Technology and Livelihood Education: Quarter 1, Wk.8 - Module 2
Technology and Livelihood Education: Quarter 1, Wk.8 - Module 2
Technology and Livelihood Education: Quarter 1, Wk.8 - Module 2
9
Technology and
Livelihood Education
Quarter 1, Wk.8 - Module 2
SET- UP WELDING EQUIPMENT
Republic Act 8293, section 176 states that: No copyright shall subsist in any
work of the Government of the Philippines. However, prior approval of the
government agency or office wherein the work is created shall be necessary for
exploitation of such work for profit. Such agency or office may, among other things,
impose as a condition the payment of royalty.
QUARTER 1
Lesson 1: (SET – UP WELDING EQUIPMENT)
Pre-test………………………………………………………………………………………………… 1
Learning Experiences/Activities................................................................. ……………………. 2
Information Sheet # 1.1........................................................................................................... 3
Self-Check #1.1...................................................................................................................... 6
Task Sheet 1.1………………………………………………………………………………………… 7
Performance Criterion Checklist # 1.1……………………………………………………………… 7
Summary……………………………………………………………………………………………. 25
Summative Test……………………………………………………………………………………. 26
Key to Answers ............................................................................................................ …. 28
References…………………………………………………………………………………………... 30
What This Module is About
Welcome…..
In this module, you are required to go through a series of learning activities in order
to complete each learning outcome. In each learning outcome are Information Sheets, Self
Checks, Operation Sheets, Performance Criterion Checklist, and Job/Tasks/Activity
Sheets. Follow and perform the activities on your own. If you have questions, do not
hesitate to ask for assistance from your facilitator.
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 is
there to support you and show you the correct ways to do things.
You will be given plenty of opportunities’ to ask questions and practice on the
job. Make sure you practice your new skills during your regular work shifts.
This way you will improve your speed, memory and your confidence.
Use the Self Checks, operation Sheets or Tasks Job Sheets at the end of
each Section to test your own progress. Use the performance criteria
Checklist or Procedural Checklist located after the Sheet to check your own
performance.
When you feel confident that you have had sufficient practice, asks 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.
i
What’s In
If you can demonstrate competence to your teacher in a particular skill, talk to your
teacher so you do not have to undergo the same module again. If you have a qualification or
Certificate of Competency from previous trainings show it to him/her. If the skills you
acquired are consistent with and relevant to this module, they become part of the evidence.
You can present these for RPL. If you are not sure about your competence skills, discuss
this with your teacher.
After completing this module, ask your teacher to assess your competence. Result of
your assessment will be recorded in your competency profile. All the learning activities are
designed for you to complete at your own pace.
In this module, you will find the activities for you to complete and relevant information
sheets for each learning outcome. Each learning outcome may have more than one learning
activity.
This module is prepared to help you achieve the required competency, in receiving
and relaying information. This will be the source of information that will enable you to acquire
the knowledge and skills in Shielded Metal Arc Welding (SMAW) independently at your own
pace with minimum supervision from your teacher.
ii
How to Learn from this Module
Completion of this module will help you better understand the succeeding module on
LAY OUT BEADS ON CARBON STEEL PLATES.
This module has three learning outcome that contains learning activities supported
by instructional 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 the 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.
iii
Icons of this Module
iv
What I Know
Diagnostic Test
DIRECTION: Encircle the letter of the correct answer for each of the following questions:
1. What process uses a length of flux-coated electrode which provided filler material metal
and atmospheric shielding?
a. Shielded Metal Arc Welding c. Welding
b. Arc Welding d. Shielded Welding
2. It is an insulated handle like tool use to hold the non-coated part of the electrode.
a. Electrode c. Electrode Holder
b. Ground Clamp d. Electrode Cable
3. When the electrode melts during welding process, what is being deposited on the base
metal?
a. Arc Stream c. Molten Pool
b. Bead d. Flux Coating
7. Its function is to connect the current from the welding machine to the electrode which we
use to weld the base metal.
a. Electrode Cable c. Electrode
b. Electrode Holder d. Ground Clamp
9. It is the kind of electrode that is used for better weld appearance and easily removed
thick slag. It is used for vertical down welding.
a. 6013 c. 6011
b. 6012 d. 6010
10. It is the kind of electrode that is used for deep penetration with a thin yet tough layer of
slag.
a. 7018 c. 6013
b. 6011 d. 6012
11. What is the filler metal that comes in a rod or wire form and is used in brazing in arc
welding?
a. Electrode c. Electrode Holder
b. Ground Clamp d. Welding Rod
12. It is the main part of the welding process. It is a machine that converts electrical energy
to heat energy to join 2 metals together.
a. Time Machine c. Printing Machine
b. Sewing Machine d. Welding Machine
14. You must be careful when you turn the machine on, the electrode holder is now?
a. Icy cold c. A little bit cold
b. Not so cold. D. Hot
15. It is the Protective clothing, helmets, goggles, or other garments or equipment designed
to protect the wearer’s body from injury or infection.
a. Personal Protective Equipment c. Equipment Protection Personal
b. Personal Equipment Protection d. Protection Personal Equipment
II. Identification
Direction: Identify labelled parts of the welding power source.
2.
3.
1.
4.
III. Essay
Directions: Briefly discuss the following questions.
1. What is power source?
2. What are the main welding power sources?
IV. Explanation
Directions: Briefly explain the given queries.
1. AC Transformer
2. DC Generator
3. Transformer Rectifier
vi
WELDING TERMINOLOGIES
AC/Alternating Current - kind of electricity which reverses its direction periodically for
60 cycles current. The current goes in one direction 60 times in the same seconds,
so the cycle changes its direction in 120 times in one second.
AC Transformer – An alternating current source that provides safe welding voltage
and current
Current Range Indicator – Provides the current output reading of the welding
machine.
DC/Direct Current - it is a current with a definite or specific sign or symbols positive
and negative.
DC Generator – direct current and of a none flexible control of arc characteristics and
a stable current.
Electrode – Filler metal. Is a metal rod having approximately the same decomposition
as the base metal to be welded.
Power Source – an output power of welding machine that supply during welding. It
might supply welding AC or DC power.
Transformer Rectifier – are designed to provide either AC or DC outputs.
Electrode Holder – Use to grip the electrode. The most common types are the collet
and pincher
Electrode – A metal rod having approximately the same decomposition as the base
metal to be welded.
Power Source – An output power of welding machine that supplies current.
Primary winding terminals – Provides cable connection from the main power supply.
Rotating Positioner – Used to hold metal for casting and add shape parts.
Secondary Winding Terminals – Provide electrode holder cable and return cable
connections to the welding machine.
Transformer rectifier – Designed to provide either AC or DC outputs.
Welding Cables – Also called welding lead, such as electrofde cable.
Welding Fixtures – A device used to speed up production and lower the cost per unit.
not experience an electrical shock when touching the two points. All the welding
current passes through the earth clamp. Without a good earth connection, the
performance of the welder and the welding machine will be compromised, this can
only mean one thing: an inferior quality weld.
Hacksaw – Were originally and principally made for cutting metal, but can also cut
various other materials such as plastic and wood.
vii
Lesson
SET – UP WELDING MACHINE
1
What I Know
DIRECTION: Encircle the letter of the correct answer for each of the following questions:
3. What process uses a length of flux-coated electrode which provided filler material metal
and atmospheric shielding?
a. Shielded Metal Arc Welding c. Welding
b. Arc Welding d. Shielded Welding
4. It is an insulated handle like tool use to hold the non-coated part of the electrode.
a. Electrode c. Electrode Holder
b. Ground Clamp d. Electrode Cable
5. When the electrode melts during welding process, what is being deposited on the base
metal?
a. Arc Stream c. Molten Pool
b. Bead d. Flux Coating
1
What I Need to Know
Assessment Criteria:
Identify welding machine parts based on manufacturer’s manual
Perform proper setting of welding machine according to manufacturer’s manual
Learning Experiences/Activities:
Learning Activities Special Instructions:
Pre-test is designed to find out what the
1. Answer Pre-Test students need more instruction on and what
they may already know.
The focus of this learning outcome provides
2. Read the attached learners the ability to perform the following
Information Sheet # 1.1 learning domains:
Task Sheet 1.1 Cognitive Skill
Psychomotor Skill
Affective Skill
3. Assessment (Self-Check &
Performance Criterion Checklist) This self- checked instrument will give the
ISSC # 1.1 necessary data or information on how far you
TSPCC # 1.1 can fill in your learning gaps.
2
Information Sheet 1.1
What’s New
Welding machine is equipment that provides high-voltage power source and convert
it into a usable arc of energy to join the two metals by means of heat causing coalescence to
fuse two materials together.
What Is It
The function of a power source is to provide the voltage necessary to maintain an arc
between the electrode and the workpiece and a sufficient supply of electric to melt the
surface of the workpiece and the end of the electrode.
Power sources may supply direct current (DC) or alternating current (AC) to the
electrode. AC is the most common power supply due to the lower cost and simplicity of the
welding machine, however, DC has some advantages. The DC arc is noticeably more stable
when using certain types of electrodes DC is better for sheet metal.
Lever Switch
http://shop.goldpeaktools.com.ph/pages/yamato-welding
3
• Current adjusting wheel is rotated either clockwise or counter clockwise until the marker in
the indicator is set to the desired current.
• Current range indicator provides the current output reading of the welding machine.
• Secondary windings terminals provides electrode holder cable and return cable
connections to the welding machine.
• Lever Switch provides/switches the machine ON/OFF whenever the machine needed for
operation.
• Primary windings terminals provide cable connection from the main power supply.
• AC TRANSFORMERS
Alternating current welding power sources (FIG.1 -2) are step down transformers, which
provide safe welding voltage. The welding
current supplied by the secondary circuit of
the transformer is controlled by a variable
resistor in this circuit or by altering either the
number of turns or the magnetic leakage
between the primary and secondary windings.
Transformer welding machines are less
complex and expensive than other types.
http://shop.goldpeaktools.com.ph/pages/yamato-welding
• DC GENERATORS
The direct current generators have the
advantages of a more flexible control of arc
characteristics and stable current. A close -
coupled electric motor or an internal
combustion engine rotates the armature in the
generator. Varying the current flowing in the
generator field windings controls welding
current.
https://m.made-in-china.com/product/Made-in-China-Two-in-One-Imitative-Welding-
Generator-DC-Welding-Generator-Welding-Machine-Generator-777743315.html
4
• TRANSFORMER RECTIFIER
Transformer rectifier is designed to provide
either DC or AC outputs. With no moving parts
like generators, they share with the transformer
the advantages of quiet operation,
convenience and lower cost.
http://www.cruxweld.com/welding-cutting-equipment/welding-rectifier-400-2/
• DC INVERTER TYPE
http://www.citihardware.com/product/category/111
5
What I Have Learned
DIRECTION: Encircle the letter of the correct answer for each of the following questions:
2. What is the filler metal that comes in a rod or wire form and is used in brazing in arc
welding?
a. Electrode c. Electrode Holder
b. Ground Clamp d. Welding Rod
3. It is the point where metals have been fused together by heating the materials to a
suitable temperature with the use of welding rod?
a. Welding Machine c. Molten Pool
b. Bread d. Weld
5. It is the main part of the welding process. It is a machine that converts electrical energy to
heat energy to join 2 metals together?
a. Machine Gun c. Bending Machine
b. Welding Machine d. Sewing Machine
6
Tasks Sheet 1.1
Title: Prepare to Set-Up Welding Machine
Performance Objective: Given a welding machine and some apparatus, you should be able
to prepare the Welding Equipment by following the standard
procedures.
Supplies/Materials : Personal protective equipment
Safety shoes
Apron
Leggings
Safety goggles
Gloves
Welding Helmet
Electrodes
Equipment : Welding Machine, Electrode Cable, Ground Clamp Cable,
Electrode Holder, Ground Clamp
Steps/Procedure:
1. Prepare an organized well lighted work area.
2. Make sure you've studied all safety instructions and wear all the PPE needed in the
welding process.
3. Place the welding machine in a safe and not in a obstructing position in the
workplace.
4. Check if the Welding Machine switch is properly turned OFF.
5. Place the Electrode Cable and Electrode Holder in front of the positive terminal of
the Welding Machine.
6. Place the Ground Clamp Cable and Ground Clamp in front of the negative terminal
of the Welding Machine
Direction:
Given a Welding Machine and some of its equipment’s. Assess your performance by comparing
it to the criteria listed in the Performance Standard.
PERFORMANCE STANDARD
Performance Level
Performance Criteria
YES NO NA
1. Is the Welding Machine switch is properly turned OFF?
2. Is the Ground Clamp Cable and Ground Clamp placed in front of
the negative terminal of Welding Machine?
3. Is the Electrode Cable and Electrode Holder placed in front of the
positive terminal of Welding Machine?
4. Is the work area properly well lighted and organized?
5. Do you wear all the necessary PPE needed during the welding
process?
7
Lesson
What’s In
What I Know
PRETEST
Labelling: Name the accessories and tools shown below
8
What I Need to Know
Assessment Criteria:
Identify welding cables/wires and other accessories based on functions and uses
Perform setting/connecting of cables and other accessories in accordance with
manufacturer’s manual
Learning Experiences/Activities:
Learning Activities Special Instructions:
Pre-test is designed to find out what the
1. Answer Pre-Test students need more instruction on and what
they may already know.
The focus of this learning outcome provides
2. Read the attached
learners the ability to perform the following
Information Sheet # 2.1
learning domains:
Task Sheet # 2.1
Cognitive Skill
Operation Sheet # 21.
Psychomotor Skill
Affective Skill
3. Assessment (Self-Check &
Performance Criterion Checklist) This self- checked instrument will give the
ISSC # 2.1 and necessary data or information on how far you
TSPCC # 2.1 can fill in your learning gaps.
OSPCC # 2.1
Answer key will definitely help you to check
4. Compare your answer with answer keys
your own capacity of learning
This statement will warn you to go back to
5. If you failed to meet the 80% of equivalent
your previous learning competencies
passing standard, simply fill necessary
because it seems that you are not yet ready
gaps that have not mastered
for the next level of competency.
Post-test is designed to measure the amount
6. At the end of this L.O. answer the post
of learning a student has acquired in a
test
specific subject.
Ladderized learning is harmonization of all
learning’s and training mechanisms that allow
7. If you pass to this learning competency,
learners to progress between technical-
then proceed to the next LO
vocational and higher education programs, or
vice-versa.
9
Information Sheet 2.1
What’s New
What Is It
(www.instructables.com)
Welding machine consist of a power source with the accessories attached to it.
Without these accessories, the welding machine will not perform its functions.
Before attempting to install to a welding machine, you should be familiar with its
accessories before using the machine
Welding Cables - The welding cables conduct from the power source to the work. The
electrode cable is connected to the electrode holder. The return cable is connected to the
return clamp. It is designed for use in electric arc-welding machines to power an electrode, a
specially designed metal rod that conducts a charge. The charge carried by the electrode is
10
needed to produce an electric arc, the heat source, between the electrode and the metals
being welded.
(www.amazon.ca)
Electrode Holders – It connects to the welding cable then connects the welding current to
the electrode. The insulated handle is to guide the electrode over the weld joint and feed the
electrode over the weld joint and feed the electrode into the weld puddle as it is consumed.
Electrode holders should be relatively light, fully insulated and sturdy enough to withstand
continual handling. Its function is to hold the electrode at desired angle.
11
Electrode holder
Should be the amperage rating and in good condition for safe.
Designed to be use at its maximum amperage rating or less
Too large holder for amperage ranged used makes it hard for the manipulation and
the operator fatigue increases.
12
Tasks Sheet 1.2
Setting Up Welding Accessories
Procedure
3. Prepare for set up
Read the operation manual provide by the manufacturer to guide you in installing,
operating, and maintaining the welding machine.
4. Connect
Electrode holder to the electrode cable and return
the clamp to the return cable.
3. Power
Power cable to the main electrical supply as shown below.
Consult a qualified electrician for primary circuit.
13
What I Have Learned
Operation Sheet
What I Can2.1
Do
What Can I Do
Performance Objective:
Given a welding machine and its accessories, you should be able to Set-Up the Welding
Accessories by following the standard procedures.
Supplies/Materials :
Personal protective equipment
Equipments:
Welding Machine, Electrode Cable, Ground Clamp Cable, Electrode Holder, Ground
Clamp, Hexagonal Key, Set of Wrenches
Steps/Procedure:
1. Prepare an organized well lighted work area.
14
2. Make sure you've studied all safety instructions and wear all the PPE needed in
the welding process.
3. Place the welding machine in a safe and not in a obstructing position in the
workplace.
4. Check if the Welding Machine switch is properly turned OFF.
5. Place the Electrode Cable and Electrode Holder in front of the positive terminal
of the Welding Machine.
6. Place the Ground Clamp Cable and Ground Clamp in front of the negative
terminal of the Welding Machine.
7. Connect the Electrode Cable to the Electrode Holder and attached the other end
of the cable to the positive terminal of the Welding Machine.
8. Connect the Ground Clamp Cable to the Ground Clamp and attached the other
end of the cable to the negative terminal of the Welding Machine.
9. Plug in the Welding Machine to the Power Source.
10. Put your Ground Clamp in position to the base metal.
11. Turn ON the Welding Machine.
12. Set the Welding Machine to its correct Current Setting. Set the amperage
matched to the selected electrode diameter and type.
Direction:
Given a Welding Machine and some of its equipment’s. Assess your performance by
comparing it to the criteria listed in the Performance Standard.
PERFORMANCE STANDARD
Performance Level
Performance Criteria YES NO N
A
1. Is the Welding Machine switch is properly turned OFF?
2. Is the Ground Clamp Cable and Ground Clamp placed in front of
the negative terminal of Welding Machine?
3. Is the Electrode Cable and Electrode Holder placed in front of the
positive terminal of Welding Machine?
4. Is the work area properly well lighted and organized?
5. Do you wear all the necessary PPE needed during the welding
process?
6. Is the Welding Machine not in a obstructing position in the work
place?
7. Is the Ground Clamp cable properly connected to negative
terminal of the Welding Machine?
8. Is the Electrode cable properly connected to positive terminal of
the Welding Machine?
9. Is the Ground Clamp properly attached to the base metal?
10. Is the Welding Machine in its correct Current Setting? Matched
with the electrode being selected to use.
15
Lesson
SET – UP WELDING POSITIONER,
3 JIGS, AND FIXTURES
What’s In
What I Know
PRETEST
DIRECTION: Encircle the letter of the correct answer for each of the following questions:
1. A device that rotates around a 360° spin that allows a welder to stand in one position
and constantly work on a level surface. It adds comfort for the welder who must perform
on odd shaped parts, such as tubular pipelines.
a. Welding Positioner c. Welding Fixture
b. Welding Jigs d. Vice Grip
2. It is used to position product parts for welding. This secures the geometry of the product
parts.
a. Welding Fixture c. Welding Jigs
a. Welding Positioner d. Pliers
3. It is a large brace that keeps a welding project stable in the face of pressure, heat,
motion, and force. A quality jig will streamline welding work by keeping parts together in
a vice grip. Whether the welding is entirely manual, partially automatic, or fully robotic, a
jig moves the work piece while the tool remains stationary.
a. Welding Fixture c. Welding Jigs
b. Welding Positioner d. Welding Machine
4. The device mechanically manipulates the workpiece; the welder can access areas that
previously would have been difficult to reach. Additionally, multiple assembly points can
be ergonomically positioned. A welder can maneuver or rotate a workpiece in 360°
manually with little effort, perhaps without the need to break an arc.
a. Welding Fixture c. Welding Jigs
b. Manual Welding Positioner d. Welding Machine
5. It is used to hold the parts in the required shape and is used from smaller parts to larger
parts of a plane.
a. Welding Fixture c. Welding Jigs
b. Manual Welding Positioner d. Welding Machine
16
What I Need to Know
Assessment Criteria:
Identify welding positioner, jigs and fixtures according to job requirements
Determine the location for setting up the welding positioner, jigs and fixtures
Set-up welding positioner, jigs and fixtures in conformity with job requirement
Observe safety practices in setting up welding positioner, jigs and fixtures
Learning Experiences/Activities:
Learning Activities Special Instructions:
Pre-test is designed to find out what the
1. Answer Pre-Test students need more instruction on and what
they may already know.
The focus of this learning outcome provides
learners the ability to perform the following
1. Read the attached
learning domains:
Information Sheet # 3.1
Cognitive Skill
Psychomotor Skill
Affective Skill
2. Assessment (Self-Check & This self- checked instrument will give the
Performance Criterion Checklist) necessary data or information on how far you
ISSC # 3.1 can fill in your learning gaps.
Answer key will definitely help you to check
3. Compare your answer with answer keys
your own capacity of learning
This statement will warn you to go back to
4. If you failed to meet the 80% of
your previous learning competencies
equivalent passing standard, simply fill
because it seems that you are not yet ready
necessary gaps that have not mastered
for the next level of competency.
Post-test is designed to measure the amount
5. At the end of this L.O. answer the post
of learning a student has acquired in a
test
specific subject.
Ladderized learning is harmonization of all
learning’s and training mechanisms that allow
6. If you pass to this learning competency,
learners to progress between technical-
then proceed to the next LO
vocational and higher education programs, or
vice-versa.
17
Information Sheet 3.1
What’s New
As welder, we need a place where we can put our welded metals in different position.
Each welding position will be well demonstrated under the various welding techniques
through the help of this welding positioners, jigs, and fixtures. In each case, a better weld
may be produced, if the parts are positioned differently and held while being welded.
What is It
A rotating positioner used for casting and odd shaped parts. Regardless of the type of
positioner, it should be constructed to hold the desired weld firmly without a long
complicated set up time. It should also be constructed so that most weld joints can be easily
approached by the welder without any tiring motion.
Manual Welding Positioner is the device mechanically manipulates the work piece; the
welder can access areas that previously would have been difficult to reach. Additionally,
multiple assembly points can be ergonomically positioned. A welder can maneuver or rotate
a work piece in 360° manually with little effort, perhaps without the need to break an arc.
18
Welding Fixtures are devices used to speed up production and lower the cost per unit are
called fixtures. When many similar parts are to be drilled with accuracy, the parts can be
stacked and drilled at the same time while held by a fixture. The fixtures are designed so
that the holes are placed properly. Fixtures should be constructed to ensure quick and
accurate placement of parts in each fixture, whether for welding, drilling, cutting, or other
purposes. Ease of removing the finished part from the fixture is also very important and
allowances must be made for distortion.
(www.tws.edu/blog/welding/what-is-a-welding-jig/)
Welding Jigs - is a large brace that keeps a welding project stable in the face of pressure,
heat, motion, and force. A quality jig will streamline welding work by keeping parts together
in a vice grip. Whether the welding is entirely manual, partially automatic, or fully robotic, a
jig moves the work piece while the tool remains stationary.
19
What is It
A. Welding Positioners
The job involves accounting not only for the weight and size of the weldment, but
also for the Center of Gravity (COG) and how far it is from the positioning device.
2. Attach weldment correctly
4. Keep It Flat
Even with small positioning equipment it is important that the unit be mounted to a
flat, even surface to prevent it from tipping. If mounting holes are provided, they
should be used to secure the positioner to a stable surface to prevent tipping when or
if it encounters an unexpected force. A positioner mounted to a workbench or stand
must be secured as well.
During welding, a ground current should be connected to the positioner itself. The
ground current transfers fro the table and into the chassis, which eliminates having to
remove and replace a welding clamp continuously. Without proper grounding,
electrical parts can be damaged and substandard weld deposits made. The
positioner should be compatible with the electric current produced by the welding
20
process. Also, all ground cables must be secured tightly by removing any paint
before bolting to the carriage.
(www.thefabricator.com)
A well-designed fixture will hold metal fabrication work in a consistent and repeatable
manner, making it suitable for temporary jobs, high mix jobs, prototyping, and one-off jobs.
In welding and fabrication, you cannot sacrifice quality in favor of speed. Your shop’s
success rests on accomplishing that trifecta of service: Speed, Quality, and Affordability. A
modular fixturing system can help you to achieve that trifecta. Comprising a ground, flat
welding table with a surface of accurately machined holes for the set-up of clamps and
components at any point on the tabletop, modular fixturing can influence your ability to
seamlessly adapt to a range of jobs. The real benefits of modular fixturing are adaptability
and repeatability. Work pieces must be set-up securely and precisely to ensure dimensional
accuracy during the welding process and to prevent distortion of the finished weldment.
Step 1 Center the work piece on the modular fixturing table to determine how much space
you have to work with. Remember to allow for adequate space for clamping elements in
addition to work pieces.
Step 2. Decide on the starting rows of holes in the fixture location. Place stops or posts in
the tabletop holes to create the fixed right angle to the first two sides of the frame. Line up to
two stops in a straight line on each side (the holes in a modular welding tabletop make this
step easy). (See Figure 1)
Figure 1
(photo courtesy of Ling Titone, Strong Hand Tools, Santa Fe Springs, California)
Elevate the workpiece from the table using spacers or rests to place all stock at a
uniform height, provide better access to joints for welding, and minimize heat transfer to the
tabletop to preserve its longetivity. (See Figure 2)
21
Figure 2
(photo courtesy of Ling Titone, Strong Hand Tools, Santa Fe Springs, California)
Step 3. Square off the other two sides of the weldment using adjustable brackets to allow for
adjustable positioning of the work pieces to set the proper size of the finished frame. Make
sure to have stops for the end pieces that don’t interfere with the intended weld path.
Step 4. Clamp the work pieces to the tabletop securely (See Figure 3). Use hold-down
clamps to ensure work pieces don’t move or warp during tack welding.
Figure 3
(photo courtesy of Ling Titone, Strong Hand Tools, Santa Fe Springs, California)
Step 6. If everything is square, go ahead and make the tack. If not, adjust the work piece
until it is square and then tack.
Step 7. Check squareness on each corner. If you’re satisfied with the end result, complete
the final welds (See Figure 4).
22
Figure 4
(photo courtesy of Ling Titone, Strong Hand Tools, Santa Fe Springs, California)
2. Determine fixture location. If the weldment is small, it may be best to place the fixture
close to the edge of the table so you can access it more conveniently.
3. Ensure the weldment is square. It’s a good habit to square off two perpendicular sides of
the weldment using fixed stops so that you know those first two sides will line up with the
tabletop holes.
4. Think about repeating weldment removal. If you work with repeating weldment, think how
the finished weldment can be removed quickly and easily to speed up production.
5. Simplify tack welding. When setting up a fixture, ensure that it will allow access to all
weld joints so you can complete the tack welding all at one time.
6. Don’t overlook clamping. Simply placing parts against a fixed stop does not replace
clamping it down. Clamping will help you to achieve accurate welding and prevent
warping during cool-down.
7. Choose a modular setup. When sourcing a modular fixturing system, choose one with
removable individual plates for unlimited fixturing options, especially when you need to
remove plates in the center of the table for weldment access, or when you need to
increase the width or length of the table to fixture oversized weldment.
(Author: Pam Farley, Marketing Manager, WELDER, www.thefabricator.com)
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What I Have Learned
SELF CHECK 3.1
DIRECTION: Encircle the letter of the correct answer for each of the following questions:
1. A device that rotates around a 360° spin that allows a welder to stand in one position
and constantly work on a level surface. It adds comfort for the welder who must perform
on odd shaped parts, such as tubular pipelines.
a. Welding Positioner c. Welding Fixture
b. Welding Jigs d. Vice Grip
2. It is used to position product parts for welding. This secures the geometry of the product
parts.
a. Welding Fixture c. Welding Jigs
b. Welding Positioner d. Pliers
3. It is a large brace that keeps a welding project stable in the face of pressure, heat,
motion, and force. A quality jig will streamline welding work by keeping parts together in
a vice grip. Whether the welding is entirely manual, partially automatic, or fully robotic, a
jig moves the workpiece while the tool remains stationary.
a. Welding Fixture c. Welding Jigs
b. Welding Positioner d. Pliers
4. The device mechanically manipulates the workpiece, the welder can access areas that
previously would have been difficult to reach. Additionally, multiple assembly points can
be ergonomically positioned. A welder can maneuver or rotate a a workpiece in 360°
manually with little effort, perhaps without the need to break an arc.
a. Welding Fixture c. Welding Jigs
b. Welding Positioner d. Pliers
5. It is used to hold the parts in the required shape and is used from smaller parts to larger
parts of a plane.
a. Welding Fixture c. Welding Jigs
b. Welding Positioner d. Welding Machine
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Summary
Set up welding equipment is a primary procedure that welders must know. These are
set up welding machine, set up welding accessories, and set up of welding positioners, jigs,
and fixtures. To set up welding machine is an eminent role that welders must do. Even
neophyte welders are obliged to know and identify the types of welding machine and its
parts and functions. Because all welders believe in a saying that the right tool for the right
job and you are only as good as your tools. The right choice and the right use of equipment
produce outstanding work and production. The advance and competitive welding machines
as well as learners training can compel more necessities than to traditional welding
practices. Welding accessories also plays a major role in tone and quality of weld. Those
accessories must be firmly in fit, in proper place, and correct mode of use to its main
components. These accessories will help you circumnavigate well in a worksite and put you
under pressure depending upon on how you manipulate its parts. To set up of jigs, fixtures,
and welding positioners are also very important in fabrication workplace. These three tools
have different functions and uses but it provides stylish artwork and designed of its own
purpose. These three tools provide work comfort, speed, and help restrain from any
ergonomic positioning. Jigs and fixtures are rare to school laboratory because these two
workpiece of welding is highly applicable for respected companies for their mass production
of welding goods and commodities. Unlike welding manual positioners is such a fit tool for
students, to where they could develop and enhance their welding skill on its own pace and
decisions. The said manual welding positioners provide creativity and projects different kinds
of positioning suitable for learners welding procedure. Knowing of these three set ups of
welding materials will generate ideas on how to prepare and contemplate to the next
challenges of the incoming module.
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Summative Test
I. Identification
Direction: Identify the following parts of welding and its accesories
6. Injection torches can use fuel gases with pressure as low as:
a. 7 psi (0.49 kg/cm²) c. 6 oz./in² (26.3 g/cm²)
b. 2 psi (0.14 kg/cm²) d. 9 oz./in² (39.4 g/cm²)
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a. Transformer Rectifier c. AC Transformer
b. DC Generators AC Transformer d. DC Inverter
8. Filler metal. Is a metal rod having approximately the same decomposition as the base
metal to be welded.
a. Welding Cable b. Flux c. Slag d. Electrode
10. The point where metals have been fused together by heating the materials to a suitable
temperature with the use of welding rod.
a. Weld b. Base Metal c. Bead d. Arc Stream
11. It is the main part of the welding process. It is a machine that converts electrical energy
to heat energy to join 2 metals together.
a. Electrode Holder c. Welding Machine
b. Welding Cable c. d.Grounding Clamp
12. It connects to the welding cable and connects the welding current to the electrode. The
insulated handle is to guide the electrode over the weld joint and feed the electrode over
the weld joint and feed the electrode into the weld puddle as it is consumed.
a. Electrode Holder c. Grounding Clamp
b. Electrode d. Welding Cable
13. It is the kind of electrode that is used for deep penetration with a thin yet tough layer of
slag.
a. 7018 b. 6011 c. 6013 d. 6012
14. This is the most dangerous part of setting up the stick welding machine.
a. Filler Rod Selection, Amperage Selection
b. Turn on and Grounding the Machine
c. Plug in the Machine
d. Just seeing the Machine.
15. You must be careful when you turn the machine on, the electrode holder is now?
a. Icy cold b. Not so cold. c. A little bit cold d. Hot
16. A device that rotates around a 360° spin that allows a welder to stand in one position
and constantly work on a level surface. It adds comfort for the welder who must perform
on odd shaped parts, such as tubular pipelines.
a. Welding Positioner c. Welding Fixture
b. Welding Jigs d. Vice Grip
17. It is used to position product parts for welding. This secures the geometry of the product
parts.
a. Welding Fixture c. Welding Jigs
b. Welding Positioner d. Pliers
18. It is a large brace that keeps a welding project stable in the face of pressure, heat,
motion, and force. A quality jig will streamline welding work by keeping parts together in
a vice grip. Whether the welding is entirely manual, partially automatic, or fully robotic, a
jig moves the workpiece while the tool remains stationary.
a. Welding Fixture c. Welding Jigs
b. Welding Positioner d. Welding machine
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19. The device mechanically manipulates the workpiece; the welder can access areas that
previously would have been difficult to reach. Additionally, multiple assembly points can
be ergonomically positioned. A welder can maneuver or rotate a workpiece in 360°
manually with little effort, perhaps without the need to break an arc.
a. Welding Fixture c. Welding Jigs
b. Manual Welding Positioner d. Welding Machine
20. Are used to hold the parts in the required shape and is used from smaller parts to larger
parts of a plane.
a. Welding Fixture c. Welding Jigs
b. Manual Welding Positioner d. Welding Machine
KEY To ANSWERS
Diagnostic Test
Test I Multiple Choice.
1. A 6. A 11. D
2. C 7. A 12. D
3. B 8. A 13. A
4. D 9. A 14. D
5. C 10. B 15. A
III. Essay
1. Provide the voltage necessary to maintain an arc between the electrode and the
workpiece.
2. Alternating Current (AC) is the main welding power source due to lower cost and
simplicity of the welding machine
IV. Explanation
1. AC transformer power source are step down transformer which provide safe welding
2. DC Generators have the advantages of a more flexible control of arc characteristics and
stable current
Pretest
1. A 2. C 3. B 4. D 5. C
Pretest
1. POWER SOURCE PLUG 6. BASE METAL
2. POWER INPUT CABLE 7. WELDING TABLE
3. ELECTRODE CABLE 8. GROUNDING TABLE
4. ELECTRODE HOLDER 9. GROUNDING CLAMP
5. ELECTRODE 10. WELDING MACHINE
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Information Sheet 1.1 (Self-Check 2.1)
1. B 2. A 3. C 4. A 5. D
Pretest
1. A 2. B 3. C 4. B 5. A
Summative Tests
Test I. Identification
1. Power Source Plug 6. Workpiece / Base Metal
2. Power Input Cable 7. Welding Table
3. Electrode Cable 8. Earthing / Grounding Cable / Return Clamp
4. Electrode Holder 9. Earthing / Grounding Clamp / Return Clamp
5. Electrode 10. Welding Machine
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REFERENCES:
For your guide, Included all third party materials or sources in developing the material
(http://shop.goldpeaktools.com.ph/pages/yamato-welding)
(https://m.made-in-china.com/product/Made-in-China-Two-in-One-Imitative-Welding-
Generator-DC-Welding-Generator-Welding-Machine-Generator-777743315.html)
(http://www.cruxweld.com/welding-cutting-equipment/welding-rectifier-400-2/)
(www.instructables.com)
(www.bakersgas.com)
(www.amazon.ca)
(www.indiamart.com)
(www.mantrafze.com)
(www.quora.com)
(www.homedepot.com)
(sg.rs-online.com)
(www.wireandsupply.com)
(www.horme.com.sg)
(www.leancentre.co.uk)
(www.sears.com)
(nitrogasweldingsupplies.com)
(www.banggood.com)
(www.wshasia.com)
(www.thefabricator.com)
(photo courtesy of Ling Titone, Strong Hand Tools, Santa Fe Springs, California)
(www.tws.edu/blog/welding/what-is-a-welding-jig/)
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