8 Fit Up Weld Materials

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8. FIT-UP WELD Materials
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COMPETENCY BASED LEARNING MATERIALS
SECTOR: METAL AND ENGINEERING
QUALIFICATION: SHIELDED METAL ARC WELDING NC II
UNIT OF COMPETENCY : FIT-UP WELD MATERIALS
MODULE TITLE: FITTING UP WELD MATERIALS
JOSE MARIA COLLEGE FONDATION, INC.

SASA, DAVAO CITY
Date Developed: Document No.
Shielded Metal 23 March 2019 Page 1 of

Arc Welding Developed by: 41 pages
NC II JMCFI

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HOW TO USE THIS COMPETENCY BASED LEARNING MATERIALS
Welcome to the Module: Fitting up weld materials. This module contains

training materials for you to complete.
The unit of competency Fit-up weld materials contains the knowledge, skills
and attitudes require for Shielded Metal Arc Welding NC II.
This learning material is designed to guide you in learning at your own pace.
To start with your trainer and agree on how you will both organize the training for
this module. Most probably your trainer will also be your supervisor or manager. He/she
is there to support you and guide you the correct way to do things. From time to time
you will be required to practice and demonstrate the skills that you have learned from
the module and you will be require some assistance from your trainer (as instructed
from the learning material).
To proceed with the learning session, you just have to go through the
learning activity sheets where in you will follow series of learning instructions
towards attaining the learning outcome.
At the end of this module is a learner’s diary. Use this diary to record important
dates, jobs undertaken and other workplace events that may provide further details to
your trainer or assessor. A Record of Achievement will be provided to you by your
trainer for you to accomplish once you complete the module.
Upon completion of this module, study the evidence plan at the end of the last
learning element of this module then ask your instructor to assess you. You will be
given a certificate of completion as proof that you met the standard requirements
(knowledge, skills and attitude) for this module. The assessment could be made in
different methods, as prescribe in the competency standards.

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RECOGNITION OF PRIOR LEARNING:
You may already have some or most of the knowledge and skill covered in this module
because:
 You have been working

 Already completed training in this area
If you can demonstrate to your trainer that you are competent in a particular
skill talk to him/her about having them formally recognized so you won’t have to do
same training again. If you have qualifications or certificates of competency from
previous trainings, show them to your trainer. If the skills you required are still
relevant to this module they may become part of the evidence you can present for
RPL.
The learning material was prepared to help you achieved the required competency
in Using hand tools. This will be the source of information for to acquire knowledge
and skills in this particular trade independently and at your own pace with
minimum supervision or help from your instructor.
Contents of this Competency – Based Learning Material
Inside the competency based learning materials are several learning activities.
Each learning activities guides the learner to achieve one learning outcome. You must
follow the learning activity sheet. The learning activity sheet will guide you through
different learning activities towards the attainment of the learning outcome.
 Information sheet – This will provide you with the information (concepts,
principles and other relevant information) needed in performing certain
activities.
 Operation sheet – This will guide you in performing single task, operation
or process in a job.
 Job sheet – This is designed to guide you on how to do the job that
will contribute the attainment of the learning outcome.
 Assignment sheet/Self check – this assignment sheet/self-check test
is a guide to use to enhance (follow up) what you have in the
information sheet, operation sheet or job sheet.
 Work sheet – are different forms that you need to filling up in certain
activities that you performed.

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COMPETENCY-BASED LEARNING MATERIALS
List of Common Competencies
No. Unit of Competency Module Title Code
APPLY SAFETY Applying Safety MEE721201

1.
PRACTICES Practices
INTERPRET DRAWING Interpreting drawing MEE721202

2.
AND SKETCHES and sketches
PERFORM INDUSTRY Performing Industry MEE721203

3.
CALCULATION calculation
CONTRIBUTE TO Contributing to quality MEE721204

4.
QUALITY SYSTEM system
5. USE HAND TOOLS Using hand tools MEE721205
PREPARE WELD Preparing Weld MEE721206

6.
MATERIALS materials
SET UP WELDING Setting up welding MEE721207

7.
EQUIPMENT Equipment
FIT-UP WELD MEE721208

8. Fitting up materials
MATERIALS
9. REPAIR WELDS Repairing Welds MEE721209

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MODULE CONTENT
Qualification: Shielded Metal Arc Welding NC II
Unit of Competency (COMMON): Fit-up weld materials
Module Title: Fitting up weld materials
Introduction:
Learning outcomes:
Upon completion of this module the trainee must be able to:
 Perform tack welding

 Check gap and alignment
Assessment Criteria:
LO1: Perform Tack welding
1. Tack welding is performed in accordance with the welding procedure

requirements
2. Joints are free from rust, paints, grease and other foreign materials prior
to fit up or tacking.
LO2: Check gap and alignment

1. Root gap is prepared/checked in accordance with WPS requirements
2. Alignment of work piece are checked in accordance with welding
standard
3. Included angle are checked in accordance with WPS

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LEARNING OUTCOME 1: PERFORM TACK WELDING
Contents:
1. Kind of tacking
2. Welding procedure standard requirement
3. Codes and specification
Assessment Criteria
1. Tack welding is performed in accordance with the welding procedure

requirements
2. Joints are free from rust, paints, grease and other foreign materials prior to
fit up or tacking.
Condition/Resources
The students/ trainee should be provided with:
 Welding machine equipment and accessories

 Tools
 Supplies/materials
 Personal protective equipment
 Drawing plan and specification
 Instructional materials
- Reference book/ modules/ learning guides/ video CDs
- Equipment manual
Methodologies:
 Lecture/demonstrations
 Self-pace learning
 Group discussion
Assessment Methods:
 Written/oral
 Direct observation
 Interview
 Demonstration

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LEARNING EXPERIENCE
LEARNING OUTCOME 1: PERFORM TACK WELDS
Learning Activities Special Instructions/Resources

Read information sheet 8.1.1-Select Information sheet 8.1.1/reference
hand tools book
SELF CHECK 8.1.1

Do self-check 8.1.1 of learning SELF CHECK QUESTIONAIRE
Outcome 1
Check your answer in the answers Answer key LO1
key

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INFORMATION SHEET 8.1.1.1
“Tack welding”
I. LEARNING OBJECTIVES
After reading information sheet, the trainee should be able to:
1. Performed tack welding in accordance with the welding procedure

requirements
II. IN TRODUCTION
This information sheet will give you an idea and knowledge about the correct
procedure of tack welding and weld codes and symbols.
III. BODY
How to Carry Out Tack Welding?
What is “Tack Welding?”
The expression “TackWelding” refers to a temporary weld used to create the initial
joint between two pieces of metal being welded together. But don’t let the
‘temporary” nature of this weld fool you, Tack Welding is an integral part of the
welding process and very important to the ultimate success of your welding projects.
Let’s use a basic welding exercise to demonstrate how Tack Welding works. Say
you’re going to weld two pieces of steel together in order to form a basic right-angle
joint. Once you have your pieces in position (typically using a c-clamp), make two
short welds, one at either end of the joint seam.
These two Tack Welds hold the pieces together, and from here you can complete
the joint by filling in the seam between the points of the two Tack Welds.

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Even though these two Tack Welds are just the initial part of the process, the welds
should be fundamentally sound, considering they provide the foundation for the entire
joint. Consider the welding exercise described above: c-clamps aren’t strong enough to
hold the two pieces of steel together, because the the stress of the heat from the
welder will separate the pieces along the seam, pulling the joint apart and
compromising the strength of the weld. Therefore, your two initial Tack Welds need to
be rock-solid to ensure the two pieces remains tight and the overall joint weld is secure.
Additional benefits of Tack Welding include:
 Ease of removal in order to correct improper alignment with components you're

welding together
 Stabilizes the overall alignment of components you’re welding together
 Reduces movement and distortion during the welding process
 Offers temporary joint strength if an object needs to be moved or
repositioned during the welding process.
A tack weld is a weld made to hold the parts of a weldment in proper alignment
until the final welds are made. A tack weld is generally a short weld made at
intermittent points to hold abutting edges together. Tack welding is likely to be
done lightly but tack welds should be subject to the same quality requirements as the
final welds. Here are tips for making sound tack welds. Specify the length of each tack
weld and the measurement from center to center of the tack welds in advance. In
addition, you should specify multiple-pass weld profiles and throat thickness of the
tack weld for tacking thick section components. The recommended minimum
length of a tack weld bead, according to the Technical Recommendations for Steel
Construction for Buildings of the Japanese Architectural Standard Specification (JASS
6), is shown in Table 1.
Recommended minimum length of a tack weld bead for steel structures

Plate thickness (mm) Min. bead length (mm)
6 max 30
Over 6 40
Note:
(1) Applied to SMAW and semi-automatic GMAW. In the case of high heat input
welding by SAW, the minimum length of a tack weld bead should be longer with a
larger throat thickness than in the case of SMAW and semi-automatic GMAW to
prevent fracturing of the tack weld bead, caused by welding distortion.
(2) Apply to the thicker component in the case of a dissimilar thickness joint.
(3) The pitch of tack welds should generally be approximately 400 mm or shorter.
According to the JASS 6 specification, do not do tack welding when the ambient
temperature at a welding area is lower than –5°C. When it is in between –5°C and
5°C, preheat the base metal at an appropriate temperature for a distance up to
100 mm from the welding joint.

NC II PTC-SAMAR

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In tacking high tensile strength steel and heat resistant low-alloy steel, a short
tack weld bead causes faster cooling rates of the weld and thereby increases the
hardness of the heat-affected zone of the base metal, which may cause cracking of the
tack weld. In order to prevent this trouble, preheating temperature should be 40-
50°C higher than in the final welding.
Avoid tack welding on sharp corners of the components where residual stress is apt to
concentrate. Figure 1 shows typical recommended locations for tack welds on a steel
structure as per the Technical Recommendations for Steel Construction for Buildings.
Fig. 1 Recommended tack weld locations for a column-to-beam connection joint. You
should progress symmetrically when you carry out tack welding on strongly
restrained thick section components as shown in Fig. 2.
Fig. 2 Symmetrical tack welding on strongly restrained thick section work
Whether they will be removed or left in place, tack welds should be made using a fillet
weld or butt weld procedure qualified per the relevant code.
Tack welds to be left in place should be made by welders qualified in accordance with
the pertinent specification. They should be examined visually for defects and removed
if found to be defective.

NC II JMCFI

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SELF CHECK 8.1.1-1
Direction: Give the correct answer that describes each item below. Write the correct
answer on your answer sheet provided.
1. What is tack welding?
2. What is the recommended minimum length of a tack weld bead for 10mm
plate thickness?
3. What is the additional benefits of tack welding?
4. What must to be avoided in performing tack welding of the component

where residual stress is apt to concentrated?
5. What will happened if we perform tack welding in a high tensile strength

and heat resistant low alloy steel?

NC II JMCFI

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INFORMATION 8.1.1-2
“WELDING CODES AND SYMBOLS”
Read and interpret welding codes and symbols
II. INTRODUCTION
This information sheet will give you an idea and knowledge about the different welding
codes and symbols
III. BODY
American Welding Society (AWS) Standard
The American Welding Society (AWS) publishes over 240 AWS-developed codes,
recommended practices and guides which are written in accordance with American
National Standards Institute (ANSI) practices. The following is a partial list of the
more common publications:
Standard symbols for welding, brazing, and non-destructive

AWS A02.4
examination
AWS A03.0 Standard welding terms and definitions
Specification for carbon steel electrodes for shielded metal
AWS A05.1
arc welding
Specification for carbon steel electrodes and rots for gas
AWS A05.18
shielded arc welding
AWS B01.10 Guide for the non-destructive examination of welds
Specification for Welding Procedure and Performance
AWS B02.1
Qualification
AWS D01.1 Structural welding (steel)
AWS D01.2 Structural welding (aluminium)
AWS D01.3 Structural welding (sheet steel)
AWS D01.4 Structural welding (reinforcing steel)
AWS D01.5 Bridge welding
AWS D01.6 Structural welding (stainless steel)
AWS D01.7 Structural welding (strengthening and repair)
AWS D01.8 Structural welding seismic supplement
AWS D01.9 Structural welding (titanium)
AWS D08.1 Automotive spot welding
AWS D08.6 Automotive spot welding electrodes supplement
AWS D08.7 Automotive spot welding recommendations supplement

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AWS D08.8 Automotive arc welding (steel)

AWS D08.9 Automotive spot weld testing
AWS D08.14 Automotive arc welding (aluminium)
AWS D09.1 Sheet metal welding
AWS D10.10 Heating practices for pipe and tube
AWS D10.11 Root pass welding for pipe
AWS D10.12 Pipe welding (mild steel)
AWS D10.13 Tube brazing (copper)
AWS D10.18 Pipe welding (stainless steel)
AWS D11.2 Welding (cast iron)
AWS D14.1 Industrial mill crane welding
AWS D14.3 Earthmoving & agricultural equipment welding
AWS D14.4 Machinery joint welding
AWS D14.5 Press welding
AWS D14.6 Industrial mill roll surfacing
AWS D15.1 Railroad welding
AWS D15.2 Railroad welding practice supplement
AWS D16.1 Robotic arc welding safety
AWS D16.2 Robotic arc welding system installation
AWS D16.3 Robotic arc welding risk assessment
AWS D16.4 Robotic arc welder operator qualification
AWS D17.1 Aerospace fusion welding
AWS D17.2 Aerospace resistance welding
AWS D18.1 Hygienic tube welding (stainless steel)
AWS D18.2 Stainless steel tube discoloration guide
AWS D18.3 Hygienic equipment welding

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Basic Weld Symbols

Over the years that there are many people out there who can weld. Some went to school.
Some learned on their own in a garage somewhere. Some of those who say they can
weld, but don't weld very well at all.
One of the things I found when looking to hire someone to do some welding for me is
that there are many people who are welders but can't read welding symbols.
Elements ofa Welding Symbol:

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Welding Symbols:
A welding symbol may include the following elements:
 Reference Line
 Arrow
 Basic Weld Symbol
 Dimensions & Other Data
 Supplementary Symbols
 Finish Symbols
 Tail
 Specifications, Process, Or Other References
Reference Line: A reference line is a horizontal line with all the other required
information drawn on or around it. It must be placed on the drawing near the joint
it describes.
Arrow: The arrow is the other required part of a welding symbol and is placed at one
or the other end of the reference line and connects the reference line to the joint
that is to be welded.
Quite often, there are two sides to the joint to which the arrow points, and therefore
two potential places for a weld. For example, when two steel plates are joined together
into a T shape, welding may be done on either side of the stem of the T.
The weld symbol distinguishes between the two sides of a joint by using the arrow
and the spaces above and below the reference line.
The side of the joint to which the arrow points is known as the arrow side, and
its weld is made according to the instructions given below the reference line. The
other side of the joint is known as the other side, and its weld is made according

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to the instructions given above the reference line. The below and above rules apply
regardless of the arrow's direction.
Basic Symbols:
Each type of weld has its own basic symbol, which is typically placed near the center
of the reference line (and above or below it, depending on which side of the joint it's
on). The symbol is a small drawing that can usually be interpreted as a simplified
cross-section of the weld. In the descriptions below, the symbol is shown in both its
arrow-side and other-side positions.
Fillet Plug
Groove Welds
Weld Weld
Weld All Around & Field Weld: There are two other elements that may be seen on
the reference line that provide information about the weld. One is a circle around the
place where the leader line connects to the reference line and indicates the weld is
“all around”. This means the weld extends all the way around the joint the arrow is
pointing at.

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The “all around” element is only used when it is possible to weld all the way
around a single surface (see below).
The other element seen on the reference line resembles a flag and is located where
the leader line joins the reference line. This element is called a "field weld" and means
the weld will be done in another location. For instance, this weld may be applied at
the job site not in the shop. Sometimes clarification will be given in the welding
symbol tail or as a specification on the print.
Field Weld Symbol
Fillet Weld:
The fillet weld (pronounced "fill-it") is used to make lap joints, corner joints, and T
joints. As its symbol suggests, the fillet weld is roughly triangular in cross- section,
although its shape is not always a right triangle or an isosceles triangle. Weld
metal is deposited in a corner formed by the fit-up of the two members and penetrates
and fuses with the base metal to form the joint. (Note: for the sake of graphical clarity,
the drawings below do not show the penetration of the weld metal. Recognize,
however, that the degree of penetration is important in determining the quality of the
weld.)

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The perpendicular (straight up and down) leg of the triangle is always drawn on the
left side of the symbol, regardless of the orientation of the weld itself. The leg size is
written to the left of the weld symbol. If the two legs of the weld are to be the same
size, only one dimension is given; if the weld is to have unequal legs (much less
common than the equal-legged weld), both dimensions are given and there is an
indication on the drawing as to which leg is longer. The welding symbol above
shows that the weld is to be done on the other side and the thickness of the weld is
5/16.
The length of the weld is given to the right of the symbol.
If no length is given, then the weld is to be placed between specified dimension

lines (if given) or between those points where an abrupt change in the weld direction
would occur (like at the end of the plates in the example above).
The Length & Pitch of Intermittent Welds:
An intermittent weld is one that is not continuous across the joint, but rather is a
given length of weld separated by a given space between them. This method of welding
may be used to control heat distortion or where the joint strength requirements allow.
Intermittent welding can save time and money if a long weld is not necessary. Used
more frequently than the length alone, the length and pitch (length first, spacing
second) are two numbers located at the right of the fillet weld symbol. The length
appears first as before followed by a hyphen then the pitch is shown.
The pitch refers to a dimension from the center of one weld to the center of the
next weld.
The pitch is not the space between welds but a measurement from center to center
of the welds. To get the spacing for layout subtract the length of one weld from the
pitch.

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The intermittent welds may be chain intermittent or staggered intermittent. Chain

intermittent the welds on both sides of the joint are opposite each other and
resemble a chain. Staggered intermittent the welds on the opposite side are usually
started in the gap between the welds on the first side. The welds then appear
staggered. If the welds are staggered the fillet weld symbol will be staggered on the
reference line.
Contours:
Some welding symbols may show a contour finish that details how the fillet weld shape
must be finished after welding. The contour may be flat or convex (having a surface
that is curved or rounded outward) and the element to describe this is placed above the
slope on the fillet weld symbol.
A letter to indicate the method of finish may be given above the finish element.

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Groove Welds:
The groove weld is commonly used to make edge-to-edge joints, although it is also
often used in corner joints, T joints, and joints between curved and flat pieces. As
suggested by the variety of groove weld symbols, there are many ways to make a
groove weld, the differences depending primarily on the geometry of the parts to be
joined and the preparation of their edges. Weld metal is deposited within the groove
and penetrates and fuses with the base metal to form the joint. (Note: for the sake of
graphical clarity, the drawings below generally do not show the penetration of the
weld metal. Recognize, however, that the degree of penetration is important in
determining the quality of the weld.
Groove Weld Size - The groove weld size is given in two dimensions and like the
fillet weld it is placed to the left of the weld symbol. The first size given is the depth
of the groove and is the dimension used to prepare the edge preparation. The depth
of groove is measured from the surface of the joint to the bottom of the preparation.
The depth of groove does not include weld reinforcement or root penetration. The
second size given is the actual weld size and is enclosed in parentheses to distinguish it
from the groove size, or depth of groove.
The actual weld size is again measured from the surface of the groove through the
bottom of the groove but now includes the expected penetration of the weld. On a
square groove only the weld size is given.
The weld size does not include face reinforcement or root reinforcement.

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Groove Opening & Angle - Two other important elements for preparing and welding
the groove are the root opening and the groove angle.
The root opening, when used, dimensions the space between the joint to be welded
and is placed inside the weld symbol.
The groove angle is also placed inside the weld symbol and is given in degrees.
The groove angle for a V groove is given as the included angle so that means the
edge bevel or chamfer for each piece is 1/2 of the degrees given.
For example; A 45 degree included angle means bevel each member at 22 1/2
degrees. J grooves angles may be detailed elsewhere on the drawing.
The root opening and groove angle are separate elements and may or may not
appear together depending on the joint requirements.
On some drawings the root opening or groove angle will be covered in a note or
specification on the drawing for all similar symbols, and does not appear on the symbol.
The Welder must always read all information given on a drawing.
Contour & Finishing - The same contour symbols that apply to fillet welds may be
used with groove welding and are placed above the weld symbol.

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Square Groove - The square groove weld, in which the "groove" is created by either
a tight fit or a slight separation of the edges. The amount of separation, if any, is
given on the weld symbol.
V- Groove - The V-groove weld, in which the edges of both pieces are chamfered,
either single or double, to create the groove. The angle of the V is given on the weld
symbol, as is the separation at the root (if any).
If the depth of the V is not the full thickness--or half the thickness in the case of a
double V--the depth is given to the left of the weld symbol.
If the penetration of the weld is to be greater than the depth of the groove, the depth
of the effective throat is given in parentheses after the depth of the V.

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Bevel Groove - The bevel groove weld, in which the edge of one of the pieces is
chamfered and the other is left square. The bevel symbol's perpendicular line is
always drawn on the left side, regardless of the orientation of the weld itself. The
arrow points toward the piece that is to be chamfered. This extra significance is
emphasized by a break in the arrow line. (The break is not necessary if the designer
has no preference as to which piece gets the edge treatment or if the piece to receive
the treatment should be obvious to a qualified welder.) Angle and depth of edge
treatment, effective throat, and separation at the root are described using the
methods discussed in the V-groove section above.
U-Groove - The U-groove weld, in which the edges of both pieces are given a
concave treatment. Depth of edge treatment, effective throat, and separation at the
root are described using the methods discussed in the V-groove section.
J-Groove - The J-groove weld, in which the edge of one of the pieces is given a concave
treatment and the other is left square. It is to the U-groove weld what the bevel groove
weld is to the V-groove weld. As with the bevel, the perpendicular line is always
drawn on the left side and the arrow (with a break, if necessary) points to the
piece that receives the edge treatment. Depth of edge treatment, effective throat, and
separation at the root are described using the methods discussed in the V-groove
section.

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Flare V Groove - The flare-V groove weld, commonly used to join two round or curved
parts. The intended depth of the weld itself are given to the left of the symbol, with the
weld depth shown in parentheses.
Flare Bevel Groove - The flare bevel groove weld, commonly used to join a round or
curved piece to a flat piece. As with the flare-V, the depth of the groove formed by
the two curved surfaces and the intended depth of the weld itself are given to the
left of the symbol, with the weld depth shown in parentheses. The symbol's
perpendicular line is always drawn on the left side, regardless of the orientation of
the weld itself.
Common supplementary symbols used with groove welds are the melt-thru and
backing bar symbols. Both symbols indicate that complete joint penetration is to be
made with a single-sided groove weld. In the case of melt-thru, the root is to be
reinforced with weld metal on the back side of the joint. The height of the
reinforcement, if critical, is indicated to the left of the melt-thru symbol, which is
placed across the reference line from the basic weld symbol.
When a backing bar is used to achieve complete joint penetration, its symbol is
placed across the reference line from the basic weld symbol. If the bar is to be
removed after the weld is complete, an "R" is placed within the backing bar symbol.
The backing bar symbol has the same shape as the plug or slot weld symbol, but
context should always make the symbol's intention clear.

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Plug & Slot Welds:
Plug welds and slot welds are used join overlapping members, one of which has
holes (round for plug welds, elongated for slot welds) in it. Weld metal is deposited in
the holes and penetrates and fuses with the base metal of the two members to form the
joint.
(Note: for the sake of graphical clarity, the drawings below do not show the
penetration of the weld metal. Recognize, however, that the degree of penetration is
important in determining the quality of the weld.)
For plug welds, the diameter of each plug is given to the left of the symbol and the
plug-to-plug spacing (pitch) is given to the right. For slot welds, the width of each
slot is given to the left of the symbol, the length and pitch (separated by a dash) are
given to the right of the symbol, and a detail drawing is referenced in the tail.
The number of plugs or slots is given in parentheses above or below the weld
symbol. The arrow-side and other-side designations indicate which piece
contains the hole(s). If the hole is not to be completely filled with weld metal, the
depth to which it is to be filled is given within the weld symbol.

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SELF CHECK 8.1.1-2
Test I. Direction: Give the correct answer that describes each item below. Write
the correct answer on your answer sheet provided.
1. Where a welder did usually performed plug and slot welding?

2. In some techniques, why a welder used backing bar or backing plate to
weld joints?
3. It is a horizontal line with all the other required information drawn
around it.
4. It is commonly used to join a round or curved piece to a flat piece.
5. What is fillet?
Test II. Direction: Enumerations
1. Give the elements of weld symbol.

2. Give the basic weld joints symbols.
3. 3 types of fillet joints.
Test III. Direction: On your answer sheet provided, Draw and Identify the weld
symbols below.
1.
1/2X3/8
STEEL PLATE
2.
3/4
8
STEEL PLATE
3.
Task sheet 5.1.1

1/2
Title: Perform tack welding
STEEL PLATE

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Performance Objective
This Unit covers the knowledge, skill and attitude in Performing tack welding.
Given the qualification assigned to you u must be able to perform the correct
procedures in tack welding in accordance with the welding procedures
specification.
Equipment’s/Implements:
1. Welding machines and accessories

2. Chipping hammer
3. Plier
4. Clamps
5. Personal Protective Equipment
6. Drawing plan and specification
7. Reference books/manuals/modules
Supplies & Materials :
1. Dark and clear glass lens

2. Electrode E6013/E6011
3. Grinding disc
4. Cutting disc
5. Steel plate
Steps/Procedure:
1. Prepare the equipment’s needed for Tack welding procedures

2. Prepare personal protective equipment
3. Check the equipment functionality
4. Prepare the weld materials/work piece for tacking
5. Aim the center of the work piece to be tacked
6. Maintain the arc length and run the electrode for a centimeter
7. Perform quick stop of electrode

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Performance Criteria Checklist of Task Sheet 5.1.1
CRITERIA
YES NO
1. Did the trainees correctly prepare the equipment needed for

tack welding?
2. Did the trainees apply safety practices?
3. Did the trainees correctly perfume tack welding?
4. Did the trainee identify the importance of tack welding?
5. Did the trainee correctly identify the weld symbols and

codes?

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LEARNING OUTCOME 2: CHECK GAP AND ALIGNMENT
Contents:
 Fit up tolerances
 Work alignment procedure
 Fit up
Assessment Criteria

2. Alignment of work piece are checked in accordance with welding standard
Condition/Resources
The students/ trainee should be provided with:
1. Measuring tools
2. Work piece
3. Personal protective equipment
5. Instructional materials
- Reference book /modules/ learning guides/ video CDs,
- Equipment manual

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LEARNING EXPERIENCE
LEARNING OUTCOME 2: CHECK GAP AND ALINGMENT
Learning Activities Special Instructions/Resources

Read information sheet 8.1.2- Check Information sheet 8.1.2/reference
Gap and Alignment book
SELF CHECK 8.1.2

Do self-check 8.1.2 of learning SELF CHECK QUESTIONAIRE
Outcome 2
Check your answer in the answers Answer key LO2
key

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INFORMATION 8.1.2-1
“JOINT FIT-UP AND ALIGNMENT”


II. IN TRODUCTION
This information sheet will give you an idea and knowledge about the fit up
tolerances and work piece alignment procedures.
III. BODY
Proper alignment is important if a piping system is to be correctly fabricated.
Poor alignment may result in welding difficulties and a system that does not function
properly.
Welding rings may be employed to assure proper alignment as well as the correct
welding gap. In addition to using welding rings, some simple procedures can be
followed to assist the pipe fitter. Below and on the following page are alignment
procedures commonly used by today’s crafts man.
FIT-UP & ALIGNMENT
 Proper fit-up is important if a good weld is to be made
 Clamping or fixturing is often done to ensure proper fit-up of the test
coupon (example: use an angle iron to lay the pipe coupons on, it keeps the
pipe coupons inline and makes it easier to tack
 Pipe coupons must be beveled correctly and consistently.
 Root openings and joint angles must be consistent all the way around the
pipe for better results
 Using a spacing tool to check and ensure proper gap root opening
(example: a piece of 1/8” tig wire or spacer blocks)
 The test coupon alignment should be 1/16” on the ID.

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PIPE–TO–PIPE
1. Level one length of pipe using spirit level

2. Bring lengths together leaving only
small welding gap
3. Place spirit level over both pipes as
shown and maneuver unpositioned
length until both are level
4. Tack weld top and bottom
5. Rotate pipe 90°
6. Repeat procedure
45° ELBOW-TO-PIPE
1. Level pipe using spirit level
2. Place fitting to pipe leaving
small welding gap
3. Place 45" spirit level on face of
elbow and maneuver elbow until
bubble is centered
4. Tack weld in place
90° ELBOW.TO-PIPE

2. Place fitting to pipe leaving
small welding gap
3. Place spirit level on face of elbow
and maneuver elbow until level
TEE-TO-PIPE
2. Place tee to pipe leaving small
welding gap
3. Place spirit level on face of tee and maneuver tee until level

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FLANGE-TO-PIPE
1. Bring flange to pipe end leaving small
welding gap
2. Align top two holes of flange with spirit level
4. Center square on face of flange as shown
6. Check sides in same way
JIG FOR SMALL DIAMETER Cut notch,PIPING

Heat and Bend
The jig is made from channel iron 3' 9" long, Heat & Bend
Use 1⁄8" x 11⁄2" for pipe sizes 11⁄4" thru 3"; 1⁄8" x
3⁄4" for Sizes 1" or smaller.
1. Cut out 90° notches about 9" from end.
2. Heat bottom of notch with torch.
3. Bend channel iron to 90° angle and weld sides.
4. Place elbow in jig and saw half thru sides Weld of channel iron as shown.
Repeat this Sides step with several elbows so jig may be used for different
operations.
5. A used hack saw blade placed in notch as shown will provide proper welding
gap.
Cut Slots Using
Cut Slots Using
Fitting as Guide
Weld Fitting as Guide
sides Weld
sides

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INFORMATION SHEET 8.1.2-2
“Weld Distortion”

II. INTRODUCTION
This information sheet will give you an idea and knowledge about the fit up
tolerances and weld distortion.
III. BODY
All welders have faced the problem of weld distortion at one time or another. The
parts start off straight and square, and after welding, the finished part is warped.
Thinner material is more susceptible, as it has less stiffness. Also stainless steels are
more susceptible, as it has greater thermal expansion and lower thermal conductivity
than carbon steels.
First, let's discuss why distortion occurs. Weld metal is deposited at a high
temperature, above the melting point of material. For steel, this is around 2,500°F
(1,370°C). As the weld cools to room temperature, it shrinks, but is restrained
from doing so by the adjacent cold base metal, resulting in high-residual tensile
stress. The weld is now like a stretched rubber band, with the work piece holding the
ends. This is the reason that the base metal moves, or springs back, when the clamps
holding the work piece are removed, distorting the part. When the weld shrinks
across its width, it causes groove welds to “wing-up” or fillet welds to close up. When
the weld shrinks along its length, it causes base metal to twist around the weld.
To minimize weld distortion, design and welding should be addressed. Weld shrinkage
cannot be prevented, but it can be controlled. These are recommended steps for
minimizing weld distortion:
1. Avoid over welding — The bigger the weld, the greater the shrinkage. Correctly
sizing a weld not only minimizes distortion, but also saves weld metal and time.

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2. Intermittent welding — To minimize the amount of weld metal, use intermittent

welds instead of continuous welds where possible.
3. Fewer weld passes — A fewer number of big passes results in less distortion
than a greater number of small passes with small electrodes. Shrinkage accumulates
from each weld pass.
4. Place welds near the neutral axis, or the center of the part — Distortion
is reduced by providing less leverage for the shrinkage forces to pull the plates out of
alignment.
5. Balance welds around the neutral axis — Welding on both sides of the
plate offsets one shrinkage force with another, to minimize distortion.
6. Use the backstep welding technique — In the backstep technique, the general
progression of welding may be left to right, but each bead segment is deposited from
right to left. As each bead segment is placed, the heated edges expand, which
temporarily separates the plates at B. As the heat moves out across the plate to C,
expansion along outer edges CD brings the plates back together. This separation is
most pronounced as the first bead. With successive beads, the plates expand less and
less because of the restraint from the prior welds.
7. Presetting the parts — Presetting parts before welding can make shrinkage
work for you. The required amount of preset can be determined from a few trial welds.
8. Alternate the welding sequence — A well-planned welding sequence involves

placing weld metal at different points of the assembly so that, as the structure shrinks in
one place, it counteracts the shrinkage forces of welds already made. An example of this
is welding alternately on both sides of the neutral axis in making a complete joint
penetration groove weld in a butt joint.
9. Clamping — Clamps, jigs, and fixtures that lock parts into a desired position
and hold them until welding is finished are probably the most widely used means for
controlling distortion in small assemblies or components. While there is some movement
or distortion after the welded part is removed from the jig or clamps, it will be lower
compared to the amount of movement that would occur if no restraint were used
during welding.
10. Peening — Peening the weld bead stretches it and relieves the residual stresses.
However, peening must be used with care. For example, a root bead should never be
peened, because of the increased risk of concealing or causing crack. Also, peening is
not permitted on the final pass, because it can cover a crack and interfere with
visual inspection. Before peening is used on a job, engineering approval should be
obtained.
11. Thermal stress relieving — Another method for removing shrinkage forces is
thermal stress relieving, i.e., controlled heating of the weldment to an elevated
temperature, followed by controlled cooling.

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Causes of fabrication distortion
Distortion is a general term used in steelwork to describe the various movements

and shrinkages that take place when heat is applied in cutting orwelding
processes.
All welding causes a certain amount of shrinkage and in some situations will also cause
deformation from the original shape.
Longitudinal and transverse shrinkage in many circumstances are only a minor

problem but angular distortion, bowing and twisting can present considerable
difficulties if the fabrication is not in experienced hands.
A full awareness of distortion is vital to all concerned with welding including the
designer, detailer, factory foreman and the welders, as each in their actions could
cause difficulties through lack of understanding and care. Weld sizes should be kept
to the minimum required for the design in order to reduce distortional effects; in
many cases, partial penetration welds can be used in preference to full penetration
welds, deep penetration welds in preference to ordinary fillet welds.
Some distortional effects can be corrected, but it is much more satisfactory to plan to
avoid distortion and thereby avoid the difficulties and costs of straightening and
flattening to achieve final acceptability.
Consider a single fillet weld making a ‘T’ joint, as shown below. On cooling, the weld
metal will induce a longitudinal contraction, a transverse contraction and an
angular distortion of the up-standing leg.
A similar section with double fillet weldwill induce greater longitudinal and
transverse contraction and the combined forces will produce an angular distortion or
bowing of the table of the Tee.
The longitudinal shrinkage is likely to be about 1 mm per 3 m of weld and transverse

contraction about 1 mm, provided the leg length of the weld does not exceed three
quarters of the plate thickness.

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Distortion of tee joint
The contractions produced by a single V buttweld(see below) induce longitudinal and

transverse shrinkage, producing angular distortion and possibly some bowing. The
transverse contraction will be between 1.5 mm and 3 mm and the longitudinal
contraction about 1 mm in 3 m. Angular distortion occurs after the first run of
weld cools, contracts and draws the plates together. The second run has the same
shrinkage effect but its contraction is restricted by the solidified first run, which acts
as a fulcrum for angular distortion. Subsequent runs increase the effect. The angular
distortion is a direct function of the number of filler runs and not the plate
thickness, although of course the two are related.
Distortion of a single V butt weld
The use of a double V preparation to balance the volume of weld about the centre of
gravity of the section will significantly reduce any angular distortion. To allow for the
effect of back gouging, asymmetric preparations are often used to advantage, but it
must be remembered that longitudinal and transverse contractions will still be
present.
Use of a double V preparation

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The contractions in a structure can be assessed, but a number of factors will affect
the result. The fit-up is most important, as any excess gap will affect the weld
volume and increase shrinkage. The largest size of electrodes should be used and
where possible semi-automatic and automatic processes should be employed, to
reduce the total heat input and the shrinkage to a minimum.
It is always worth considering the effects of weld preparation on quality of the weld,
Single V butt welds give good access to the root of the weld and can limit the amount of
positional work required for the welder. Double V butt welds will reduce distortion but
increase the amount of positional welding, which may lead to expensive repairs. In both
cases, the material thickness and process need to be assessed with an eye to practicality.
A single V weld preparation
A double V weld preparation
In certain circumstances, residual rolling stresses in the

parent metal can have considerable effect and may cause
otherwise similar sections to react differently. The extent of
final distortion will be a combination of the effects of inherent
stresses and those introduced by welding.
Pre-setting and clamping
All members that are welded will shrink in their length, so each member will either
be fabricated over-length and cut to length afterwelding, or an estimate of shrinkage
will be added to anticipate the effect during the fabrication of the member. For the
control of angular distortion and bowing, there are two methods of control that can
be considered if the distortion is likely to be of significance.

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Pre-setting. The section is bent in the opposite direction to that in which it is

expected to distort and welding is then carried out under restraint. When cool, the
clamps are removed and the section should spring straight. Trials and experience can
determine the extent of pre-bend for any particular member. Clamping. The units are
held straight by clamps whilst the welding is carried out, which reduces the
distortion to tolerable amounts.
Effect of design on distortion. A good design will use the minimum amount of weld
metal consistent with the required strength. Where a flange changes direction (for
example at the end of a haunch on a bridge girder) it is preferable for the plate to be
bent, rather than butt welded. Where a cross section is asymmetric, the shrinkage of the
two web-to-flange welds will lead to curvature, because the shrinkage is not balanced.
Weld shrinkage effects on asymmetric Example of an asymmetric fabricated

sections girder (J-section)
Heat straightening. Sections can be straightened with the aid of hydraulic presses
or using special bar bending or straightening machines. Some sections are too large
for this type of straightening and it is necessary to adopt techniques involving the
application of heat – so-called heat straightening. In this procedure, heat is applied
to the face opposite to that with the welds which caused the distortion. The technique
is based on the fact that if heat is applied locally to a member, the heated area will
try to expand but will be constricted by the surrounding area of cold metal, which is
stronger than the heated area. Upon cooling, the metal in the heated area gains
strength as it shrinks, causing the member to curve, with the cooling face on the
inside of the curve.
Correction of web panel distortion

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SELF CHECK 8.1.2

Test I. Direction: Give the correct answer that describes each item below. Write
the correct answer on your answer sheet provided.
1. What is weld distortion?
2. What are those recommended steeps to minimize weld distortion?
3. What is heat straightening?
Task sheet 8.1.2

Title: Check Gap and Alignment
Performance Objective
This Unit covers the knowledge, skill and attitude in Checking of gap and
alignment before welding. Given the qualification assigned to you must be able to
perform the correct procedures in checking of gap and alignment in accordance
with the welding procedures specification.
Equipment’s/Implements:
1. Measuring tools
2. Work piece
3. Personal protective equipment
5. Instructional materials
Supplies & Materials :
1. Dark and clear glass lens

2. Electrode E6013/E6011
3. Grinding disc
4. Cutting disc
5. Steel plate
Steps/Procedure:
1. Prepare the equipment’s needed for Tack welding procedures

2. Prepare personal protective equipment’s
3. Check the equipment’s functionality
4. Prepare the weld materials/work piece for tacking
5. Aim the center of the work piece to be tacked
6. Maintain the arc length and run the electrode for a centimeter
7. Perform the correct gap and alignment using the appropriate
measuring tools

NC II JMCFI

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Performance Criteria Checklist of Task Sheet 8.1.2
CRITERIA
YES NO
1. Did the trainees correctly prepare the equipment needed for

tack welding?
2. Did the trainees apply safety practices?
3. Did the trainees correctly perform the prescribe

alignment of a work piece?
4. Did the trainee correctly identify the weld symbols and
codes?

NC II JMCFI

8 Fit Up Weld Materials

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8. FIT-UP WELD Materials

BS in Civil Engineering (Jose Maria College)

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COMPETENCY BASED LEARNING MATERIALS

SECTOR: METAL AND ENGINEERING

QUALIFICATION: SHIELDED METAL ARC WELDING NC II

UNIT OF COMPETENCY : FIT-UP WELD MATERIALS

MODULE TITLE: FITTING UP WELD MATERIALS

JOSE MARIA COLLEGE FONDATION, INC.

Date Developed: Document No.

Shielded Metal 23 March 2019 Page 1 of

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HOW TO USE THIS COMPETENCY BASED LEARNING MATERIALS

Welcome to the Module: Fitting up weld materials. This module contains

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RECOGNITION OF PRIOR LEARNING:

 You have been working

Contents of this Competency – Based Learning Material

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COMPETENCY-BASED LEARNING MATERIALS

List of Common Competencies

No. Unit of Competency Module Title Code

APPLY SAFETY Applying Safety MEE721201

INTERPRET DRAWING Interpreting drawing MEE721202

PERFORM INDUSTRY Performing Industry MEE721203

CONTRIBUTE TO Contributing to quality MEE721204

5. USE HAND TOOLS Using hand tools MEE721205

PREPARE WELD Preparing Weld MEE721206

SET UP WELDING Setting up welding MEE721207

FIT-UP WELD MEE721208

9. REPAIR WELDS Repairing Welds MEE721209

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Qualification: Shielded Metal Arc Welding NC II

Unit of Competency (COMMON): Fit-up weld materials

Module Title: Fitting up weld materials

Upon completion of this module the trainee must be able to:

 Perform tack welding

LO1: Perform Tack welding

1. Tack welding is performed in accordance with the welding procedure

LO2: Check gap and alignment

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LEARNING OUTCOME 1: PERFORM TACK WELDING

1. Tack welding is performed in accordance with the welding procedure

The students/ trainee should be provided with:

 Welding machine equipment and accessories

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LEARNING OUTCOME 1: PERFORM TACK WELDS

Learning Activities Special Instructions/Resources

SELF CHECK 8.1.1

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INFORMATION SHEET 8.1.1.1

After reading information sheet, the trainee should be able to:

1. Performed tack welding in accordance with the welding procedure

How to Carry Out Tack Welding?

What is “Tack Welding?”

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Additional benefits of Tack Welding include:

 Ease of removal in order to correct improper alignment with components you're

Recommended minimum length of a tack weld bead for steel structures

Date Developed: Document No.

Shielded Metal 23 March 2019 Page 9 of