols.
Key Point: A hazardous substance can be any substance,

whether solid, liquid or gas, that may cause harm to your health.
Hazardous substances are classified on the basis of their potential

health effects whether acute (immediate) or chronic (long-term).
Dangerous goods are classified on the basis of immediate physical

or chemical effects, such as fire, explosion, corrosion, and poisoning. An
accident involving dangerous goods could seriously damage property or
the environment.
Harm to health may happen suddenly (acute), such as dizziness,

nausea and itchy eyes or skin; or it may happen gradually over years
(chronic), such as dermatitis or cancer. Some people can be more
susceptible than others.
We use hazardous substances and dangerous goods almost every

day of our lives. It may be antiseptic for a cut, paint for the walls, or a
cleaning product for the bathroom. While they may seem harmless, even
these ordinary things can make you very sick if they are not used properly.
Key Point: It is the responsibility of the school and your

teacher to provide you with safe work procedures for
handling hazardous substances and dangerous goods,
and to provide information, training and supervision.
First aid treatment for hazardous substances and
dangerous goods should be part of your training.

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Material Safety Data Sheet
A material safety data sheet (MSDS) provides detailed information

about a hazardous substance of a dangerous goods. It gives more
information than you will find on a label. Manufacturers and suppliers of
hazardous substances and dangerous goods are legally required to
provide MSDS's to your school if requested.
It is important that hazardous substances and dangerous goods in

workplaces are used strictly according to the manufacturers‟ or
suppliers‟ written instructions. Any risk controls specified by the MSDS
and the procedures developed by the workplace must also be closely
followed.
Remember:
1.Follow safe work procedures,
2.Always wear the right personal protective equipment and clothing

provided.
3.Do not eat, drink or smoke while working with a hazardous

substance or dangerous goods.
4.Do not keep food or drink near the substances.
5.Wash your hands and face and other exposed areas with soap and
water before going to the toilet, eating and drinking.
6.Read the MSDS before using any hazardous substance. If there is no

MSDS, ask your shop teacher or school personnel to provide you one.

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SELF-CHECK 7
Direction: Give the classification of each given sign and symbols. Write on
the
Classification column: A – if it is a prohibition, B – if its hazard avoidance,
and C – if it is for hazard alertness. of each given sign and symbols below.
On the third column when and how it is used in the workplace.
Example Classification How it is used in the workplace

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4

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10

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SELF-CHECK 7.1
DIRECTION: After you have read Information sheet 101-2,

answer the following questions
1. What are the good habits of a skilled shopworker?

___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
2. Explain in your own word „IT HURTS TO GET HURT‟
________________________________________________________
_______
______________________________________________________________
_______
______________________________________________________________
_______
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
______________________________________________________________
_______
______________________________________________________________
_______
______________________________________________________________
_______
______________________________________________________________
_______
______________________________________________________________
_______
______________________________________________________________
_______ _____________________________________

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SELF-CHECK 7.2
DIRECTION: In Column A, the picture of machine tools and equipment

are shown. Write in Column B the name of the EQUIPMENT or TOOL. In
Column C, write at least 3 precautionary procedures in using the
machine.
A B C
1.
2.
3.
4.
5.
6.

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7.
8.
9.
10.

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SELF-CHECK 7.3
DIRECTION: After you have read the Information sheet 0101D, answer the following
questions:
1. In the work place, how do you keep other people free from risk?
___________________________________________________________
__________________________________________________________
___________________________________________________________
__________________________________________________________
2. Enumerate the three steps used to manage safety at work.
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
3. What are the three think safe steps to prevent accident?
___________________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________
4. Getting rid of hazard in the work place is not always 100% possible.
Enumerate the options in making hazard less dangerous:
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
_____________________________________________________________________________

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WORKSHEET 4
Hazardous Substances and Dangerous Goods Identification

and Control
Work in the classroom by pairs or by yourself with the supervision of your

teacher.
Task 1:
In a Worksheet 1 list some of the hazardous substances and dangerous
goods that you come in contact with at school, at home or at workplace.
Be specific. Some examples are given below.
• Home Economics:
• Art:
• Science lab:
• Manual Arts:
• Office:
• Home or work:
Task 2:
1. Choose TWO hazardous substances and the/or dangerous goods
from your list in Worksheet 1 and write them down in Worksheet 2
(You will need a copy for each substance).
2. Work by yourself or discuss with your partner and write down your
answers under the headings in Worksheet 2.

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WORKSHEET SHEET 5
LO1. IDENTIFY HAZARDS
Title: Hazards and Risks Identification and Control
Hazardous substances and dangerous goods found at HOME

_____________________________________________________________
______
_____________________________________________________________
______
_____________________________________________________________
______
_____________________________________________________________
______
____________________
Hazardous substances and dangerous goods found in SCHOOL
_____________________________________________________________
______
_____________________________________________________________
______
_____________________________________________________________
______
_____________________________________________________________
______
____________________
Hazardous substances and dangerous goods found at WORK
_____________________________________________________________
______

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WORKSHEET SHEET 6
Title: Hazards and Risks Identification and Control

Name of a hazardous substances or dangerous goods
_____________________________________________________________
______
_____________________________________________________________
______
Area of the school/home/workplace where it is found:
_____________________________________________________________
______
_____________________________________________________________
______
Main use of the substance (e.g. cleaning, lubricant, colouring hair):
_____________________________________________________________
______
_____________________________________________________________
______
Ways on how the substance is used or applied (e.g. sprayed, added to water, wiped on):
_____________________________________________________________
______
_____________________________________________________________
______
_____________________________________________________________
______

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Ways the substance could affect you (e.g. headache, rash on skin, burns) not sure, read the label
or Material Safety Data Sheet (MSDS):
_____________________________________________________________
______
_____________________________________________________________
______
_____________________________________________________________
______
Main control strategies by users (e.g. gloves, mask, good ventilation):
_____________________________________________________________
______
_____________________________________________________________
______
_____________________________________________________________
______
_____________________________________________________________
______

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WORKSHEET 7
Title: Hazards: Risk Assessment and Control
Risk Assessment Work

Work in the classroom in pairs or in small group, with the supervision of your teacher. Do the task
below.
Resource:
Information Sheet and Risk Assessment Chart.
Task:
1. Choose an industry or type of workplace (e.g. manufacturing, hairdressing salon).
2. Make a list of hazards that may be present in that workplace e.g. slippery floors from spilt
water, oil etc; uneven floors from changing floor level
3. Choose 3 or 4 hazards and list them on your Worksheet.
4. Read the Information Sheet and the relevant information.
5. Use the Risk Assessment Chart to assess the risk.
6. Write down ways to control the hazards in the Worksheet 1.3

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WORKSHEET SHEET 8
Risk Assessment and Control
Spot the Hazard Assess the Risk Make the Changes
A Hazard is anything that How likely the hazard will hurt Eliminate, substitute, isolate, add
can hurt you or someone else someone and how badly they can safeguards, use safest way, use
be hurt protective equipment
List the hazards Describe the risks Suggest ways on how to control the
risks
1. 1.
1.
2. 2.
2.
3. 3.
3.
4. 4.
4.
5. 5.
5.
6. 6.
6.
7. 7.
7.
8. 8.
8.

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OPERATION SHEET 3
Sub-title: Hazards: Risk Assessment and Control

TO CARRY OUT A BASIC RISK STEP 1: INFORMATION WHAT INFORMATION DO YOU HAVE
ASSESSMENT ABOUT EACH HAZARD?
Gather information about each
hazard identified.
FOLLOW THE FOUR STEPS WHO WILL BE EXPOSED TO THE

STEP 2: LIKELIHOOD HAZARD AND FOR HOW LONG?
Think about how many young people

are likely to be exposed to each
hazard and for how long.
You need to take into account the

different situations/conditions that
may exist in your workplace that may
increase the likelihood, such as a WHAT WILL BE THE
change to operations, inspection, CONSEQUENCES IF THE
cleaning, maintenance, servicing and HAZARD CAUSES AN INJURY OR
repair, new or inexperienced staff. HARM TO HEALTH?
STEP 3: CONSEQUENCES
Use the information to assess the

consequences of each hazard.
• Fatality HOW DO YOU RATE THIS RISK?
• Major injuries
(significant long term
effects)
• Minor injuries (usually

requiring several days off
work)
• Negligible injuries
(maybe first aid)
STEP 4: RATING THE RISK
Use the risk table on the next page to

work out the risk associated with
each hazard

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RISK ASSIGNMENT TABLE
LIKELIHOOD
of Injury or Harm CONSEQUENCE of any injuries or harm to health
to health
Insignificant (e.g. Minor (e.g. first Moderate Major (e.g. Catastrophic

no injuries) aid onsite only) (e.g. medical extensive (e.g.
treatment) injuries) fatalities)
Very likely SIGNIFICANT SIGNIFICANT HIGH HIGH HIGH
Likely MODERATE SIGNIFICANT SIGNIFICANT HIGH HIGH
Moderate LOW MODERATE SIGNIFICANT HIGH HIGH
Unlikely LOW LOW MODERATE SIGNIFICANT HIGH
Highly unlikely LOW LOW MODERATE SIGNIFICANT SIGNIFICANT

(rare)

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Assignment Sheet 1
Using Machinery and Equipment Safely
Work by yourself or with a partner in this activity as a home assignment.
For your information:

Safe work procedures are like rules or instructions for doing a particular work task or
operating machinery or equipment safely. Sometimes safe work procedures may include
questions or a checklist of things to do before you start the work and they may refer to particular
personal protective equipment you should wear (e.g. safety glasses or steel cap boots).
Written assignment:
• Choose two items of mechanical equipment or machinery. Describe what they are used for.
Look for pictures of the equipment or machinery.
• List the likely hazards associated with each type of equipment (for example, sharp blades,
and moving parts).
• Next to each hazard identified, list the possible injury or harm that may be result (for
example, cuts, amputation of fingers or hand, crush injury).
• List some of the safe work procedures that may apply to the equipment or machinery.
• List any particular items of personal protective clothing or equipment that

should be worn.
Reference/Source:
• Search about mechanical equipment available from

http://www.sofweb.vic.edu.au/safe@work
• Relevant books from a library or information from http://www.worksafe.vic.gov.au/ Hint:
use the „search‟ box to search for specific information about equipment such as angle
grinders or power presses.

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HOW TO USE THIS MODULE

Welcome to the Module on Metal Works. This module contains

The unit of competency “Perform Metal Works” contains the

In connection, this module contains a topic that focused on

You are also required to answer the Pretest before you go

Follow these activities on your own and answer the Self-Check

If you have questions, do not hesitate to ask your facilitator for

Date Developed: Document No.

ZALDY A. JUL JR.

How to use this Module…………………………………………………..............1

Covered Competencies and Assessment Criteria………………………………....4

Information Sheet 1………………………………………………………………13

Answer Key 1.2……………………………………………………………….....17

Information Sheet 2………………………………………………………………18

Answer Key 2.2………………………………………………………………….28

Information Sheet 3……………………………………………………………...29

Answer Key 3.2………………………………………………………………….39

Information Sheet 4……………………………………………………………...40

Date Developed: Document No.

ZALDY A. JUL JR.

Answer Key 4.2…………………………………………………………………..49

Information Sheet 5……………………………………………………………...50

Answer Key 5.2………………………………………………………………….54

Information Sheet 6………………………….......................................................55

Job Sheet 1……………………………………………………………………….68

Job Sheet 2……………………………………………….....................................69

Job Sheet 3……….................................................................................................70

Job Sheet 4……………………………………………………………………….71

Date Developed: Document No.

ZALDY A. JUL JR.

Module Title: WELDING GROOVE WELD ON CARBON STEEL

This module contains information and suggested learning activities on

SUMMARY OF LEARNING OUTCOMES:

Upon completion of the module the students should be able to:

Refer to assessment criteria of learning outcomes of this module.

Date Developed: Document No.

ZALDY A. JUL JR.

Bevel angle- is the angle at which a bevel is cut.

Groove angle -is the total included angle of the groove.

V-groove- is a straight angular groove on both metal pieces to be joined.

Date Developed: Document No.

ZALDY A. JUL JR.

MODULE TITLE : PERFORMING GROOVE WELDING ON CARBON

LearningOutcome#1 : Weld carbon steel plates in flat position (1G)

1. Root penetration not exceeding allowable tolerances specified by welding

Date Developed: Document No.

ZALDY A. JUL JR.

MODULE TITLE : PERFORMING GROOVE WELDING ON CARBON

LearningOutcome#2 : Weld carbon steel plates in Horizontal position (2G)

6. Root penetration not exceeding allowable tolerances specified by welding

Date Developed: Document No.

ZALDY A. JUL JR.

MODULE TITLE : PERFORMING GROOVE WELDING ON CARBON

LearningOutcome#3 : Weld carbon steel plates in Vertical Position (3G)

11. Root penetration not exceeding allowable tolerances specified by welding

Date Developed: Document No.

ZALDY A. JUL JR.

MODULE TITLE : PERFORMING GROOVE WELDING ON CARBON

LearningOutcome#4 : Weld carbon steel plates in Over Head Position (4G)

16. Root penetration not exceeding allowable tolerances specified by welding

Date Developed: Document No.

ZALDY A. JUL JR.