PARTS OF A COMPETENCY-BASED LEARNING MATERIAL

PACKAGE

References/Further Reading

Performance Criteria Checklist

Operation/Task/Job Sheet

Self Check Answer Key

Self Check

Information Sheet

Learning Experiences

Learning Outcome Summary

Module Competency

Front Page

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 METALS AND ENGINEERING
SECTOR :
QUALIFICATION Shielded Metal Arc Welding
TITLE: (SMAW) NC II
UNIT OF WELD CARBON STEEL PLATES AND
COMPETENCY: PIPES USING SMAW

MODULE TITLE: WELD CARBON STEEL PLATES AND

PIPES USING SMAW

DEVELOPED BY: LAARNI M. LIQUE

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 Shielded Metal Arc Welding NC
II
List of Competencies

No. Unit of Competency Module Title C

O
D
E

1. WELD CARBON WELDING CARBON MEE7213

STEEL PLATES STEEL PLATES
06

HOW TO USE THIS COMPETENCY- BASED LEARNING

MATERIAL

Welcome!
The unit of competency, "WELD CARBON STEEL PLATES ", is one of the
competencies of SHIELDED METAL ARC WELDING (SMAW) NC II, a
course which comprises the knowledge, skills and attitudes required for a
TVET
trainer to possess.

The module, WELDING CARBON STEEL PLATES, contains training

materials and activities related to identifying learner’s requirements,
preparing session plan, preparing basic instructional materials and
organizing learning and
teaching activities for you to complete.

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, Task Sheets and Job 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:

Read information sheets and complete the self-checks. Suggested

references are included to supplement the materials provided in this
module.

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Perform the Task Sheets and Job Sheets until you are confident that your
outputs conform to the Performance Criteria Checklist that follows the
sheets.

Submit outputs of the Task Sheets and Job Sheets to your facilitator for
evaluation and recording in the Accomplishment Chart. Outputs shall
serve as your portfolio during the Institutional Competency

Evaluation. When you feel confident that you have had sufficient
practice, ask your trainer to evaluate you. The results of your assessment
will be recorded in your Progress Chart and
Accomplishment Chart.

You must pass the Institutional Competency Evaluation for this

competency before moving to another competency. A Certificate of
Achievement will be awarded to you after passing the evaluation.

You need to complete this module before you can perform the module on
Facilitating Learning Sessions.

MODULE CONTENT

UNIT OF COMPETENCY: WELD CARBON STEEL PLATES

USING SMAW
MODULE TITLE: WELDING CARBON STEEL PLATES
USING SMAW
MODULE DESCRIPTOR:
This module covers the skills, knowledge and
attitudes required in welding carbon steel plates and
pipes using SMAW process.

NOMINAL DURATION: 120 HRS.

LEARNING OUTCOMES:
At the end of this module you MUST be able to:
1. Perform root pass
2. Clean root pass
3. Weld subsequent/filling passes
4. Perform capping

ASSESSMENT CRITERIA:

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1.1 Root pass is performed in accordance with WPS
and/or client specifications.

1.2 Task is performed in accordance with company

or industry requirement and safety procedure.

1.3 Weld is visually checked for defects and repaired,

as required

1.4 Weld is visually acceptable in accordance with

applicable codes and standards

2.1 Root pass is cleaned and free from defects and

discontinuities

2.2 Task is performed in accordance with approved

WPS

3.1 Subsequent/ filling passes is performed in

accordance with approved WPS

3.2 Weld is visually checked for defects and repaired,

as required

3.3 Weld is visually acceptable in accordance with

applicable codes and standards

4.1 Capping is performed in accordance with WPS and/or client

specifications

4.2 Weld is visually checked for defects and repaired, as required

4.3 Weld is visually acceptable in accordance with applicable codes and

standards

LEARNING OUTCOME SUMMARY

LEARNING OUTCOME NO.1 - PERFORM ROOT PASS

CONTENT:

1. Welding Techniques and Procedures

ASSESSMENT CRITERIA:

1.1 Root pass is performed in accordance with WPS and/or client

specifications.

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 1.2 Task is performed in accordance with company or industry
requirement and safety procedure.
1.3 Weld is visually checked for defects and repaired, as required
1.4 Weld is visually acceptable in accordance with applicable codes and
standards

METHODOLOGY:

 Modular/Self-paced
 Demonstration
 Lecture/Discussion

RESOURCES:

Equipment Training materials

 DC welding machine complete with  Reference books
accessories  Manuals
 Welding booth  Catalogs
 Welding table or jig  Brochures
 Stabilizing oven  Modules/LEs
 CDs/Video tapes
Tools/accessories/supplies  Arc welding manuals
 Set of box wrench  Welding standards
 Welding mask  Welding procedures specifications
 Chipping hammer (WPS)
 Steel brush
 Dark glass Personal protective equipment
 Clear glass  safety shoes
 Weld gauge  safety goggles
 Penlight  apron
 Dye penetrant (DPT) kit  gloves
 Electrodes  leggings
 Cutting / grinding disk
 Carbon steel plates / pipes
 Portable oven
 Portable grinder

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 LEARNING EXPERIENCES

LEARNING OUTCOME NO.1 PERFORM ROOT PASS

Learning Activities Special Instructions

Read information sheet 1.1-1 on Read and understand
Welding Techniques and Procedures the information sheet
and check yourself by
answering the self check.

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Answer Self-Check 1.1-1
You must answer all the question
before proceeding to the next
activity

Compare answers with Answer Key The performance criteria

1.1-1 Checklist will guide you
and help you to evaluate
your work as you are
practicing your skill.
After doing all all activities
Perform Task Sheet 1.1-1 on welding
of this LO you are ready to proceed to
techniques and procedures
next LO on facilitating
training sessions.

INFORMATION SHEET 1.1-1

Welding Techniques and Procedures

Learning Objectives:

After reading this INFORMATION SHEET, YOU MUST be able to:

1. Identify welding techniques and procedures in carbon steel plate in

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 flat position.
2. Describe welding techniques and procedures in carbon steel plate in
flat position.

Introduction

In the previous information, the safety practices and other welding

principles have been discussed. Those concepts are very important in performing
actual welding. By following the different welding principles and standards, the
quality of the output will be internationally accepted. In this information sheet,
the procedure on how to weld steel plates in flat position will be discussed and
other ideas related to welding.

General Concept of Welding

The actual welding technique utilized depends on the electrode, the

composition of the work piece, and the position of the joint being welded.

The choice of electrode and welding position also determine the welding
speed. Flat welds require the least operator skill, and can be done with electrodes
that melt quickly but solidify slowly.

This permits higher welding speeds. Sloped, vertical or upside-down welding

requires more operator skill, and often necessitates the use of an electrode that
solidifies quickly to prevent the molten metal from flowing out
of the weld pool.

However, this generally means that the electrode melts less quickly, thus
increasing the time required to lay the weld.

Welding Techniques and Procedures:

Welding

This is the process of joining metals by melting the parts and then using a filler
to form a joint. It can be done using different energy sources, from a gas flame or
electric arc to a laser or ultrasound

Five Steps to Improving Your Welding Technique

Paying attention to the five basic elements of stick welding technique

significantly improve your stick welding results.

1. Current setting: The electrode you select will determine whether your
machine should be set up in DC positive, DC negative or AC. Make sure you have
it set correctly for your application. (fig.1)

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 Fig. 1

2. Length of Arc: The correct arc length varies with each electrode and
application. As a good starting point, arc length should not exceed the diameter of
the metal portion (core) of the electrode, e.g. an 1/8-in. 6010 electrode is held
about

1/8 in. off the base material. (fig. 2)

Fig. 2

3. Angle of travel: Stick welding in the flat, horizontal and overhead position
uses a “drag” or “backhand” welding technique. Hold the electrode perpendicular
to the joint, and then tilt the top in the direction of travel approximately 5 to 15
degrees. For welding vertical up, use a “push” or “forehand” technique and tilt the
top of the electrode 0 to 15 degrees away from the direction of travel. (See fig. 3.)

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 Fig. 3
4. Manipulation of Electrode: Each welder manipulates the electrode a little
differently than the next. Develop your own style by observing others, practicing
and noting which techniques produce the best results. Note that on material 1/4
in. and thinner, weaving the electrode is typically not necessary because the bead
will be wider than necessary. In many instances a straight bead I All that’s
needed. (see Fig. 4)

Fig.4

5. Speed of travel: Your travel speed should allow you to keep the arc in the
leading one third of the weld pool.

An Electrode is a metal wire that is coated. It is made out of materials with a

similar composition to the metal being welded. There are a variety of factors that
go into choosing the right electrode for each project.

SMAW or stick electrodes are consumable, meaning they become part of the
weld, while TIG electrodes are non-consumable as they do not melt and become
part of the weld, requiring the use of a welding rod.The MIG welding electrode is a

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continuously fed wire referred to as wire. Electrode selection is critical to ease of
cleanup, weld strength, bead quality and for minimizing any spatter. Electrodes
need to be stored in a moisture free environment and fully removed from any
package (follow the directions to avoid damage).

WELDING ELECTRODE CLASSIFICATION

Mild Steel Coated ElectrodesE7018-X E-this is an electrode 70 which

indicates how strong this electrode is when welded. This is measured in
thousands of pounds per square inch. 1 Indicates in what welding positions it can
be used. 8 Indicates the coating, penetration, and current type used. X Indicates
that there are more requirements.

WELDING POSITIONS

1 Flat, Horizontal, Vertical (up), Overhead 2 Flat, Horizontal 4 Flat, Horizontal,

Overhead, Vertical (down) Flat Position - usually groove welds, fillet welds only if
welded like a “V” Horizontal - Fillet welds, welds on walls (travel is from side to
side).

Vertical - welds on walls (travel is either up or down). Overhead - weld

that needs to be done upside down.

PROCEDURE OF WELDING TECHNIQUES

Scratch technique

Strike the electric arc when starting a SMAW operation, the electrode is
brought into contact with the work piece, dragged like lighting a match, and then
pulled away slightly. If the arc lights and then goes out, that means
the electrode was pulled too far away from the base metal. If the
electrode
sticks to the metal, give a twist and it should come free.

Tapping Technique

Move the electrode straight down to the base metal. Then lift slightly.

The arc should start. If the arc goes out, that means it was lifted too high
off the work piece.

Operating the Electrode Holder

This initiates the melting of the work piece and the consumable
electrode, and causes droplets of the electrode to be passed from the electrode to
the weld pool.

Arc Welding Position

The types of welds, joints, and welding positions used in manual shielded
metal arc welding are very similar to those used in oxygen gas welding. Naturally,
the techniques are somewhat different because of the equipment involved is

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different.

Flat-Position Welding

Earlier we explained that welding can be done in any position, but itis
much simpler when done in the flat position. In this position, the work is less
tiring, welding speed is faster, the molten puddle is not as likely to run, and better
penetration can be achieved. Whenever possible, try to position the work so you
can weld in the flat position. In the flat position, the face of the weld is
approximately horizontal. Joint Type Butt joints are the primary type of joints
used in the flat position of welding; however, flat-position welding can be made on
just about any type of joint providing you can rotate the section you are welding
on to the appropriate position. Techniques that are useful in making butt joints in
the flat position, with and without the use of backing strips, are described below.

Flat-Position Welding Techniques and procedure

1.Butt joints in the flat position.
2. Butt welds with multi-pass beads.
3. Weave motions used in manual shielded arc welding.

BUTT JOINTS WITHOUT BACKING STRIPS

A butt joint is used to join two plates having surfaces in about the same plane.
Several forms of butt joints are shown in figure1.

Fig.5 BUTT JOINTS IN THE FLAT POSITION

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 Plates up to 1/8 inch thick can be welded in one pass with no special edge
preparation.

Plates from 1/8 to 3/16 inch in thickness also can be welded with no special
edge preparation by welding on both sides of the joint.

Tack welds should be used to keep the plates aligned for welding. The
electrode motion is the same as that used in making a bead weld. In welding 1/4-
inch plate or heavier, you should prepare the edges of the plates by beveling or by
J-, U-, or V-grooving, whichever is the most applicable. You should use single or
double bevels or grooves when the specifications and/or the plate thickness
require it.

Use the portable grinder to prepare the edge of the plate. The first bead is
deposited to seal the space between the two plates and to weld the root of the
joint. This bead or layer of weld metal must be thoroughly cleaned to remove all
slag and dirt before the second layer of metal is deposited.

In making multi-pass welds, as shown in figure2, the second, third, and

fourth layers of weld metal are made with a weaving motion of the electrode. Clean
each layer of metal before laying additional beads. You may use one of the weaving
motions shown in figure2., depending upon the type of joint and size of electrode.

Fig. 6

Fig.6 BUTT WELDS WITH MULTI PASS BEADS

Fig.7 WEAVE MOTION USED IN MANUAL SHIELDED ARC WELDING

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 Self- Check 1.1-1

I. Multiple Choice: Choose the best answer. Write the letter of your choice on
your answer sheet.

1. The process of joining metals by melting the parts and then using a filler To
form a joint is _________.

a.) V- groove
b.) Procedure
c.) Welding
d. Techniques

2.Move the electrode straight down to the base metal. Then lift slightly.The arc
should start. If the
arc goes out, that means it was lifted too high off the work piece.

a.) welding electrode

b.)Square groove weld
c.) Scratch techniques
d.) Tapping techniques.

3.To strike the electric arc when starting a SMAW operation, the electrode is
brought into contact with
the work piece, dragged like lighting a match, and then pulled away slightly.

a.) Scratch Techniques

b.) Tapping techniques
c.) Operation
d.) electric

4.This initiates the melting of the work piece and the consumable electrode,
and causes droplets of
the electrode to be passed from the electrode to the weld pool.

a.)Operating the Electrode Holder

b.) Melting
c.) Consumable
d.)Electrode

5.A metal wire that is coated. It is made out of materials with a similar
composition to the
metal being welded.

a.) Composition
b.) Metal
c.)Materials
d.)Electrode

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 II. Enumeration: Enumerate the 5 Steps To Improving Your Welding
Technique.

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 ANSWER KEY 1.1-1

I.
1.C
2. D
3. A
4. A
5. D

II.
1. Current setting,
2. Length of arc,
3. Angle of electrode,
4. Manipulation of electrode
5. Speed of travel

TASK SHEET 1.1-1

Title: Weld Carbon Steel Plate in Flat Position

Performance Objective: Given the carbon steel plate, electrode, you should be
able to perform flat Position welding by following the standard techniques and
procedure in 4 hours.

Supplies/Materials: Carbon Steel Plate, Electrode

Equipment: Welding Machine (ACDC)

Welding booth
Welding table
Portable grinder

Steps/Procedure:
1.Clean the work location before starting.
2.Prepare tools and materials.
3.Prepare and utilize PPE.
4.Lat out and measure the carbon steel plate.
5.Mark the carbon steel plate with the required length.
6.Cut and bevel the carbon steel plate by using portable grinder.
7.Tack and align the carbon steel plate in flat position.
8.Start welding the carbon steel plate in root pass penetration.
9.Proceed to the next step, hot pass and capping pass then submit

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 to the trainers for evaluation.

Assessment Method:

Written test
Demonstration

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 Reference Materials

https://www.armi.com/blog/new-reference-material-for-cast-iron-
welding-applications

https://pct.libguides.com/welding-and-metal-fabrication/

https://www.hsl.gov.uk/publications-and-products/welding-fume

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