COMPETENCY BASED

LEARNING MATERIAL

Sector : METALS AND ENGINEERING

Qualification Title: SHIELDED METAL ARC WELDING NC I

Unit of Competency: Weld Carbon Steel Plates using SMAW

Module Title: Welding on Carbon Steel Plates using SMAW

R. NADORA TRAINING CENTER INC.

Brgy. Lourdes, Cabanatuan City, Nueva Ecija
Philippines, 3100
(044)806-1224/09202219295
 LIST OF COMPETENCIES

No. Unit of Competency Module Title Code

1 Weld carbon steel plates 1.1 Performing groove welding MEE721

and pipes using SMAW on carbon steel plate 306

Code No. Date: Developed Date: Revised Page #

AST-NC2-C1.2 01-03-2016 ii
HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to this Competency Based Learning Material for the Module Weld Carbon Steel Plates
in Shielded Metal Arc Welding (SMAW).

This learning material contains activities for you to complete. It covers knowledge, skills and
attitudes required to complete the competency: Weld Carbon Steel Plates, one of the modules in
the Core Competencies for Shielded Metal Arc Welding NC-l.

You are required to go through a series of learning activities in order to complete each of the
learning outcomes of this module. In each learning outcome, Learning Elements and Reference
Materials are available for your further reading to assist you for the required activities. You are
expected to accomplish all the required activities and to answer the self-check after each learning
element. Please note that you need to have 100% correct answers to each self-check to pass the
activity. You are required to go through a series of learning activities in order to complete each of
the learning outcomes of this module.

You are required to obtain answer sheets which are available from your trainer at the end of each
learning element, to reflect your answers for each self-check. If you have questions, please do not
hesitate to call our attention for assistance.

Recognition of Prior Learning (RPL)

You may have acquired some or most knowledge and skills covered in this learning material
because you have:

 Actual experience on the job;

 Already completed training in this area.

If you can demonstrate to your trainer that you are competent in a particular skill, you do not have to
take this training again. If you feel having the skill, tell your trainer to have it formally recognized.
You can show your Certificate of Competency from previous training and if your acquired skill is still
relevant to the module, it is now part of the evidence as required of the RPL.

A Learners Diary can be found at the end of this learning material. Use this diary to record
important dates, jobs undertaken and other workplace events that will assist you in providing further
details to your trainer as assessor. A Record of Achievement is also provided for your trainer to fill-
in upon completion of this module.

This module was prepared to help you achieve the required competency in welding carbon steel
plates. This will serve as a source of information for you to acquire the required knowledge and
skills for Shielded Metal Arc Welding with minimum supervision or help from your trainer. This
material will aid you in acquiring the competency at your own pace, independently.
 Talk to your trainer and agree on how you will both organize your training on this unit. Read
through the Competency Based Learning Material carefully. It is divided into sections which
covers all the skills and knowledge you need to successfully complete this module.

 Most probably your trainer will also be your supervisor. He will be there to assist you and
show you the correct way to do things. Ask for help if you need one.

 Your trainer will tell you about the important things you need to consider when doing the
activity. It is important that you listen and take note.

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AST-NC2-C1.2 01-03-2016 iii
  You will have plenty of opportunities to ask questions and undergo rigid practice. This will
help you in achieving competency in the new skill. More practice will improve your speed,
memory and confidence.

 Talk to some experienced colleagues and ask for guidance.

 Answer Self-checks at the end of each section to test your own progress.

 When you are through with each element, and feel ready to demonstrate the activities
outlined in the learning material, approach your trainer.

 As you are working through with the activities, your trainer is taking notes of your
performance. He will provide you with feedbacks on your progress. Your readiness for
assessment will reflect on the report whether you successfully completed each element.

After completion of the module and you feel confident that you have had sufficient practice,
you may request your trainer to arrange an appointment with a registered assessor for your
assessment. The result of the assessment will be recorded in your Competency Achievement
Record.
Remember to:

 Work through all the information and complete the activities in each section.
 Read information sheets and complete the self-check. Suggested references are
included to supplement the materials provided in this module.
 Most probably your trainer will also be your supervisor or manager. He/she is
there to support you and show you the correct way to do things.
 You will be given plenty of opportunity to ask questions and practice on the job.
Make sure you practice your new skills during regular work shifts. This way
you will improve both your speed and memory and also your confidence.
 Use the Self-checks, Operation Sheets or Job Sheets at the end of each section
to test your own progress.
 When you feel confident that you have had sufficient practice, ask your Trainer
to evaluate you. The results of your assessment will be recorded in your
Progress Chart and Accomplishment Chart.
You need to complete this module before you can perform the next module.


Code No. Date: Developed Date: Revised Page #

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 LEARNING OUTCOME
Performing Groove Welding
(LO) 1in Carbon Steel Plate
LEARNING EXPERIENCES
Learning Activities
Read Information Sheet 1.1-1
Work-Based Training
Answer Self Check 1.1-1
Read Information Sheet 1.2-1
Trainees Training Requirement
Answer Self Check 1.2-1
Read Information Sheet1.3-1
Work-Based Training
Answer Self Check 1.3-1
Read Information Sheet 1.4-1
Trainees Training Requirement
Answer Self Check 1.4-1
Read Information Sheet 1.5-1
Trainees Training Requirement
Answer Self Check 1.5-1
Code No.
AST-NC2-C1.2
Special Instruction
If you feel you can explain work-based
training and enumerate its objectives,
you can now answer Self Check 1.1-1
If you score 100% upon comparing your
answer to Answer Key of Self Check 1.1-1
you may now proceed to Information
Sheet 1.1-1.
If you feel that you can already determine
the current competencies of the trainees
and identify their training requirements,
please proceed to Job Sheet 1.2-1
If you score 100% upon comparing your
answer to Answer Key of Self Check 4.1-1
you may now proceed to Information
Sheet 1.2-1. If not, return to Information
Sheet 1.1-1
If you feel you can explain work-based
training and enumerate its objectives,
you can now answer Self Check 1.3-1
If you score 100% upon comparing your
answer to Answer Key of Self Check 4.1-1
you may now proceed to Information
Sheet 1.3-1. If not, return to Information
Sheet1.2-1
If you feel that you can already determine
the current competencies of the trainees
and identify their training requirements,
please proceed to Job Sheet 1.4-1
If you score 100% upon comparing your
answer to Answer Key of Self Check 1.4-1
you may now proceed to Information
Sheet 1.4-1. If not, return to Information
Sheet 1.3-1
If you feel that you can already determine
the current competencies of the trainees
and identify their training requirements,
please proceed to Job Sheet 1.5-1
If you score 100% upon comparing your
Date: Developed Date: Revised Page #
01-03-2016 v
 Learning Activities Special Instruction
answer to Answer Key of Self Check.

SHIELDED METAL ARC WELDING NC I

Sector Metals and Engineering

Qualification Shielded Metal Arc Welding NC-l
Unit of Competency Weld Carbon Steel Plates
Module Welding Carbon Steel Plates

Course Description:

The Shielded Metal Arc Welding (SMAW NC-I) Qualification consists of

competencies that a person must achieve to weld carbon steel plate
components as specified by layout, blueprints, diagrams, work order, welding
procedure or oral instructions using shielded metal arc welding equipment and
accessories.

This Qualification conforms to American Welding Society (AWS D1.1)

Structural Welding Code; American Society of Mechanical Engineers (ASME
IX) Boiler and Pressure Vessel Code; American Petroleum Institute (API 1104)
Code for Gas and Oil Pipeline Facilities; and International Standards
Organization (ISO 9606-1) Qualification of Welders for Steel.

Learning Content:

1. Essentials of welding
2. International welding standards
3. Weld profile
4. Safe welding practices

Code No. Date: Developed Date: Revised Page #

AST-NC2-C1.2 01-03-2016 vi
INTRODUCTION:
This unit covers the knowledge, skills and attitudes required to plan training
sessions which include identifying trainee’s requirements, preparing session
plans, preparing basic instructional materials, and organizing learning and
teaching resources.

CONTENTS PAGE

The Aim of This Module 2

What You Should Achieve 3

What You Can Do Already 8

What You Need To Complete This Module 9

Symbols 10

How to Use This Workbook 11

Summary 12

MODULE 1 Essentials of welding 1

MODULE 2 International welding standards 2

MODULE 3 Weld profile 3

MODULE 4 Welding techniques and procedures 4

Terms and definitions:

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 INFORMATION SHEET 1.1-1
ESSENTIALS OF WELDING

Learning Objective:

After reading this INFORMATION SHEET, you should be able to:

1. Identify the essentials of welding

2. Develop techniques and welding manipulations

5 ESSENTIALS IN WELDING

1. CURRENT SETTING

The rate of current should be appropriate to the following:

 Size of Electrode
 Thickness of Metal Electrode Table
 Classification of Carbon Steel
ELECTRODE AMP PLATE
DIAMETER RANGE
(THICKNESS)

1/16" 20 - 40 UP TO 3/16"

3/32" 40 - 125 UP TO 1/4"

1/8 (3.2mm) 75 - 185 OVER 1/8"

5/32" 105 - 250 OVER 1/4"

3/16" 140 - 305 OVER 3/8"

1/4" 210 - 430 OVER 3/8"

5/16" 275 - 450 OVER 1/2"

Fig. 1.1-1
2. ELECTRODE ANGLE

Make the bead while holding the electrode perpendicular to the plate at an angle
of 15° to 30° in the direction of travel.

If right-handed, weld from left to right, and if left

handed weld from right to left.

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 3. ARC LENGTH

The distance between the tips of electrode to the surface of base metal

ELECTRODE

ARC LENGTH should not exceed to the size of electrode

BASE METAL

4. SIZE OF ELECTRODE

Arc welding electrodes are identified using the A.W.S, (American Welding
Society) numbering system and are made in sizes from 1/16 to 5/16.
An example would be a welding rod identified as an 1/8" E308, E309
electrode. The electrode is 1/8" in diameter. (See fig. 1.1)

5. TRAVEL SPEED

o If the travel speed is too fast, the weld pool does not last long enough and impurities are
lacked in the weld
o If the travel speed is too slow, the metal piles up excessively on the base metal and the bead
is high and wide, with straight ripple

Direction of weld

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 SELF CHECK 1.1-1
ESSENTIALS OF WELDING
WRITTEN TEST

Multiple Choice:

Instruction: Choose the letter of the best answer. Write letter of your choice
on your answer sheet

1. A range of amperes depends on the thickness and size of electrode.

a. Current setting
b. Electrode size
c. Travel speed
d. Electrode angle

2. The directions of electrode movement that should be constant to its motions.

a. Welding operations
b. Travel speed
c. Arc length
d. Electrode angle

3. This is the degree angle of electrode to the base metal where the welder manipulate
in operations.

a. Current setting
b. WPS standards
c. Travel speed
d. Electrode angle

4. What is the ideal arc length?

a. Should not larger than the pipe itself.

b. Must be the size of electrode.
c. Should not exceed to the size of electrode.
d. Should depend on the welder.

5. It is the distance between the tip of electrode and the surface of base metal.

a. Welding operations
b. Travel speed
c. Arc length
d. Electrode angle

6. It is the measurement of the filler metal correspond to amperage, metal classification

and thickness of metal.

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AST-NC2-C1.2 01-03-2016 x
 a. Current setting
b. WPS standards
c. Travel speed
d. Electrode size

7. What is the electrode in welding Carbon steel plate?

a. E7018
b. E309
c. ER23
d. E6010

8. Cause of burn through defect.

a. Current setting
b. Travel speed
c. Electrode size
d. Arc length

9. Cause of narrow weld appearance.

a. Current setting
b. Travel speed
c. Electrode size
d. Arc length

10. Cause of excessive spattering.

a. Current setting
b. Travel speed
c. Electrode size
d. Arc length

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AST-NC2-C1.2 01-03-2016 xi
 Answer key
Self check LO1.1-1

1. a

2. b

3. d

4. c

5. c

6. d

7. b

8. a

9. b

10. d

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 INFORMATION SHEET 1.2-1
INTERNATIONAL WELDING STANDARDS

Learning Objective:

After reading this INFORMATION SHEET, you should be able to:

1. Identify the welding procedure specifications

2. Prepare groove weld requirements and special
preparations.

WELDING STANDARDS
Welding standards are information to prepare weld groove requirements specifically
according to company standards.

1. Tack Welds
Prevent butt joint distortion by tack welding the materials in position before final weld.
Workpiece distortion occurs when heat is applied locally to a joint. One side of a
Metal plate will “curl” up toward the weld.
Distortion will also cause the edges of a butt joint to pull together ahead of the
Electrode as the weld cools.
2. Single Bevel Groove Weld
3. Double Bevel Groove Weld
4. Single V-Groove Weld
5. Double V-Groove Weld
Materials up to 3/16 in (5 mm) thick can often be welded without special preparation
using the square groove weld. However, when welding thicker materials it may be
necessary to prepare the edges(V-groove) of butt joints to ensure good welds.
The single or double V-groove weld is good for materials 3/16 − 3/4 in (5-19 mm) thick.
Generally, the single V groove is used on materials up to 3/4 in (19 mm) thick and when, regardless
of thickness, you can weld from one side only. Cut the bevel with oxyacetylene
or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used
to prepare bevels. Create a 30 degree angle of bevel on materials
in V-groove welding. (Also see fig. 1.1-1)

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 SELF CHECK 1.2-1
INTERNATIONAL WELDING STANDARDS
WRITTEN TEST

Multiple Choice:

Instruction: Choose the letter of the best answer. Write letter of your choice
on your answer sheet

1. The thickness of plate without special preparations.

a. 6mm
b. 8mm
c. 5mm
d. 12mm

2. Applying small amount of weld used to hold temporarily the base metals.

a. Preheating
b. Back step welding
c. Tack welding
d. Intermittent welding

3. What is the required root gap for groove welds?

a. 2mm to 3mm
b. 3mm to 4mm
c. 1mm to 2mm
d. 5mm to 4mm

4. Application of preheating use to avoid distortion.

a. Tack welding
b. Back step welding
c. Groove welding
d. Spot weld

5. What is the required root face for groove welds?

a. 2mm to 3mm
b. 3mm to 4mm
c. 1mm to 5mm
d. 1mm to 3mm

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AST-NC2-C1.2 01-03-2016 xiv
 Answer key
Self check LO1.2-1

1. c

2. c

3. a

4. a

5. d

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 INFORMATION SHEET 1.3-1
WELD PROFILE

Learning Objective:

After reading this INFORMATION SHEET, you should be able to:

1. Identify the quality weld standard appearance.

2. Identify the causes and corrective actions of weld defect.

WELD PROFILE
Weld profile are welding requirements for groove weld appearance and to prevent weld poor
appearances.

 Practice making a single V-groove weld on 1/4 in (6 mm) plate beveled 30°. Start with a 1/8
in electrode for the first bead and finish with a 5/32 in (4 mm) electrode. Be sure to
penetrate about 1/32 in(1 mm) beyond the bottom of the “V” or root.
 Perform a similar exercise on thicker materials. Generally, deposit a bead for each 1/8 in
(3mm) of material thickness, cleaning the joint between layers.
 On heavier plates, it may be necessary to weave the top layers to fill the groove.
 After completing the practice welds, test them using performance checklist.

Capping required
2.5mm to 3mm
METAL
WELD
BASE
BEAD Root penetration
Fig. 1.3-1 required 2.5mm to
3mm

Good Weld Bead Characteristics

1. Fine Spatter Identify weld defect
2. Uniform Bead according to
3. Moderate Crater During essentials of welding
Welding
Weld a new bead or layer for each
1/8 in (3.2 mm) thickness in metals
being welded.
4. No Overlap
5. Good Penetration Into Base Metal
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AST-NC2-C1.2 01-03-2016 xvi
Poor Weld Bead Characteristics
1. Large Spatter Deposits
2. Rough, Uneven Bead
3. Slight Crater During
Welding
4. Bad Overlap
5. Poor Penetration

SELF CHECK 1.3-1

WELD PROFILE
Matching Type

Matching Type:

Instruction: Match column A with Column B. Write the letter only.

Column A Column B

1. Bad Overlap A. Good weld bead characteristics

2. Uniform Bead B. Poor weld bead characteristics

3. Rough, Uneven Bead

4. No Overlap

5. Good Penetration Into Base Metal

6. Large Spatter Deposits

7. Moderate Crater During

8. Slight Crater During Welding

9. Fine Spatter

10. Poor Penetration

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AST-NC2-C1.2 01-03-2016 xvii
 Answer key
Self check LO1.3-1

1. b

2. a

3. b

4. a

5. a

6. b

7. a

8. a

9. a

10. b

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 INFORMATION SHEET 1.4-1
SAFE WELDING PRACTICES

Learning Objective:

After reading this INFORMATION SHEET, you should be able to:

1. Identify the hazard and hazardous locations

2. Identify the personal protective equipment in welding
operations.

1 . Terms and definitions

a. Oxygen displacement - A reduction of oxygen caused by any arc or flame

in the work zone around a welding activity

b. Toxic hazards - Poisonous gases, fumes, and vapors produced by

chemical reactions in certain welding processes

c. Contaminants - Impurities formed from chemical reactions between base

metals, flux, and electrodes, and usually present in fumes and vapors

CAUTION: TOXIC HAZARDS AND CONTAMINANTS ARE

USUALLY PRESENT IN FUMES AND VAPORS.

2. Electrical safety for arc welding

a. All electrical equipment should have an earth ground for safety reasons, and this
ground should not be confused with the work lead to workpiece ground that
completes the welding circuit.

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AST-NC2-C1.2 01-03-2016 xix
 b. Keep electrical connections tight, clean, and dry because poor connections can
heat up, cause bad welds, produce dangerous arcs and sparking, and even
melt.

c. Keep work area, equipment, and clothing dry because even a slight amount of

moisture can conduct enough electricity to cause a severe shock.

d. Never dip an electrode holder in water to cool it.

e. When working with welding machines set up for multiple operation, be very
careful not to touch hot parts of the electrode holders because open-circuit
voltages from two machines are increased and can cause a severe shock.

f. Remove electrode from electrode holder when work is finished.

g. Disconnect and lock out all electric power sources before doing any work on
electrical equipment.

h. When working in high places, carefully examine work area for electrical hazards
because a shock in such conditions could cause a fall and severe injury.

i. Keep welding cables free of conduits, motors, and any other equipment that
could cause a short circuit.

j. Keep ground as far away from the arc as possible.

3. Rules for handling welding cables

a. Never drag a welding cable through oil, and never pull on a cable to force it over
an obstruction.

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 b. Use only clean, dry rags to clean welding cables, and never use gasoline or an
oily rag to clean a cable.

c. When not in use, keep welding cables free of kinks and properly stored on a flat
surface off the floor.

d. Never drape a welding cable over any type of gas cylinder.

4. Rules for handling hollow castings or containers

a. Hollow castings or containers should be vented before any heating, cutting, or

welding activity.

b. Tanks, drums, and containers should not be heated, cut, or welded.

c. The rule for beginning welders is to never attempt heating, cutting, or welding

on hollow castings or containers.

5. Hazards from arc rays

a. A welding arc produces ultraviolet and infrared radiation that can severely burn
eyes that are unprotected with a proper shade of protective lens.

A welding helmet or hood protects the head from flying

sparks, but the shaded lens and safety glasses are required
for total eye protection.

b. Radiation from a welding arc is strong enough to burn or sometimes blister bare
skin if the exposure is intense or for an extended period, so arms, legs, and
torso should be covered with durable flame-resistant clothing.

c. Work stations and work areas should be shielded to prevent an arc flash from
injuring nearby workers or visitors.

6. Types of welding hoods

a. Stationary filter lens - This type hood has a fixed lens housing with the
shaded lens held in by a spring retainer from where a lens can be slipped out
and replaced as welding requires.

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AST-NC2-C1.2 01-03-2016 xxi
 b. Flip-front filter lens - This type hood has a lens housing with a front side that
can be flipped up so that it leaves a clear-glass lens that permits the hood to be
worn while chipping.

7. Steps in selecting a safe lens shade for shielded metal arc welding

a. Determine the electrode size and amperage range for the electrode because
electrode size and amperage used dictate the lens protection required.

b. Select lens shade according to the lens manufacturer's selection chart, but
never select less than a #8 lens shade for shielded metal arc welding.

When you remove your hood after arc welding and you see
white spots or white blotches as after images, it means that
you are getting too much light through the lens and you
should switch to a shade at least one number darker, or
check the seal on your lens.

Electrode Size Amperage Shade #

---- 30 -75 8
1/16 – 5/32 75 to 200 10
3/16 - 1/4 200 to 400 12
5/16 – 3/8 400 + 14

c. A rule of thumb is that the larger the diameter of the electrode, the higher the
number required for a lens shade.

8. Protective clothing required for arc welding

a. Basic clothing requirements:

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 1. Heavy, long sleeve shirts with pocket flaps

2. Heavy, cuff less pants not frayed at the bottom

3. No clothing made of synthetic materials

b. A welder's cap has a flexible bill that can be slipped around to cover either ear
and keep sparks or metal splatter out of the ear opening.

c. Leather jackets and aprons should be worn for additional protection, especially
when welding out of position or in confined areas where flying sparks present
an increased hazard.

d. Boots should be made of heavy leather with uppers that reach above the ankl
to help prevent burns from sparks and spatter.

Although steel-toed boots are not required, they are highly

recommended.

e. Heavy leather gloves with gauntlets are required for all welding and cutting
activities
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 f. Safety glasses should have nonmetal frames, and impact-resistant lenses with
side shields to protect from flying objects.

g. To provide good visibility when chipping or grinding, wear a clear, plastic-type

face shield because it will provide protection from slag or metal.

h. Wear a face shield when required, but do not substitute a face shield for safety
glasses because safety glasses should be worn at all times in the welding
workplace.

i. In situations where the danger of falling materials or tools may be present,

always wear a hard hat.

9. Environmental problems and their safety requirements

a. Ventilation - Many welding activities produce toxic fumes and vapors that are
hazardous to breathe, and every work station should be equipped with
ventilation or an exhaust system capable of safely dangerous and irritating
smoke and contaminants.

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AST-NC2-C1.2 01-03-2016 xxiv
b. Respirators - In confined areas where the hazard of toxic fumes is increased,
a welder should wear an air-supplied respirator or a self-
contained breathing apparatus, not a filter-type mask that
cannot compensate for oxygen displacement.

c. Noise - This is a workplace hazard frequently overlooked, but ear plugs or

muffler-type ear protectors should be worn when the work area subjects a
welder to high noise levels, especially high noise levels that are continuous.

d. Lighting - Lighting in a work area or at a work station should be bright enough

to provide good visibility free of glare because poorly lit work areas contribute
to eye fatigue, irritation, and poor work.

SELF CHECK 1.4-1

SAFE WELDING PRACTICES
WRITTEN TEST

Multiple Choice:

Instruction: Choose the letter of the best answer. Write letter of your choice
on your answer sheet

1. A rigid device that is worm to provide protection for the head and which is held in place by a
suitable suspension.

a. Hard Hat or Safety Helmet

b. Welding Shield
c. Face shield
d. Earplugs-

2. Protective device intended to shield eyes and face from optical radiation and impact. 

a. Hard Hat or Safety Helmet

b. Welding Shield
c. Face shield
d. Earplugs

3. Protective device intended to shield the wearer’s face or portions thereof from striking
objects or chemical, heat and glare hazards.

a. Safety Shoes
b. Welding Shield
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AST-NC2-C1.2 01-03-2016 xxv
 c. Face shield
d. Earplugs

4. Hearing protectors placed inside the ear to block out noise. To work effectively, they should
fit snugly into the near canal.

a. Welding Helmet
b. Face shield
c. Welding Shield
d. Earplugs

5. The primary protective devices intended to fit the face immediately surrounding the eyes.

a. Welding Shield
b. Goggles
c. Hard Hat or Safety Helmet
d. Earplugs

6. Protects the foot root from punctured hazards.

a. Safety Shoes
b. Welding helmet
c. Face shield
d. Earplugs

7. It shield your hands from rough surfaces & heat.

a. Leather gloves
b. Face shield
c. Safety Shoes
d. Earplugs

8. Protective device intended to shield the body or portions thereof from striking objects or
chemical, heat and glare hazards.

a. Safety Shoes
b. Leather gloves
c. Face shield
d. Welding apron / leather jocket

9. What is the consideration to prevent electric shock.

a. Weld on a damp or wet area

b. Weld with safety belt.
c. Do not weld on a damp or wet area
d. Do not weld on high place.

10. A protective device used to protect as from ultra violet rays.

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AST-NC2-C1.2 01-03-2016 xxvi
 a. Welding helmet
b. Goggles
c. Face shield
d. Eye glass

Answer key
Self check LO1.3-1

1. a

2. b

3. b

4. d

5. b

6. a

7. a

8. d

9. c

10. a

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 INFORMATION SHEET 1.5-1

WELDING TECHNIQUES AND PROCEDURES ON WELDING

CARBON STEEL PLATES IN ALL POSITIONS

Butt Joint Training Procedure

1. Practice welding butt joints on 1/8 in (4 mm) or thicker material. (Avoid thinner
Materials since they require greater skill.)

2. Separate the squared edges of the material about 1/16 in (1.6 mm) and make a
butt weld all the way through with a 1/8 in electrode. (You may need to adjust the weld
current and travel speed to obtain the desired weld.)

3. Perform a similar exercise on 1/4 in (6 mm) material, depositing a bead on each

side of the joint and fusing one to the another (no bevel needed).

4. Practice making a single V-groove weld on 1/4 in (6 mm) plate beveled 30°. Start
with a 1/8 in electrode for the first bead and finish with a 5/32 in (4 mm) electrode.

5. Be sure to penetrate about 1/32 in (1 mm) beyond the bottom of the “V” or root.

6. Perform a similar exercise on thicker materials. Generally, deposit a bead

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for each 1/8 in (3mm) of material thickness, cleaning the joint between layers.

7. On heavier plates, it may be necessary to weave the top layers to fill the groove.
After completing the practice welds, test them as described in fig. 1.3-1

Information to Perform groove weld on Carbon steel plates in flat position (1G).

When welding FLAT POSITION, high current may distort the molten metal.

This technique is not suitable for all electrodes.

1. Electrode
2. Backing Strip
Single V edges if warranted by material thickness (see fig. 1.1-1). Tack weld a
backing strip to the plates to make the first weld pass (root pass) easier.

Information to Perform groove weld on Carbon steel plates in horizontal position (2G).

When welding HORIZONTAL POSITION, gravity may distort the molten metal.

This technique is not suitable for all electrodes.

1. Electrode
2. Backing Strip
Single V edges if warranted by material thickness (see fig. 1.1-1).). Tack weld a
backing strip to the plates to make the first weld pass (root pass) easier.

Information to Perform groove weld on Carbon steel plates in vertical t position (3G).

When welding vertically, gravity may distort the molten metal.

This technique is not suitable for all electrodes.

1. Electrode
2. Backing Strip
Weld vertically by carrying the weld upward or starting at the top and welding down.
Welding upward is easier and is shown in these illustrations.
Single V edges if warranted by material thickness (see fig. 1.1-1).). Tack weld a backing
Strip to the plates to make the first weld pass (root pass) easier.
When welding vertically, gravity may distort the molten metal. Weld pass (root pass) easier.

This technique is not suitable for all electrodes.

For maximum strength, weld both sides of joint.

Information to Perform groove weld on Carbon steel plates in over head position (4G).

When welding overhead, gravity may distort the molten metal.

This technique is not suitable for all electrodes.

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 1. Electrode
2. Backing Strip
Welding overhead is the most difficult welding skill to master. When welding overhead, use a
welding motion that draws arc out and slightly away from the crater to allow weld puddle to
solidify. When weaving is necessary, use the pattern shown.
Single V edges if warranted by material thickness (see fig. 1.1-1).). Tack weld a backing strip
to the plates to make the first weld pass (root pass) easier.

SELF CHECK 1.5--1

WELDING TECHNIQUES AND PROCEDURES ON WELDING

CARBON STEEL PLATES IN ALL POSITIONS

Multiple Choice:

Instruction: Choose the letter of the best answer. Write letter of your choice
on your answer sheet

1. What is meant by 1G?

a. Flat position in groove weld.

b. Horizontal position in groove weld
c. Vertical position in groove weld
d. Over head position groove weld

2. What is meant by 2G?

a. Flat position in groove weld.

b. Horizontal position in groove weld
c. Vertical position in groove weld
d. Over head position groove weld

3. What is meant by 4G?

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AST-NC2-C1.2 01-03-2016 xxx
 a. Flat position in groove weld.
b. Horizontal position in groove weld
c. Vertical position in groove weld
d. Over head position groove weld

4. What is meant by 3G?

a. Flat position in groove weld.

b. Horizontal position in groove weld
c. Vertical position in groove weld
d. Over head position groove weld

5. What is meant by G in 1G?

a. Goggles
b. Gloves
c. Groove
d. Globe

Answer key
Self check LO1.5-1

1. a

2. b

3. d

4. c

5. c

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