Signed off_ SMAW11 _q1_m3_Laying Out Beads and Carbon Steel Plates_v3.pdf
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Shielded Metal Arc Welding (SMAW) NC-1 - Senior High School
Alternative Delivery Mode
Module 3: Laying Out Beads on Carbon Steel Plates
First Edition, 2020
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Telefax: ________________________________________________
E-mail Address: ________________________________________________
Development Team of the Module
Authors: Aaron A. Adesas
Marco Antonio E. Sosobrado
Roy M. Legaspi
Nolan V. Alvear
Editors:
Reviewers: Dexter A. Delfin
Lovenres J. Enanoria
Ronald M. Ortega
Illustrator and Layout Artist:
Nolan V. Alvear
Management Team:
Purificacion J. Yap
Sherlita L. Daguisonan
Development Team of the Module:
Authors: Aaron A. Adesas
Marco Antonio E. Sosobrado
Roy M. Legaspi
Nolan V. Alvear
Reviewers: Dexter A. Delfin
Lovenres J. Enanoria
Ronald M. Ortega
Illustrator: Nolan V. Alvear
Management Team:
Chairperson: Dr. Arturo B. Bayocot, CESO III
Regional Director
Co-Chairpersons: Dr. Victor G. De Gracia Jr., CESO V
Asst. Regional Director
Mala Epra B. Magnaong
CES, CLMD
Members: Dr. Bienvenido U. Tagolimot, Jr.
Regional ADM Coordinator
Elson C. Jamero
EPS-Designate-TLE
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E-mail Address: region10@deped.gov.ph
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Department of Education Republic of the Philippines
Senior High School
Shielded Metal Arc
Welding (SMAW) NC-1
Unit of Competency : Surface Welding on Carbon
Steel Plates
Module Title : Laying Out Beads on Carbon
Steel Plates
This instructional material was collaboratively developed and reviewed by
educators from public and private schools, colleges, and or/universities. We
encourage teachers and other education stakeholders to email their feedback,
comments, and recommendations to the Department of Education at action@
deped.gov.ph.
We value your feedback and recommendations.
4. iv
Table of Contents
What This Module is About.……………………………….………………………………….….1
Recognition of Prior Learning……………………………………………………………………1
What I Need to Know…………………………………………….……………………………….2
How to Learn from this Module……………………………………………………………….….2
Technical Terms ………………………………………………………….……………......….….3
Icons of this Module……………………………………………………………………………….5
What I Know………………………………………………………………………………………..6
Learning Outcome #1 Strike an Arc……………….……………………….……………8
Learning Experiences/Activities ………………………………………….….………….8
Information Sheet #1.1.……………………………………………………….….………9
Self-Check #1.1 …………………………………………………………………...…….11
Information Sheet #1.2.……………………………………………………….….…… 12
Self-Check #1.2 …………………………………………………………………...…….19
Operation Sheet # 1.1………………………………………………………………..….20
Self-Check #1.1 (Operation Sheet)……………………………………………...…….23
Learning Outcome #2 Deposit Straight Bead.….…………………………….………24
Learning Experiences/Activities …………………………….…………………………24
Information Sheet # 2.1 ………………………………………….…………….……….25
Information Sheet # 2.2 ………………………………………….…………….……….26
Operation Sheet 2.1 …………………………………………………………………….27
Self-Check #2.1 …………………………………………………….…………………...30
Information Sheet # 2.3 ………………………………………….…………….……….31
Assessment: (Post-Test) …………………………………………………………….32
Answer Key ………………………………………………………………………………………34
References ……………………………………………………………………………………….35
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5. 1
What This Module is About
Welcome to the Module “LAYING OUT BEADS ON CARBON STEEL PLATES”. This
module contains training materials and activities for you to complete.
The unit of competency “Surface Weld on carbon Steel Plates” contains the
knowledge, skills and attitudes required for Shielded Metal Arc Welding (SMAW) required
to obtain the National Certificate (NC) level I.
You are required to go through a series of learning activities in order to complete each
of the learning outcomes of the module. In each learning outcome there are Information
Sheets, Job Sheets, Operation Sheets and Activity Sheets. Do these activities on your
own and answer the Self-Check at the end of each learning activity?
If you have questions, do not hesitate to ask your teacher for assistance.
Recognition of Prior Learning (RPL)
You may already have some basic knowledge and skills covered in this module.
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.
6. 2
What I Need to Know
This module contains information and suggested learning activities on surface weld on
carbon steel plates. It includes instruction and procedure on how laying out beads on carbon
steel plates.
Completion of this module will help you better understand the succeeding module on
fitting up welds.
This module consists of two (2) learning outcomes. Each learning outcome contains
learning activities supported by instruction sheets. Before you perform the instruction, read the
information sheets and answer the self- check and activities provided. To ascertain your
competence, your teacher will assess what you have acquired when the knowledge necessary
to perform the skill portion of 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.
Upon completion of the module you should be able to:
• LO1 Strike an Arc TLE_IAAW9-12LBIIa-e-1
• LO2 Deposit Straight Bead TLE_IAAW9-12LBIIf-j-2
How to Learn from this Module
To achieve the objectives cited above, you are to do the following:
• Take your time reading the lessons carefully.
• Follow the directions and/or instructions in the activities and exercises diligently.
• Answer all the given tests and exercises.
7. 3
What is It
TECHNICAL TERMS
1. Welding is a method of joining two metals by applying heat to melt and fuse them,
producing a coalescence of materials with or without the use of filler metal.
2. Flux Coated Electrode is a metal rod coated with a special substance called flux,
which determines the nature of the electrode. During welding it is melted to fill up
joints in the base metal.
3. Bare Electrode a filler metal electrode use in arc welding, consisting of a metal wire
with no coating on its surface.
4. Flux is a fusible material or gas used to dissolve and/or prevent the formation of
oxides, nitrides or other undesirable inclusions formed in welding.
5. Base or Parent Metal The metal that is to be welded or worked.
6. Weldment an assembly or structure whose component parts are joined by welding.
7. Weld Bead it is a deposit of filler metal from a single welding pass.
8. Stringer Bead/Straight Weld Bead a type of weld bead with appreciable transverse
oscillation or side to side movement.
9. Face of a Weld expose surface of the weld.
10. Electrode Angle it is an angle from the electrode which is perpendicular to the base
metal.
11. Arc Length is a normal distance of approximately equal to the diameter of the
electrode.
12. Puddle part of the weld that is melted (molten) due to heat of welding.
13. Pass refers to the layer of beads which has been deposited in the base metal.
14. Ripple is the shape/appearance of the beads which results from the movement of
the electrode.
15. Crater is the flattened portion produced when the electrode comes in contact with the
base metal
8. 4
16. Slag refers to the outer covering of the deposited bead when the electrode melts
during the welding process.
17. Blowholes are the cavities produced by gas entrapment during the solidification of
the weld metal.
18. Penetration refers to the depth of fusion of beads with the base metal.
19. Joint is the point where two or more parts meet
20. Welding Position the stock to be welded may assume any of the main welding
positions, namely, flat, horizontal, overhead and vertical.
21. Spatter in arc and gas welding, it is the metal particles expelled during welding and
which do not form part of the weld.
22. Travel Angle is the angle of the electrode in relation to the axis of weld when the
electrode is perpendicular to the axis of weld.
23. Work Angle is the angle of an electrode in relation to the surface or surfaces of a
work piece when the electrode is perpendicular to the axis of weld.
24. Coalescence the growing together or growth into one body of the materials being
welded.
25. Fusion Welding the melting together of filler metal and base metal, or of base metal
only to produce a weld.
26. Shielded Metal Arc Welding arc welding process that produces a coalescence of
material by heating them with an arc between a covered electrode and work piece.
Shielding is obtained from the composition of the electrode cover; pressure is not use
and filler metal is obtained from the electrode.
9. 5
Icons of this Module
What I Need to
Know
This part contains learning objectives that
are set for you to learn as you go along the
module.
What I know This is an assessment as to your level of
knowledge to the subject matter at hand,
meant specifically to gauge prior related
knowledge
What’s In This part connects previous lesson with that
of the current one.
What’s New An introduction of the new lesson through
various activities, before it will be presented
to you
What is It These are discussions of the activities as a
way to deepen your discovery and under-
standing of the concept.
What’s More These are follow-up activities that are in-
tended for you to practice further in order to
master the competencies.
What I Have
Learned
Activities designed to process what you
have learned from the lesson
What I can do These are tasks that are designed to show-
case your skills and knowledge gained, and
applied into real-life concerns and situations.
Additional
Activities
An activity in any form that can increase the
strength of the response and tends to induce
repetitions of actions/learning
Answer Key
10. 6
What I Know
LO-1 Striking an Arc
Direction: Write the letter of the correct answer in every item. Provide a separate
answer sheet.
1. What is the basis for identifying the recommended arc length to be maintained when
striking an arc?
a. diameter of filler metal c. type of electrode
b. diameter of the flux d. thickness of the base metal
2. This type of welding rod is used mostly in root penetration.
a. E6013 b. E6011 c. E7018 d. E7020
3. What is the recommended travel angle and work angle in striking an arc in flat
position?
a. 65° - 75°, 90° c. 70°, 90°
b. 75° - 85°, 95° d. 60°, 85°
4. What is the recommended welding position in the electrode E6011?
a. flat position only c. vertical and overhead position
b. horizontal position only d. all of the above
5. What is the recommended angle in striking an arc in horizontal position?
a. 65° - 75°, 90° c. 70°, 90°
b. 75° - 85°, 95° d. 60°, 85°
6. Below are examples of weaving motion except:
a. crescent motion. c. square motion
b. figure 8 motion d. linear motion
7. What is the prescribe safe lens shade if the electrode size is 1/16 – 5/32 and
amperage is 75-200 amperes?
a. # 8 b. # 10 c. # 12 d. # 14
8. What is the prescribe safe lens shade if the electrode size is 5/16 – 3/8 and
amperage is 400+ amperes?
a. # 8 b. # 10 c. # 12 d. # 14
9. Below is an example of a rutile electrode:
a. E6013 b. E6011 c. E6010 d. E7011
10. Below is an example of a cellulosic electrode:
a. E6013 c. E7018
b. E6011 d. E6012
11. 7
11. The growing together or growth into one body of materials being welded is called.
a. coalescence c. fusion welding
b. spatter d. bead
12. A joining process produces a coalescence of materials by heating to a melting point,
with or without the use of filler metal is called.
a. oxyacetylene gas cutting c. grinding
b. sawing d. welding
13. A non-metallic solid material entrapped or formed on top of weld metal or between
the weld metal and base metal is called.
a. Slag b. flux c. bead d. spatter
14. The function of flux in an electrode is:
a. stabilize the arc
b. forms a gaseous atmosphere which protect the weld pool
c. to provide a means of welding alloy to the weld metal
d. all of the above
15. The key to maintain a stable arc in welding is:
a. correct electrode size and electrode angle
b. correct current
c. correct arc length and travel speed
d. all of the above
LO-2: Deposit Stringer Bead
16 – 20 Enumerate at least 5 weaving motion in welding.
21 – 30 Labeling: Identify the parts of a welding process
12. 8
What I Need to Know
Assessment Criteria:
1. Weld procedure in striking arc is applied according to weld standard.
2. Methods of striking an arc are applied accordingly.
Learning Experiences/Activities:
Learning Activities Special Instructions:
Note: Answer the pretest before you
read this module
1. Read the attached information sheet
1.1/1.2 Methods of Striking an Arc
2. Perform the operation sheet 1.1
3. Answer the self-check 1.1/1.2
(Operation Sheet 1.1) to test your
knowledge on method of striking an arc.
4. Compare your answer on the answer
keys.
5. If you miss some of the items go over
this information sheet.
6. When you are ready, you can proceed
to the next LO.
Answer the self-check without looking at the
information sheet.
LO - 1 Strike an Arc
13. 9
What’s New
LO1: Strike an Arc
1. Identify the methods of striking an arc.
2. Prepare the safety gears needed for striking an arc.
A welding arc is maintained when the welding current is forced across a gap between the
electrode tip and the base metal. A welder must be able to strike and establish the correct arc
easily and quickly.
What Is It
There are two general methods of striking the arc:
1. Scratching
2. Tapping
The scratching method is easier for beginners and when using an AC machine. The
electrode is moved across the plate inclined at an angle, as you would strike a match. As the
electrode scratches the plate an arc is struck. When the arc has formed, withdraw the
electrode momentarily to form an excessively long arc, then return to normal arc length (see
figure 1).
Figure 1. "Scratching" method Figure 2. "Tapping" method
In the tapping method, the electrode is moved downward to the base metal in a vertical
direction. As soon as it touches the metal it is withdrawn momentarily to form an excessively
long arc, then returned to normal arc length (see figure 2).
The principal difficulty encountered in striking the arc is "freezing," or when the
electrode sticks or fuses to the work. This is caused by the current melting the electrode
tip and sticking it to the cold base metal before it is withdrawn from contact. The extra high
Information Sheet 1.1
14. 10
current drawn by the "short circuit" will soon overheat an electrode and melt it or the flux,
unless the circuit is broken. Giving the electrode holder a quick snap backward from the
direction of travel will generally free the electrode. If it does not, it will be necessary to open
the circuit by releasing the electrode from the holder.
Warning: Never remove your face shield from your face if the electrode is frozen. Free the
electrode with the shield in front of your eyes, as it will "flash" when it comes loose.
Tip: Brush your work free of dirt and scale before you strike an arc.
https://www.lincolnelectric.com/en-ca/support/welding-how-to/Pages/strike-establish-arc-detail.aspx
15. 11
What I Have Learned
Self-Check # 1.1
LO - 1: Strike an Arc
Directions:
Choose the correct answer from the series given for every item. Write the letter only. Use a
separate answer sheet.
1. What method in striking an arc is recommended for the beginners?
a. Tapping method
b. Scratching method
c. Any of these
d. None of the above
2. In the symbol E-6013; letter “E” stands for:
a. Electric
b. Energy
c. Electrode
d. None of the above
3. Eyes can be protected during welding operations by using:
a. Gloves
b. Leggings
c. Goggles
d. Apron
4. It is done by touching the electrode to the base metal like scratching a match.
a. Tapping Method
b. Scratching Method
c. All of these
d. None of there
5. It is done by moving the electrode downward until it steps to the base metal then
bringing the electrode up slightly to form an arc.
a. Taping Method
b. Scratching Method
c. All of these
d. None of these
16. 12
What’s New
Shielded Metal Arc Welding
Shielded metal arc welding is defined as arc welding with covered electrodes manually
controlled by the welder, without automatic or semi- automatic replacement of electrode. This
process uses a length of flux coated electrode which provided filler metal and atmospheric
shielding.
The electrode is held by the welder in an electrode holder with an insulated handle. The
holder grips the bare end of the electrode for good current transfer.
The welder strikes and draws an arc which melts the base metal forming a weld pool at
the same time. The tip of the electrode melts and metal droplets are projected into the weld
pool.
The chemicals and minerals in coating, melt and decompose to serve as an alloying
element and to form a protecting gas shield around the arc and weld pool. Furthermore, a slag
is formed to cover the deposited weld.
What Is It
SELECTING ELECTRODE
Objective: The learner will select the type of arc welding electrodes.
Selecting an electrode
• The choice of the right electrode depends on the following factors:
1. Kinds of Base Metal. Electrodes are classified according to the kind of the base metal
for which they are recommended into mild steel low hydrogen, low energy, cast iron,
stainless steel and various non-ferrous electrodes.
2. Types of Welding Equipment. Determine what current is available, as not all electrodes
can be used for both AC or DC current and others are more economical to use with one
type of current than the other. It may also be necessary to check the open circuit voltage
of the welding machine to be used for source electrodes (e.g. basic low hydrogen type) It
requires higher open circuit voltage than other for best performance.
Information Sheet 1.2
17. 13
3. Dimension and Design of Parts. Heavy materials of complicated design require
electrodes of high ductility thin plates require low penetration electrodes with stable arcs
at low current values.
4. Joint Preparation and Set up. Deep penetration electrodes are required when edge is
not levelled and fit-up is tight. Mild penetration, thin- coated electrodes are best when
gaps are open.
5. Welding Position. Some electrodes are preferable to others for off- position welding
6. Specification and Service Condition. Job specifications may indicate class of
electrodes to be used: Otherwise the service requirements (e.g. desired tensile strength,
ductility, corrosion or abrasion resistance, etc.) should be considered
7. Practicability of Heat Treatment. If shop facilities preclude the employment of pre-
heating or post-heating for critical job, the use of low heat input electrodes is the only
recourse.
8. Cost Limits. The choice of expensive electrodes whose qualities or properties exceed
those normally demanded by the job is economically unwise when less expensive
electrodes, just as suitable quality electrodes and win the risk of the weldment failing in
service or having the job redone at additional cost when dependable brands are in the
market
ELECTRODES
https://www.mechanicwiz.com/welding-rod-chart/
Common ways of classifying electrode (by the covering on the electrode).
1. Bare-Electrode
2. Dusted Electrode
3. Flux-Dipped Electrode
4. Extended Electrodes and Covering
Common electrode width sizes Common lengths of electrodes
3/32ӯ 1/8ӯ 5/32ӯ 14-inches
3/16ӯ 7/32ӯ 1/4 ӯ 18-inches
19. 15
ELECTRODE CODING
Electrode Classification End Color Spot Color Group Color
E-6010
6011 Blue
6012 White
6013 Brown
6020 Green
7010-Al Blue White
7011-Al Blue Yellow
7016 Blue Orange Green
7018 Black Orange Green
7020-Al Blue Yellow Silver
8015-B1 White Brown Green
8016-B1 White Black Green
9016-B3 Brown Blue Green
10013 Green Brown Silver
10015 Red Red Green
10016 Green Orange Green
12016 Orange Orange Green
Table #2 Electrode Coding
Fourth Digit Type of Coating Welding Current
1 Cellulose potassium AC, DCSP, DCRP
2 Titania sodium AC, DCSP
3 Titania potassium AC, DCSP, DCRP
4 Iron powder titania AC, DCSP, DCRP
5 Low hydrogen sodium DCRP
6 Low hydrogen potassium AC, DCRP
7 Iron powder oxide AC, DC
8 Iron powder, low hydrogen AC, DCRP, DCSP
0 Low hydrogen, iron powder DC reverse polarity
Table #3 Classification Number of Electrode
20. 16
ELECTRODE CLASSIFICATION
Electrode
Classification
Number
Type of coating or
covering
Capable of producing
satisfactory weld in
position
Type of Current
E-45 series-minimum tensile strength of deposited metal in non-stress relived condition
45,000 Psi
E-4510 Sulcoated F.V.OH.H not specified generally
E-4520 Light coated H. fillet F
DCSP-electrode
negative
E-60 series- minimum- tensile strength of deposited metal in non-stress relieved condition
60,000 Psi
E-6010 Hi. Cellulose sodium F.V.OH.H use DC reverve polarity
E-6011 Hi. Cellulose potassium F.V.OH.H use AC. DCRP
E-6012 Titania Sodium F.V.OH.H use AC or DCSP
E-6013 Titania Potassium F.V.OH.H use AC or DCSP
E-6015 Lo-hydro sodium F.V.OH.H use DCRP only
E-6030 Hi-iron oxide H. fillet F. use AC. DC both polarity
E-70 series-minimum strength of deposited metal in stress relieved condition 70,000 Psi
E-7010 Hi. Cellulose sodium F.V.OH.H use DCRP
E-7011 Hi.Cellulose potassium F.V.OH.H use AC. DCSP
E-7020 i-iron oxide H. fillet F. use AC. DCSP
E-7030 Hi-iron oxide F use AC. DC both polarity
Table #4 Electrode Classification
Note: Sod. – Sodium, Pot- potassium, Ox. - oxide
21. 17
Welding Flux
1. Relationships of arc, base metal, electrode and flux:
a. Arc stream is created by holding an electrode approximately 1/8" (3 mm) away from
the base metal.
b. The arc stream creates a molten pool or crater that tends to flow away from the arc
and cools of solidify as it moves
c. Flux from the electrode covering forms a slag on the top of the weld to protect it
from contaminants during cooling.
2. How flux covered electrode works:
a. flux covered electrode have a core of metal wire with a baked on chemical covering
b. the wire core melts in the arcs stream and droplets of metal are transferred across
the arc to make the molten puddle and provide the filler metal to fill the gap or
groove between two base metal
c. the flux covering also melts in the arc stream to stabilize the arc to provide a shield
around the arc, to keep it free from atmospheric impurities and to form slag
covering to protect the weld
Welding Lens
Steps in selecting a safe lens shade for shielded metal arc welding:
1. Determine the electrodes size and amperage range because this are used to dictate
the lens protection required.
2. Select lens shade according to the lens manufacturer’s selection chart, but never
select less than a # 8 length shade for shielded metal arc welding.
Note: When you remove your hood after arc welding and you see white spots or white blotches
as after image it means that you are getting much light through the lens and you should switch
to a shade at least at least one number darker, or check the seal on your lens.
A rule of thumb is that the larger the diameter of the electrodes, the higher the number
required for a lens shade.
Electrode Size Amperage Shade #
- 30 to 75 8
1/16 – 5/32 75 – 200 10
3/16 – 1/4 200 – 400 12
5/16 – 3/8 400 + 14
23. 19
What I Have Learned
Self-Check # 1.2
Directions:
Choose the correct answer from the series given for every item. Write the letter only. Use a
separate answer sheet.
1. The coating of electrode is sometimes called:
a. Flux
b. Shield
c. Covering
d. All of these
2. The electrode which has no coating is called:
a. Shielded
b. Bare
c. Dusted
d. Dipped
3. The symbol E-6013;60 means
a. Welding Position
b. Tensile Strength
c. Power Supply
d. Flux Coating
4. The third digit in the symbol E-6013; 1 stands for
a. Welding Position
b. Tensile Strength
c. Power Supply
d. Flux Coating
5. The diameter of the electrode to be used in welding operation depends upon the:
a. Thickness of the Base Metal
b. Welding Position
c. Type of Base Metal
d. None of these
24. 20
What I Can Do
Title: Striking an Arc.
Performance Objective: The learner will perform the striking of an arc using Tapping and
Scratching.
Conditions or situations for the operations:
1. The distance of an arc must be equal to the diameter of electrode regardless of the
method you used in striking an arc.
2. The materials and equipment must be properly checked.
Supplies/Materials:
1. Video or PowerPoint presentation for: Striking an Arc
2. Electrode E6013, 3.2mm. Diameter
3. Safety gears (Gloves, Safety Helmet, Apron)
4. 10mm x 50mm x 100mm steel plate
5. Chipping hammer
6. Steel brush
Equipment: AC Welding Machine with Accessories
Precautions:
1. Always check the welding machines and its accessories before and after using them
2. See to it that there are no combustible materials near the welding area.
3. Always wear protective gears.
4. Observe safety measures while working.
Quality Criteria:
1. The height of the arc is maintained not more than diameter of electrode. The proper
distance of an arc must be maintained for at least 5-10 seconds
Assessment Method: DEMONSTRATION
Operation Sheet 1.1
25. 21
WELDING PROCEDURE:
1. Prepare the tools, equipment and materials
needed.
2. Set up the welding machine and set the
current to 100 amps.
3. Wear protective clothing and equipment.
4. Clamp the bare end of the electrode in the
holder.
5. Position your body in such a way that your
head will be cleared of the column of fumes
arising from the arc (Fig. 28).
6. Strike the arc by either of the two methods.
1. SCRATCHING
1.1 Point the electrode downwards at an angle
of approximately 75O
and the striking end
about 30 mm above the start position on
the plate surface.
1.2 Strike the end of the electrode on the plate
surface similar to striking a match.
1.3 When a spark appears, withdraw the
electrode quickly and draw an arc of
approximately 6 mm.
1.4 Move the electrode to the start position
and then reduce the arc length to a
distance equal to the diameter of the
electrode.
26. 22
2. TAPPING
2.1 Point the electrode downwards at an angle
of approximately 75O
and the striking end to
about 15 mm above the start position on the
plate surface.
2.2 Lower the electrode on the plate surface.
2.3 When a spark appears, withdraw the
electrode quickly to an arc length equal to
its diameter.
NOTE: If the electrode welds to the plate, quickly
snap the electrode to one side.
If the electrode does not release, switch off the
welding machine and detached the electrode with a
cold chisel.
27. 23
What I Have Learned
SELF-CHECK # 1.1 (OPERATION SHEET)
Directions:
Use the check-list below as basis for judging whether you meet the required competency.
Write YES or NO for your answer in a separate answer sheet.
In performing striking an arc you should be able to hold the arc for 10 seconds. The arc
length should not be bigger than 4mm at angle of approximately 75O
.
1. Perform the tapping method.
2. Perform the scratching method.
The learners are able to do the following…
CRITERIA YES NO
1.Can be able to strike electrode at correct angle and arc length.
2. Able to strike the end of the electrode on the plate surface similar to
striking a match.
3.
3.Able to withdraw the electrode quickly and draw an arc of approximately
6 mm.
4.Able to reduce the arc length to a distance equal to the diameter of the
electrode.
What’s More
For Further Study
Have learners assess their performance. For criteria needing assistance, provide the
appropriate intervention/s.
28. 24
What’s New
Bead Formations:
Objectives:
1. Identify the types of weld beads
2. Identify the different types of weaving motion beads.
3.Determine the appropriate electrodes to be used applicable for the specific bead
and weld positions.
Type of beads
a. Stringer Bead- a straight forward bead in which you either drag or push the
electrode across the joint with minimal side to side movement.
b. Weave motion Beads - is a method for electrode manipulation in joining metal
to achieve good weldment.
Fig.# 1.
Information Sheet 2.1
29. 25
Fig. # 2
Some of the weave bead motion technique used in stick welding.
Crescent
Figure of 8
Circular
1. Circular Motion- often used in flat position weld on butt,tee,and outside corner joints for
build-up surfacing operation.
2. Crescent Weave Motion- A half round bead formation in which formed a side to side semi
circular electrode movement.
3. Figure of eight motion weave –An electrode manipulation pattern where a continuous figure
of number eight is formed.
4. V- Pattern motion weave – a weave pattern commonly used in Hot pass and cap pass by
forming V-motion.
5. Stringer Bead- - a straight forward bead in which you either drag or push the
electrode across the joint with minimal side to side movement.
6. Square Pattern motion Bead – good for flat welds but they can also be used for
vertical position. They can also be used if there is a large gap to be filled.
7. J- pattern weave motion- works well on flat and horizontal positions.
8. T- pattern weave motion – works with fillet weld in vertical and over head position.
.It can also be used for deep grove welds for the hot pass.
9. Zigzag pattern motion weave–used as cover passes in flat and vertical positions.
30. 26
What I Have Learned
Self-check 2.1
MATCHING TYPE:
Match column A. with column B. Write the letter of the correct answer on the blank
provided before the number. Use separate answer sheet.
A B
_____1. Crescent motion
_____2. Square Pattern motion
_____3. J- Pattern motion
_____4. Circular motion
_____5. Figure of 8 motion
_____6. V- Pattern motion
_____7. T- pattern motion
_____8. Zigzag motion
_____9. Stringer bead
a. A straight forward bead with minimal side
to side motion
b. Works well on flat and horizontal positions
c. Used as a cover passes in flat and vertical
positions.
d. A half round bead in a semi circular
movement.
e. A continuous movement using number
eight pattern
f. Commonly used in hot pass formed by V-
motion
g. Works with fillet weld in vertical position
with letter T- formation.
h. Often used in flat position weld on butt ,Tee
and outside corner joints for build –up.
i. Good for most flat weld but it can also be
used for vertical position weld.
31. 27
What I Need to Know
Assessment Criteria:
1. Uniformity of bead ripples is checked in accordance with welding standard.
2. Stringer or Straight beads are deposited in accordance with welding standards.
3. Finish weldment is performed based on acceptable standards for:
• Spatter
• Slag
• Uniformity of beads
LEARNING EXPERIENCES/ACTIVITIES
Learning Outcome 2: Deposit Straight Bead
Learning Activities Special Instructions
1. Read the attached information sheets 2.1,
activity sheets 2.2, Deposit Straight Bead
2. Answer the self-check 2.1, Deposit straight
bead to test your knowledge.
3. Compare your answer on the answer keys.
4. If you missed some of the items go over this
information on sheets.
5. NOTE: At the end of this L.O. answer the
post test.
6. If you pass, then proceed to the next LO.
Answer the self-check without looking at
the information sheet
LO - 2 Deposit Straight Bead
32. 28
What’s New
Deposit straight beads
Objective:
1. Prepare the metal to be welded
2. Determine the requirements in base metal preparation
3. Deposit a straight bead.
What is it
Requirements in base metal:
1. The base metal must be clear
2. The base metal must be free from oil, grease & paints
3. The plate must have been checked for its type.
Information Sheet 2.2
33. 29
What I can do
Title: Stringer Bed in Flat Position
Performance Objective: To weld stringer bead flat position. The bead should be straight,
of even height and width and with fine ripples.
Supplies/Materials:
1. Video or PowerPoint presentation for: Striking an Arc
2. Electrode E6013, 3.2mm. Diameter
3. Safety gears (Gloves, Safety Helmet, Apron)
4. Mild steel plate, 6mm x 75mm x 150mm (1 pc)
5. Chipping hammer
6. Steel brush
Equipment: AC Welding Machine with Accessories
Precautions:
1. Always check the welding machines and its accessories before and after using them
2. See to it that there are no combustible materials near the welding area.
3. Always wear protective gears.
4. Observe safety measures while working.
Plan/ Illustration:
Assessment Method: DEMONSTRATION
Operation Sheet 2.2
34. 30
PROCEDURE:
1. Prepare the tools, equipment and materials needed.
2. Set up the welding machine. Check the electrical connections before switching
on the machine. Set current between 90-140 amperes.
3. Wear suitable protective clothing.
4. Lay the plate flat in a welding table where you are comfortable as possible when
welding commences.
5. Strike an arc on the first line of the plate. If you are right-handed, the weld should
start from the left to right, but if you are left-handed, start from right to left.
6. When the arc is established, position the electrode at 75o
travel angle and 90o
work
angle.
7. Move the electrode with constant rate of travel controlling and maintaining the width
of bead at about 2 ½ times of the diameter of the electrode.
8. Continue welding until you reach the end of the line. Quickly withdraw the
electrode if you want to stop or reach the end of the line.
75o
stevenling-ilpks.blogspot.com%2Fp%2Fset-up-smaw-equipment.html
35. 31
9. Clean the weld using a chipping hammer and steel brush. Use clear goggles when
chipping. The direction of chipping should be away from you.
10. Inspect the weld run. The weld should be straight, of even thickness and width
with fine ripples. The thickness of the bead should be about one and one-half of
the electrode diameter.
11. Finish all the laid-out lines. Avoid the same mistakes you did on your first try.
36. 32
What I Have Learned
Self-Check 2.1
The marking system below will guide you in assessing the quality of your weld. Follow the
marking schedule in rating your weld and record the marks on the table provided for the
purpose. Subtract the total marks from 20 points, which is the highest rating to determine your
final points.
THE PASSING MARK IS 10 POINTS
MARKING TABLE
CRITERIA MARKS SUBTRACTED
1. Straightness
2. Width of bead
3. Height of bead
4. Ripple
TOTAL MARKS SUBTRACTED
FINAL POINTS = 20 minus Total Marks Subtracted
20 - Deductions
FINAL POINTS =
MARKING SCHEDULE:
1. Straightness
Subtract 1 mark for each degree of deflection from the line of weld.
2. Width of Bead
Subtract 2 marks for each 10mm length of bead which is 1mm less than or more than
the bead width of 8mm.
3. Height of Bead
Subtract 2 marks for 10mm length of bead which exceeds the bead height of 3mm.
4. Ripple
Subtract 3 points for uneven and coarse ripple.
37. 33
What Is It
Common Causes and Cure for Weld Defects:
CAUSE REMEDY
1. Arc Blow- is caused when magnetic forces
present in DC build up lines of magnetism
around the arc and cause the arc to blow wildly
forward or to outside, and spatter badly.
It can also be caused by high amperage and the
major problem areas are thick plates, corners,
deep groove and the start and finish of
joints.
• Reduce current or suitable polarity.
• Change current to AC.
2. Pinholes and porosity
Both pinholes and porosity can be caused when
length is too long and travel is too fast.
Other causes for pinholes and porosity are faulty
electrodes incorrect polarity, surface conditions
of the base metal or high Sulphur and other
impurities.
• Use shorter arc length and keeping
the puddle molter for a longer period
so that the gasses may boil out
before the metal freezes.
• Use dry electrode and clean the
surface of the base metal.
3. Undercutting
It is usually caused by too high current of too
long arc length.
It is also caused by improper electrode angle
manipulation or too
fast welding speed.
• Reduce the current and shorten the
arc length.
• Use a smaller diameter electrode
• Change the electrode angle
4. Spatter
➢ Too high current
➢ To long arc length
• Reduce current
• Shorten arc length
5. Incomplete penetration
➢ Faulty joint design
➢ Insufficient welding current
➢ Large electrode used
➢ Too fast welding speed
• Check the joint carefully,
inducting the root opening, root face
dimension and the groove force
angle.
• Increase the weld current
• Reduce the welding speed
• Use a smaller diameter electrode
Information Sheet 2.3
38. 34
Assessment: (Post-Test)
LO-1 Striking an Arc
Direction: Write the letter of the correct answer in every item. Provide a separate
answer sheet.
2. What is the basis for identifying the recommended arc length to be maintained when
striking an arc?
c. diameter of filler metal c. type of electrode
d. diameter of the flux d. thickness of the base metal
3. This type of welding rod is used mostly in root penetration.
b. E6013 b. E6011 c. E7018 d. E7020
4. What is the recommended travel angle and work angle in striking an arc in flat
position?
c. 65° - 75°, 90° c. 70°, 90°
d. 75° - 85°, 95° d. 60°, 85°
5. What is the recommended welding position in the electrode E6011?
c. flat position only c. vertical and overhead position
d. horizontal position only d. all of the above
6. What is the recommended angle in striking an arc in horizontal position?
c. 65° - 75°, 90° c. 70°, 90°
d. 75° - 85°, 95° d. 60°, 85°
7. Below are examples of weaving motion except:
c. crescent motion. c. square motion
d. figure 8 motion d. linear motion
8. What is the prescribe safe lens shade if the electrode size is 1/16 – 5/32 and
amperage is 75-200 amperes?
b. # 8 b. # 10 c. # 12 d. # 14
16. What is the prescribe safe lens shade if the electrode size is 5/16 – 3/8 and
amperage is 400+ amperes?
b. # 8 b. # 10 c. # 12 d. # 14
17. Below is an example of a rutile electrode:
b. E6013 b. E6011 c. E6010 d. E7011
18. Below is an example of a cellulosic electrode:
c. E6013 c. E7018
d. E6011 d. E6012
39. 35
19. The growing together or growth into one body of materials being welded is called.
c. coalescence c. fusion welding
d. spatter d. bead
20. A joining process produces a coalescence of materials by heating to a melting point,
with or without the use of filler metal is called.
c. oxyacetylene gas cutting c. grinding
d. sawing d. welding
21. A non-metallic solid material entrapped or formed on top of weld metal or between
the weld metal and base metal is called.
b. Slag b. flux c. bead d. spatter
22. The function of flux in an electrode is:
e. stabilize the arc
f. forms a gaseous atmosphere which protect the weld pool
g. to provide a means of welding alloy to the weld metal
h. all of the above
23. The key to maintain a stable arc in welding is:
e. correct electrode size and electrode angle
f. correct current
g. correct arc length and travel speed
h. all of the above
LO-2: Deposit Stringer Bead
16 – 20 Enumerate at least 5 weaving motion in welding.
21 – 30 Labeling: Identify the parts of a welding process
41. 37
References:
"How to Strike and Establish an Arc | Lincoln Electric Canada." Lincolnelectric. Accessed
January 28, 2020. https://www.lincolnelectric.com/en-ca/support/welding-how-
to/Pages/strike-establish-arc-detail.aspx.
Jacob. "SMAW (Stick Welding)." SlideServe. Last modified January 23, 2012.
https://www.slideserve.com/jacob/smaw-stick-welding.
JEFFUS, LARRY, and HAROLD JOHNSON. Welding Principles and Application. n.d.
KENNEDY, GOWER A. Welding Technology 2nd Ed.. n.d.
Kennedy, Gower A. Welding Technology, 1982 ed. Bobbs Merrill, n.d.
RHONE, L. C. Total Auto Body Repair, 3rd Ed.. n.d.
Welding Inspection Technology. Education Department, American Welding Society, n.d.
