Sector: METALS AND ENGINEERING

Qualification: SHIELDED METAL ARC WELDING NC II

Unit of Competency: Weld Carbon Steel Plates Using SMAW

Module Title: Welding Carbon Steel Plates Using SMAW

 HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to the Module; Welding Carbon Steel Plates using SMAW.

This module contains training materials and activities for you to complete.

The unit of competency “Weld Carbon Steel Plates using SMAW"

covers the skills, knowledge, and attitudes in welding carbon steel plates
using SMAW process. It is one of the Core Competencies of Shielded Metal
Arc Welding National Certificate Level II (SMAW NC II).

You are required to go through a series of learning activities in order

to complete each learning outcome of the module. In each learning outcome
there are Information Sheets, Resource Sheets and Reference Materials
for further reading to help you better understand the required activities.
Follow these activities on your own and answer the self-check at the end of
each learning outcome. Get the answer key from your instructor and check
your work honestly. If you have questions, please don’t hesitate to ask your
facilitator for assistance.

Remember to:

 Read Information Sheets and complete the self-checks. Suggested

references are included to supplement the materials provided in
this module.
 Perform the Task Sheets and Job Sheets until you are confident
that your outputs conform to the Performance Criteria Checklist
that follow the sheets.
 Submit outputs of the Task Sheets and Job Sheets to your
facilitator for evaluation and recording in Accomplishment Chart.
Outputs shall serve as your portfolio during the Institutional
Competency Evaluation. When you are 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 another competency. A Certificate of
Achievement will be awarded to you after passing the evaluation.

When you fell that you have had sufficient practice, ask your trainer
to evaluate you. The results of your assessment will be recorded in your
Record of Achievement and reflected in your Progress Chart and/or
Achievement Chart.

If you have questions, don’t hesitate to ask your Trainer for

assistance.

Recognition of Prior Learning (RPL)

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 You may already have some or most of the knowledge and skills
covered in this module because you have:
• Been working for some time
• Already completed training in this area

If you can demonstrate to your trainer that you are competent in a

particular skill or skills, talk to your trainer about having them formally
recognized so you won't have to do the same training again.

If you have qualification or Certificates of Competency from previous

training, show them to your trainer. If the skills you acquired are still
relevant to this module, they may become part of the evidence you can
present for RPL.

At the end of this learning material is a Learner’s Diary, use this diary
to record important dates, jobs undertaken and other workplace events that
will assist you in providing further details to your trainer or assessors. A
Record of Achievement is also provided for your trainer to complete once you
completed the module.

This learning material was prepared to help you achieve the required
competency in interpreting blueprint. This will be the source of information
for you to acquire the knowledge and skills in this particular trade
independently and at your own pace with minimum supervision or help from
your instructor.

In doing the activities to complete the requirements of this module,

please be guided by the following:
 Talk to your trainer and agree on how you will both organize the
training under this module. Read through the module carefully. It
is divided into sections which cover all the skills and knowledge
you need to successfully complete.

 Work through all information and complete the activities in each

section. Read the information sheets and complete the self-check.
Suggested references are included to supplement the materials
provided in this module.

 Most probably your trainer will also be your supervisor or manager.

He/she is there to support you and show you the correct way to do
things. Ask for help.

 Your trainer will tell you about the important things you need to
consider when you are completing the activities and it is important
that you listen and take notes.

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  You will be given plenty of opportunities to ask questions and
practice on the job. Make sure you practice your new skills during
regular work shifts. This way you will improve both your speed and
memory and also your confidence.

 Talk to more experienced work mates and ask for their guidance.

 Use self-check questions at the end of each section to test your

own progress.

 When you are ready, ask your trainer to watch you perform the
activities outlined in this module.

 As you work through the activities, ask for written feedback on

your progress. Your trainer keeps feedback/pre-assessment
reports for this reason. When you have successfully completed
each element, ask your trainer to mark on the reports that you are
ready for assessment.

 When you have completed this learning material and feel confident
that you have had sufficient knowledge and skills, your trainer will
arrange an appointment with a registered assessor to assess you.
The results of your assessment will be recorded in your
Competency Achievement Record.

SHELDED METAL ARC WELDING

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 NC II

COMPETENCY-BASED LEARNING MATERIALS

List of Competencies

No. Unit of Competency Module Title Code

Welding Carbon Steel

Weld Carbon Steel Plates Using SMAW
1. Plates and Pipes MEE721306
Using SMAW Welding Carbon Steel
Pipes Using SMAW

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 TABLE OF CONTENT

HOW TO USE THIS COMPETENCY-BASED LEARNING MATERIAL………….. 1

RECOGNITION OF PRIOR LEARNING……………………………………………….. 2
LIST OF COMPETENCIES………………………………………………………………. 4
TABLE OF CONTENT…………………………………………………………………….. 5
MODULE CONTENT………………………………………………………………………. 6
LEARNING OUTCOME #3 Weld carbon steel plates in vertical position (3G).. 8
LEARNING EXPERIENCE……………………………………………………………….. 11
INFORMATION SHEET 1.3-1…………………………………………………………… 13
Self-Check 1.3-1……………………………………………………………………………. 18
Answer Key 1.3-1…………………………………………………………………………. 19
INFORMATION SHEET 1.3-2…………………………………………………………… 20
Self-Check 1.3-2……………………………………………………………………………. 22
Answer Key 1.3-2………………………………………………………………………….. 24
INFORMATION SHEET 1.3-3…………………………………………………………… 25
Self-Check 1.3-3……………………………………………………………………………. 27
Answer Key 1.3-3………………………………………………………………………….. 28
INFORMATION SHEET 1.3-4…………………………………………………………… 29
Self-Check 1.3-4……………………………………………………………………………. 33
Answer Key 1.3-4………………………………………………………………………….. 34
INFORMATION SHEET 1.3-5…………………………………………………………… 35
Self-Check 1.3-5……………………………………………………………………………. 38
Answer Key 1.3-5………………………………………………………………………….. 39
INFORMATION SHEET 1.3-6…………………………………………………………… 40
Self-Check 1.3-6……………………………………………………………………………. 45
Answer Key 1.3-6………………………………………………………………………….. 46
INFORMATION SHEET 1.3-7……………………………………………… .. 47
Self-Check 1.3-7……………………………………………………………… .. 50
Answer Key 1.3-7……………………………………………………………… .. 51
JOB SHEET……………………………………………………………………….. 52
PERFORMANCE……………………………………………………………… .. 56
BIBLIOGRAPHY………………………………………………………………… .. 57
TECHNICAL TERMS…………………………………………………………….. 58

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 MODULE CONTENT

QUALIFICATION: Shielded Metal Arc Welding NC II

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 in different positions such as 1G, 2G, 3G and 4G using SMAW
process.

NOMINAL DURATION: 114 hrs

LEARNING OUTCOMES:
Upon completion of this module, you must be able to:
1. Weld carbon steel plates in flat position (1G)
2. Weld carbon steel plates in horizontal position (2G)
3. Weld carbon steel plates in vertical position (3G)
4. Weld carbon steel pates in overhead position (4G

ASSESSMENT CRITERIA:
1. Workplace is prepared in accordance with OH&S policies and procedures
2. Established risk control measures for work preparation are followed
3. Responsible person is consulted for effective and proper work
coordination
4. Required materials, tools and equipment are prepared and checked in
accordance with established procedure
5. Parts and components needed to complete the work are identified,
prepared and obtained according to requirements
6. Root pass is performed in accordance with WPS and/or client
specifications.
7. Task is performed in accordance with company or industry requirement
and safety procedure.
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8. Weld is visually checked for defects and repaired, as required
9. Weld is visually acceptable in accordance with applicable codes and
standards
10. Root pass is cleaned and free from defects and discontinuities
11. Task is performed in accordance with approved WPS
12. Subsequent/ filling passes is performed in accordance with approved
WPS
13. Capping is performed in accordance with WPS and/or client
specifications
14. Finished products are subjected to final visual/sensory inspection and
testing in accordance with quality standards, procedures and
requirements
15. Work completion is documented and responsible person is informed in
accordance with established procedures
16. Housekeeping procedures are observed in accordance with 5S discipline
and established procedures

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 LEARNING OUTCOME SUMMARY

Qualification : SMAW NC II
Unit of Competency : Weld Carbon Steel Plates using SMAW
Module Title : Welding Carbon Steel Plates using SMAW
Learning Outcomes # 3 : Weld carbon steel plates in vertical position (3G)

CONTENT:
1. Essential of welding
2. Safe welding practices
3. International welding codes and standards
4. Acceptable weld profiles
5. Weld defects, causes and remedies
6. Welding Procedure and Specifications (WPS)
7. Welding techniques and procedures
8. Welding carbon steel plates in vertical position (3G)

ASSESSMENT CRITERIA:
1. Required materials, tools and equipment are prepared and checked in
accordance with established procedure
2. Parts and components needed to complete the work are identified,
prepared and obtained according to requirements
3. Root pass is performed in accordance with WPS and/or client
specifications.
4. Task is performed in accordance with company or industry
requirement and safety procedure.
5. Weld is visually checked for defects and repaired, as required
6. Weld is visually acceptable in accordance with applicable codes and
standards
7. Root pass is cleaned and free from defects and discontinuities
8. Task is performed in accordance with approved WPS
9. Subsequent/ filling passes is performed in accordance with approved
WPS
10. Capping is performed in accordance with WPS and/or client
specifications

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 11. Finished products are subjected to final visual/sensory inspection and
testing in accordance with quality standards, procedures and
requirements
12. Work completion is documented and responsible person is informed in
accordance with established procedures
13. Housekeeping procedures are observed in accordance with 5S
discipline and established procedures

CONDITION:

Students/trainees must be provided with the following:

1. WORKPLACE LOCATION

2. EQUIPMENT

 Welding machine (AC or AC/DC) with complete accessories

 Portable grinder
 Welding booth with table
 Jigs and positioners
 Electrode oven
 Complete PPE

3. SUPPLIES & MATERIALS:

 Carbon steel plates

 Electrode E6011, E6013, E7018
 Carbon brush
 Cutting disc (wheel)
 Grinding disc (wheel)
 Clear and dark glass

2. TOOLS:

 Welding mask
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  Welding tongs
 Try square, steel brush
 Chipping hammer
 Ball pen hammer
 Adjustable locking pliers
 C-Clamp
ASSESSMENT METHOD:
1. Written Examination
2. Demonstration with oral questioning

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 Learning Experiences
Learning Outcome #3

Welding carbon steel plates in vertical position (3G)

Learning Activities Special Instructions
Read information sheets Read the information sheet 1.3-1 and check
1.3-1 on essentials of yourself by answering the self-check 1.3-1.
welding You must answer all questions correctly before
proceeding to the next activity.
Answer self-check 1.3-1 Compare your answer to the answer key 1.3-1.
If you got 100% correct answer in this self-
Compare answer with
check, you can now move to the next
Answer Key 1.3-1
information sheet. If not review the
information sheet and go over the self-check
again.
Read information sheets Read the information sheet 1.3-2 and check
1.3-2 on International yourself by answering the self-check 1.3-2.
Welding Codes and You must answer all questions correctly before
Standards proceeding to the next activity.
Answer self-check 1.3-2 Compare your answer with the answer key
Compare answer with 1.3-2. You are required to get all the answer
correct. If not, read the information sheet
Answer Key 1.3-2
again in order to answer all the questions
correctly.
Read information sheets Read the information sheet 1.3-3 and check
1.3-3 on Acceptable yourself by answering the self-check 1.3-3.
Weld Profiles You must answer all questions correctly before
proceeding to the next activity.
Answer self-check 1.3-3 Compare your answer to the answer key 1.3-3.
Compare answer with If you got 100% correct answer in this self-
check, you can now move to the next
Answer Key 1.3-3
information sheet. If not review the
information sheet and go over the self-check
again.
Read information sheets If you have some problem on the content of the
1.3-4 on Weld Defects, information sheet, don’t hesitate to approach
Causes and Remedies your facilitator.
If you feel that you are now knowledgeable on
the content of the information sheet, you can
now answer the self-check provided in the
module.

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Answer self-check 1.3-4 Compare your answer with the answer key.
Compare answer with You are required to get all the answer correct.
If not, read the information sheet again in
Answer Key 1.3-4
order to answer all the questions correctly.
Read information sheets Read the information sheet 1.3-5 and check
1.3-5 on Welding yourself by answering the self-check 1.3-5.
Procedure Specification You must answer all questions correctly before
proceeding to the next activity.
Answer self-check 1.3-5 Compare your answer to the answer key 1.3-5.
Compare answer with If you got 100% correct answer in this self-
check, you can now move to the next
Answer Key 1.3-5
information sheet. If not review the
information sheet and go over the self-check
again.
Read information sheets If you have some problem on the content of the
1.3-6 on Safe Welding information sheet, don’t hesitate to approach
Practices your facilitator.
If you feel that you are now knowledgeable on
the content of the information sheet, you can
now answer the self-check provided in the
module.
Answer self-check 1.3-6 Compare your answer to the answer key 1.3-6.
Compare answer with If you got 100% correct answer in this self-
check, you can now move to the next
Answer Key 1.3-6
information sheet. If not review the
information sheet and go over the self-check
again.
Answer self-check 1.3-7 Compare your answer to the answer key 1.3-7.
Compare answer with If you got 100% correct answer in this self-
check, you can now move to the next
Answer Key 1.3-7
information sheet. If not review the
information sheet and go over the self-check
again.
Perform Job Sheet No. Read and interpret Job Sheet No. 1.3-8 on
1.3-8 on welding welding techniques and procedures in vertical
techniques and position
procedures in vertical
position
If you find difficulty and Ask your trainer to demonstrate the process.
did not meet the If you pass, you can proceed to the next
standard, please go over activity
again.

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 Information Sheet 1.3-1
Essentials Variables of Welding

Learning Objective:

After reading this information sheet, you must be able to:

1. Know on how to control the amperage variable by setting the correct

amperage required on the welding machine.
2. Can enumerate and define the essential variables of welding.

Introduction:

Welding is a practical skill that requires continual practice and careful

attention to the variables that the welder controls to improve. The old golden
rule “practice makes perfect” applies to welding in that the more you do, as
long as you or someone evaluates your welds, the better you become.

The term variable as used in this text means something the welder
has to control of either before welding or during welding.

Essential Variables of Welding

1. Current Setting

The welding current or amperage is essential to producing welds with

good appearance and the required strength characteristics. The welder
controls the amperage variable by setting the correct amperage required on
the welding machine prior to welding.
The amperage is set from the recommended ranges according to the size of
the electrode, the type of electrode, and the type of current (Alternating
Current (AC), Direct Current Reverse Polarity (DCRP), and Direct Current
Straight Polarity (DCSP)) to be used.

Size E6010/E6011 E7018

3/32 60-90 70-100
1/8 90-120 120-160
5/32 110-130 130-170

Some electrodes are designed to work best on a given Current

and Polarity, for example an E-6010 should be used with DCEP (direct
current electrode positive).

Some electrodes are designed to work best on DCEN while others

allow a selection of Current to be used.

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 Illustration below gives an idea of the evaluation process.

A B C

A – Amperage correct
B – Amperage too low
C – Amperage too high

3. Length of Arc

The arc is the term used to describe the distance from the tip of the
electrode to the base metal and can be varied from lightly touching the metal
at an angle sufficient to maintain an arc to a distance far enough from the
base metal to extinguish the arc.

The welding machines used in SMAW are known as Constant Current

Welding Machines which means that the current stays relatively constant
through changes in the voltage. The machine increases the voltage as the
arc length is increased to maintain current flow at the amperage level set on
the machine. If the voltage is increased too much the arc may become
unstable and result in a poor quality weld.

The correct arc length may vary according to the type and size of
electrode and the position of welding.
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 4. Angle of Electrode

In SMAW process two electrode angles that the welder must have to
control. The first angle is the one formed between the electrode and the
base metal called the work angle. The second angle is the angle of the
electrode is held at relative to the direction of travel called the travel angle.

4. Speed of Travel

The rate of travel across the joint is controlled by the welder during
welding and greatly affects the appearance and strength characteristics of
the welds

The amount of weld metal deposited (weld deposition rate) and the
travel speed may vary with the type and size of electrode being used. The
correct weld speed will result in a well formed weld bead that shows good
fusion, penetration and a gradual transition of weld metal into the corners of
the joint.

Too fast travel speed will result in stringy weld with poor strength.

Too slow a speed will result in a heavy weld that has too much
convexity.

5. Selection of Electrode

There are a variety of electrodes available for welding a wide range of

metals. The electrode for a given application must be selected.

In general the electrode weld metal must be matched to the type and
composition of the base metal being welded. Further some electrodes within
the available scope are designed for specific purposes.

Some of the most widely used Electrodes are those used for welding
carbon Steel.

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 The following is a brief description of the most commonly used
electrodes for welding Carbon Steel.

The electrodes are classified by a letter and numbering system as

follows:

The tensile strength is defined as the ability of the weld metal to

withstand forces acting to pull it apart.

The last digit indicates the type of flux or electrode covering and in
turn determines the type of current, penetration and appearance of the
weld.

The following are some commonly used electrodes and their

characteristics.

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Electrode Coating Position Current Penetration Appearance Tensile
Strength
E-6010 High All DCEP Deep Rippled 62,000
Cellulose Position Flat PSI
Sodium
E-6011 High All DCEP Deep Rippled 62,000
Cellulose Position AC Flat PSI
Potassium
E-6012 High All DCEP Medium Smooth 67,000
Titanium Position AC Convex PSI
Sodium
E-6013 High All DCEP Shallow Smooth 67,000
Titanium Position DCEN Flat to PSI
Potassium AC Convex
E-7018 Iron All DCEP Shallow to Smooth 72,000
Powder Position AC Medium Flat to PSI
Low Convex
Hydrogen
E-7028 Iron All DCEP Shallow to Smooth 72,000
Powder Position AC Medium Convex PSI
Low
Hydrogen

Self – Check No. 1.3-1

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 Essential Variables of Welding
Test I
Multiple Choice:

Direction: Select the best answer and write only the letter that
corresponds to your choices on answer sheet.

1. Direct Current Reverse Polarity (DCRP) set up means positive terminal of

the welding machine is connected to the,

a. circuit breaker c. ground of the welding machine

b. electrode holder d. item being welded

2. Is defined as the ability of the weld metal to withstand forces acting to

pull it apart.

a. Flux characteristics c. Type of polarity

b. Tensile strength d. welding position

3. The correct arc length may vary according to

a. size of electrode c. welding position

b. type of electrode d. all of the above

4. The correct travel speed will result in a well formed weld bead that shows
a. good fusion c. spatter
b. heavy weld with much convexity d. thin stringy weld

5. What is the required amperage setting for E6011 1/8” in diameter?

a. 50-70 amps c. 90-100 amps

b. 70-80 amps d. 90-120 amps

Test II
Enumeration:

Give the following.

Enumerate the 5 essential variables in welding.

Answer Key 1.3-1

Essential Variables of Welding
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Test I

1. B
2. B
3. D
4. A
5. D

Test II

1. Current setting
2. Length of arc
3. Angle of electrode
4. Speed of travel
5. Selection of electrode

INFORMATION SHEET NO. 1.3 -2

Safe Welding Practices

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Learning Objective:

After reading the Information Sheet, youmust be able to identify the

different personal protective equipment and their uses.

Introduction:

The hazards in arc welding can endanger a welder’s life if he/she is

not wearing the proper protective clothing and equipment. Here are some
information on the suitable outfit that a welder must wear while welding:

WELDING SHIELD/HELMET
Welding shield/helmet is used to protect the face and eyes from the
arc rays (Infrared Rays, Ultra Violet Rays) and heat and spatter from the
molten metal. The arc is viewed through a filter which reduces the intensity
of radiation but allows a safe amount of light to pass for viewing the weld
pool and end of the electrode.
The recommended minimum protective filter based on the welding
current to be used is shown in the table below:

Approximate Range Filter Lens Number

Of Welding Current

Up to 100 8
100 - 200 10
200 - 300 11
300 - 400 12
Over 400 13

LEATHER JACKET
Leather jacket is made of chrome leather and prevents the entry of
sparks between the welder’s clothes and body.

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LEATHER APRON
Leather apron is made of chrome leather and provides a welder with
complete protection from sparks and hot metal from his/her chest to mid
calf.

LEATHER GLOVES
Gloves are made of chrome leather and protect the welder’s hands
from heat, spatter, and radiation.

LEATHER SPATS
Spats are made of chrome leather and protect the feet from spatter.

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SAFETY GLASSES
Safety clear glasses are used to protect the eyes when chipping slag
and grinding.

WELDERS LEATHER BOOTS

Welding Leather Boots is used to protect our feet from falling spatter,
sparks, and hot metals when welding overhead and confined spaces.

FACE SHIELD
Face Shield must also be worn where required to protect eyes. Welders
must wear safety glasses and chippers and grinders often use face shield in
addition to safety glasses.

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 SELF – CHECK 1.3-2
Safe Welding Practices

MULTIPLE CHOICE: Choose the correct answer and write the letter that
correspond to your choice on the answer sheet provided.
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 1. A safety gadget used to protect the face and eyes from the arc rays, heat
and spatter.

a. Welding gloves
b. Welding jacket
c. Safety shoes
d. Welding helmet/shield

2. The most serious danger from exposure to welding arc is,

a. X – rays
b. Beta – rays
c. Ultra Violet Rays
d. Sun rays

3. Protect the entry of falling hot slag and spatter.

a. Leggings
b. Welding gloves
c. Welding helmet
d. Clear glass

4. When welding at a current setting of 120 amperes, what is the

recommended filter lens number?

a. 8
b. 12
c. 10
d. 11

5. Safety gadget used to protect the eyes when chipping slag and grinding.

a. Safety glasses
b. Leather spats
c. Leggings
d. Welding gloves

ANSWER KEY 1.3-2

Safe Welding Practices

1. d

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2. c

3. a

4. c

5. a

Information Sheet No. 1.3-3

International Welding Codes and Standards

Learning Objectives:

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

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1. Identify the different welding codes and standards.
2. Identify the application of the different welding codes and standards.

Introduction:

In previous lesson you learned the basic theories and principles of the
essential variables of welding. The provided slf-check is also the basis for
assessing the knowledge that you have learned.
Now in this lesson you are focusing on the International Codes and
Standards. It is important to help you standardize in welding procedure.

Some of the common codes and standards in welding:

1. American Welding Society (AWS)

This code covers the welding requirements for any type of welded
structure made from the commonly used carbon and low-alloy steels.

The following AWS Standards

AWS D1.1 Structural Welding (Steel)

AWS D1.2 Structural Welding (Aluminum)
AWS D1.3 Structural Welding (Sheet Steel)
AWS D1.4 Structural Welding (Reinforcing Steel)
AWS D1.5 Bridge Welding
AWS D1.6 Structural Welding (Stainless Steel)
AWS D1.7 Structural Welding (Strengthening and Repair)
AWS D10.11 Root Pass Welding for Pipe
AWS D10.12 Pipe Welding (Mild Steel)
AWS D10.18 Pipe Welding (Stainless Steel)

2. American Society of Mechanical Engineers (ASME) IX

The American Society of Mechanical Engineers (ASME) Boiler and

Pressure Vessel Code (BPVC) cover all aspects of design and manufacture of
boilers and pressure vessels. All sections contain welding specifications,
however most relevant information is contained in Sections V and IX.

ASME BPVC Section V: "Nondestructive testing"

ASME BPVC Section IX: "Welding and Brazing Qualifications"
ASME B16.25: "Butt welding ends" (of pipes and piping components)

3. American Petroleum Institute (API) 1104

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 This code applies for gas and oil pipeline facilities. When segments of
pipe nipples are used, they shall be supported so that typical flat,
horizontal, vertical, and overhead welds are produced.

Self – Check No. 1.3-3

International Welding Codes and Standards

Multiple Choice:

Direction: Read and analyze the statement carefully. Choose the best
answer and write the letter only in your answer sheet.

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1. American Welding Society D1.1 is applied in all welding activities.

a. Cross-country pipelines
b. Fabrication
c. Pressure Vessel and Boiler
d. Structural welding

2. Welding pipelines and related facilities is API number

a. 1102
b. 1103
c. 1104
d. 1105

3. Which of the following welding codes that covers all aspects of design and
manufacturers of boiler sand pressure vessel?

a. API
b. ASME
c. AWS
d. ISO

4. Which AWS code is for root pass welding for pipe?

a. AWS D1.2
b. AWS D1.2
c. AWS D10.11
d. AWS D10.18

5. In what structural welding is AWS D10.12?

a. Pipe welding (mild steel)

b. Pipe welding (stainless steel)
c. Root pass welding for pipe
d. Structural welding (stainless steel)

6. Structural Welding (Reinforcing steel)

a. AWS D1.1
b. AWS D1.2
c. AWS D1.3
d. AWS D1.4

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7. Pipe Welding (Stainless steel)

a. AWS D1.7
b. AWS D10.11
c. AWS D10.12
d. AWS D10.18

8. Bridge Welding

a. AWS D1.5
b. AWS D1.6
c. AWS D1.7
d. AWS D10.11

9. Root pass welding for pipe

a. AWS D1.6
b. AWS D10.11
c. AWS D10.12
d. AWS D10.18

10. Structural Welding (Aluminum)

a. AWS D1.1
b. AWS D1.2
c. AWS D1.3
d. AWS D1.4

Answer Key 1.3-3

International Welding Codes and Standards

1. D
2. C
3. B
4. C
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 5. A
6. D
7. D
8. A
9. B
10. B

Information Sheet No. 1.3-4

Acceptable Weld Profiles

Learning Objectives:

After reading this information sheet you must be able to identify the
acceptable and unacceptable weld profiles.

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Introduction:
In the previous topic you learn already and interpret the international
welding codes and standards, in this information sheet you will be notice
the acceptable and unacceptable and acceptable weld profiles.

The profile of a completed weld could possibly have considerable affect

for the performance of that weld operating. It is your welding inspector’s
function to distinguish these discontinuities by way of visual inspection and
quite often to evaluate his/her acceptance, or negativity.

Note: Convexity C of a weld or individual surface bead with dimension

shall not exceed the value of the following table

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 Self – Check No. 1.3-4
Acceptable Weld Profiles

Multiple Choice:

Direction: Read and analyze the statement carefully. Choose the best
answer and write the letter only in your answer sheet.

1. Acceptable convexity of weld reinforcement in groove weld shall not

exceed

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 a. 3 mm
b. 4 mm
c. 5 mm
d. 6 mm

2. The most common way of evaluating the weld is through

a. leak test
b. visual inspection
c. ultrasonic test
d. written test
3. A person who evaluates the acceptability and negativity of the weld

a. fitter
b. machinist
c. welder
d. welding inspector

4. A fillet weld bead having an 8mm width should have a convexity of

a. 1.6 mm
b. 3mm
c. 5mm
d. 10mm

5. A fillet weld bead having a1inch width should have a convexity of

a. 3 mm
b. 10 mm
c. 15 mm
d. 20 mm

Answer Key 1.3-4

Acceptable Weld Profiles

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

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 Information Sheet No. 1.3-5
Weld Defects, Causes, and Remedies

Objectives:
After reading this information sheet you must be able to identify
the different weld defects its causes and remedies.

Introduction:

In the previous topic you will notice already the unacceptable and
acceptable weld profiles in this information sheet you will determine the
weld defects, causes and its remedies. The most common defects and
corresponding causes and preventions are discussed below.

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Weld Defects

A weld should have a good appearance. However, a defective weld is

one that will be strong enough to do the job and may fail after it is put into
used. Weld defects usually happen when the correct preparation and/or
welding techniques are not used.

General Classification of Weld Defects:

1. Structural Defects – include surface and internal cracks and defects

Types of Structural Defects:

1.1 Crater Cracks – cracks left at the depression at the end of the
bead

Cause: Improper termination of the electrode at the end of the weld

1.2 Longitudinal Cracks – cracks run parallel to the weld bead. They
may be in the bead itself or in the metal along the edge of the bead.

Causes: a. Wrong electrode

b. Improper joint design
c. Poor edge preparation
d. Poor clamping of the welded joint

1.3 Cross-sectional Crack – cracks across the weld bead.

Causes: a. Wrong electrode

b. Improper joint design
c. Poor edge preparation
d. Poor clamping of the welded joint

1.4 Undercutting – depression at the toe of the weld – the weld metal
is below the level of the base metal.

Causes: a. Faulty electrode manipulation

b. Current too high
c. Travel speed is too slow

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 1.5 Slag Inclusion – entrapment of nonmetallic materials such as
cellulose or limestone at the weld and base metal.

Causes: a. Poor edge preparation

b. Dirty filler metal and parent metal
c. Incorrect use of the different welding techniques

1.6 Porosity – small gas pockets or holes in the welded metal

Causes: a. Dirty filler metal and parent metal

b. Too short arc length
c. Insufficient puddling time

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 1.7 Poor Penetration – happens when the joint or root weld
penetration does not meet the weld requirement for full strength

1.7.1 Incomplete Penetration

Causes: a. Poor edge preparation

b. Travel speed is too fast
c. Low current setting

1.7.2 Over Penetration

Causes: a. Poor edge preparation

b. Travel speed too slow
c. Too short arc length
d. Current too high

1.8 Incomplete Fusion – when the filler metal and parent metal are
not completely fused

Causes: a. Poor edge preparation

b. Travel speed is too fast
c. Low current setting
d. Insufficient dwell

2. Dimensional Defects – if the joint preparation, weld size, and/or weld

shape differ from the specification
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 Types of Dimensional Defects:

2.1 Warpage – (also known as bowing or cambering) shrinkage of the

weld bends the metal or pulls the metal parts out of alignment

Causes: a. Poor joint alignment

b. Current too high

2.2 Angular Distortion or Angular Warpage – when the metal parts are
at an angle to one another and the shrinkage changes the angle.

Causes: a. Poor joint alignment

b. Current too high

2.3 Longitudinal Shrinkage – distortion along the length of the weld.

Causes: a. Poor joint alignment

b. Current too high

2.4 Transverse Shrinkage – distortion across the weld

Causes: a. Poor joint alignment

b. Current too high

Self – Check No. 1.3-5

Weld Defects, Causes, and Remedies

IDENTIFICATION:

Direction: Give at least 10 different weld defects and identify each

item.

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 Answer Key 1.3-5
Weld Defects, Causes and Remedies

1. Crater Cracks – cracks left at the depression at the end of the bead
2. Longitudinal Cracks – cracks run parallel to the weld bead. They
may be in the bead itself or in the metal along the edge of the
bead.
3. Cross-sectional Crack – cracks across the weld bead.
4. Undercutting – depression at the toe of the weld – the weld metal
is below the level of the base metal.
5. Slag Inclusion – entrapment of nonmetallic materials such as
cellulose or limestone at the weld and base metal.
6. Porosity – small gas pockets or holes in the welded metal
7. Poor Penetration – happens when the joint or root weld penetration
does not meet the weld requirement for full strength

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 8. Incomplete Fusion – when the filler metal and parent metal are not
completely fused
9. Angular Distortion or Angular Warpage – when the metal parts are
at an angle to one another and the shrinkage changes the angle.
10. Warpage – (also known as bowing or cambering) shrinkage of the
weld bends the metal or pulls the metal parts out of alignment

Information Sheet No. 1.3-6

Welding Procedures and Specifications

Objectives:
After reading this information sheet you must be able to interpret and
define welding procedures and specifications.

Introduction:

In the previous topic you determine already the weld defects, causes
and its remedies, in this information sheet you will understand the
importance of welding procedures and specifications.

Welding Procedures and Specifications (WPS) is a document that

describes how welding is to be carried out in production. They are
recommended for all welding operations and many application codes and
standards make them mandatory.

Before any welding can be done on a structure, the procedure that will
be used must first be approved or qualified. Welding Procedures
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Specification (WPS) is written to specify welding requirements for
commercial jobs such as bridges, pipelines, or steel structures. Outlines
exactly how each weld is to be made and generally prepared by engineers.

A welding procedure qualification record shows the properties of a

weld that was made by following the welding procedures specification is said
to be qualified. Once welding procedure specifications are written and
qualified, the WPS can be followed and welding can begin on the project.
Both the WPS and the WPQR must be kept on file.

Welding Procedures Specification No: PRACTICE 6-7

Date: _______________

TITLE

Weld Carbon Steel Plates Using SMAW

SCOPE

This procedure is applicable for V-groove plate with a backing strip

within a range of 3/8 “ (10mm) through 3/4" (20 mm)
Welding may be performed in the following positions: 1G, 2G, 3G and
4G.

BASE METAL

The base metal shall conform to AWS specification No. E 6010 or E

6011 root pass and E 7018 for the cover pass from AWS specification A5.1.
This filler metal falls into F-number: F3 and F4 and A –number: A-1

SHIELDING GAS
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 The shielding gas or gases shall conform to the following compositions
and purity: N/A

JOINT DESIGN AND TOLERANCES

PREPARATION OF BASE METAL

The V-groove is to be ground, flame cut, or machined on the deg of the

plate before the parts are assembled. All parts must be cleaned prior to
welding of all contaminants, such as paints, oils, grease, or primers. Both
inside and outside surfaces within 1” (25.4 mm) of the joint must be
mechanically cleaned using a wire brush or grinder.

ELECTRICAL CHARACTERISTICS

The current shall be AC or DCRP. The base metal shall be on the work
lead or negative side of the line.

PREHEAT

The parts must be heated to a temperature higher than 70º F (21º C)

before any welding is started.

BACKING GAS: N/A

WELDING TECHNIQUE

Tack welds the plates together with the strip. There should be about a
1/8” (3.2 mm) root gap between the plates. Use the E 6010 or E 6011 arc
welding electrodes to make a root pass to fuse the plates and backing strip
together. Clean the slag from root pass and use either a hot pass or grinder
to remove any trapped slag.

Using E 7018 arc welding electrode, make a series of filler welds in the
groove until the joint is filled.
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INTERPASS TEMPERATURE

The plate should not be heated to a temperature higher than 400º F (205º C)
during the welding process. After each weld pass is completed, allow it to
cool, the weldment must not be quenched in water.

CLEANING

The slag can be chipped and/or ground off between passes but can only be
chipped off of the cover pass.

INSPECTION

Visually inspect the weld for uniformity and other discontinuities. If

the weld passes the visual inspection, then it is to be prepared and guided
bend tested according to Guided Bend Test. Repeat each of the weld until
you can pass this test.

Self – Check No. 1.3-6

Welding Procedures and Specifications

Multiple Choice:

Direction: Read and analyze the statement carefully. Choose the best
answer and write the letter only in your answer sheet.

1. A document that describes how welding is to be carried out in the

production.
a. Welding Procedure Specification (WPS)
b. Welders Qualification Test (WQT)
c. Welding Codes and Standards
d. Welders Procedure Qualification Record (WPQR)

2. The maximum root gap made in preparing single-V groove is

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

3. The maximum root face made in preparing single-V groove is

a. 3/32” c. 1/8”
b. 5/32” d. 1/4"

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4. The correct bevel angle in preparing butt joint is
a. 30 deg. c. 50 deg.
b. 40 deg. d. 60 deg.

5. The appropriate size of tack weld in joining the work piece is

a. 5 mm c. 15 mm
b.10 mm d. 20 mm

Answer Key 1.3-6

Welding Procedures and Specifications

1. A

2. B

3. C

4. A

5. A

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 Information Sheet 1.3-7
Welding techniques and procedures

Learning Objective:

After reading this information sheet, you must be able to:

1. Identify weld carbon steel plates in vertical position (3G)

2. Define the basic techniques for performing welds in the vertical position

Introduction:

Welding is a practical skill that requires continual practice and careful

attention to the variables that the welder controls to improve. The old golden
rule “practice makes perfect” applies to welding in that the more you do, as
long as you or someone evaluates your welds, the better you become.

In this Information sheet, you will learn the techniques in Welding

carbon steel plates in vertical position (3G)

Vertical Welding

There are two basic techniques for performing welds in the vertical
position. These two techniques are commonly referred to as “vertical up” and

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“vertical down.” These two techniques can be used to perform welds in the
3G and 3F positions.
The following is a set of instructions for performing “vertical up” and
“vertical down” welds. For most welders, light metal is easier to weld than
heavy metal because it requires less penetration.
Be certain that the metal plate is secured in a vertical position. The use
of adjustable locking pliers or C-clamps is recommended to aid in securing
the metal in position.
Position the electrode at an angle of 60º to the plate and in the path of
the weld. The electrode should be perpendicular to the sides of the plate.
For “vertical down” welding, begin at the top of the plate with a short arc.
If the electrode sticks stop, increase the amperage. If the electrode burns
through the metal, lower the amperage. If the electrode continues to burn
through the metal, increase the speed of the electrode movement downward.

Vertical Down

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 When welding “vertical up”, position the electrode 85º to the plate in
the path of the weld. Begin at the bottom of the plate and work up. Use the
same procedures if the electrode sticks or burns through the metal

Vertical Up

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 As you become better at welding in the 3G positions, begin work on
thicker metals. Experiment and increase the amperage accordingly. When
welding thick plate, use one or more side-to-side electrode movements.
As with groove welds, “vertical up” and “vertical down” welds will need
more than one pass. A root pass should be made, along with a filler and cap
pass.

Self-Check No. 1.3-7

Welding techniques and procedures

Essay:

1. Explain what is welding in vertical position?

2. Identify the two basic techniques of vertical position.

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 Answer Key 1.3-7
Welding techniques and procedures

1. “Vertical weld” is defined as a weld that is applied to a vertical surface

or one that is inclined 45 degrees or less. Erecting structures, such as
buildings, pontoons, tanks, and pipelines, require welding in this
position. Welding on a vertical surface is much more difficult than
welding in the flat or horizontal position due to the force of gravity.
Gravity pulls the molten metal down. To counteract this force, you
should use fast-freeze or fill-freeze electrodes. Vertical welding is done
in either an upward or downward position. The terms used for the
direction of welding are vertical up or vertical down.

2. Vertical down welding is suited for welding light gauge metal because
the penetration is shallow and diminishes the possibility of burning
through the metal. Furthermore, vertical down welding is faster which
is very important in production work.

3. When welding “vertical up”, position the electrode 85º to the plate in
the path of the weld. Begin at the bottom of the plate and work up.
Use the same procedures if the electrode sticks or burns through the
metal.

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 JOB SHEET 1.3-8
Weld carbon steel plates in in vertical position (3G)

PERFORMANCE OBJECTIVE:
Given the necessary tools, materials and equipment in welding the trainee
should be able to make a single V-groove butt weld in vertical position (3G)

I. Equipment and materials

A. Arc welding station and required tools

B. Mild steel plates two pieces 3/8" thick, 2" x 6"
C. Electrode E-6011 1/8" (3.2mm) for the root pass
D. Electrode E-6013 or 7018 1/8” (3.2mm) for the hot pass and
cover pass
E. Current DCRP + at the electrode
F. Protective clothing

II. Procedure

1. Adjust welding machine for correct current and amperage

settings.

(NOTE: Vertical up requires less amperage than flat and

horizontal welding.)

2. Prepare plates for welding

3. Bevel each plate 30 degress

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 FIGURE 1

4. Remove all burrs and slag if flame cut

5. Tack plates together leaving a 3/32" to 1/8" root gap (Figure 2)

FIGURE 2

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 6. Position electrode 90° or straight into joint angling electrode 5"-
10" up from horizontal (Figure 4)

8. Perform Root pass. Strike arc and hold a high arc length to
heat plates; move to bottom of' plate and start weld

(NOTE: Melt out key hole as large as electrode diameter as illustrated in

Figure 5.)

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 FIGURE 5

9. Fill crater to about 3/16" bead width

(NOTE: Some form of electrode manipulation is helpful in forming a bead.)

(Figure 6)

(NOTE: The root pass should have 100% penetration on both plates
extending through the root and overlapping 1/16" of an inch on each side.
Also, the back of the root pass should have a convex appearance when
observed from the bottom of the plate.) (See Figure 6.)

10. Should arc be broken before completion of bead, remove slag

from end of bead and re-strike arc below the keyhole (Figure 7)

Date Developed: Document No.

CBLM on Shielded
Issued by:
Metal Arc Welding NC II Date Revised:
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Welding Carbon Steel Developed by:
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Revision # 01
11. Remove slag and brush each weld before applying next pass
12. Deposit necessary filler passes to fill joint using stringers or
weaves
13. Make cover pass or passes slightly convex and overlapping top
edge of groove 1/16" on each side
14 Cut and prepare coupons
15 Cool plates or coupons in still air slowly

(CAUTION: Do not cool in water,)

16. Test coupons, or prepare for next job sheet as directed by your
instructor

Date Developed: Document No.

CBLM on Shielded
Issued by:
Metal Arc Welding NC II Date Revised:
Page 54 of 59
Welding Carbon Steel Developed by:
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Revision # 01
 Observation Checklist 3G

1. Weldment of workpiece is free of defects.

2. Weld size not greater than 2mm for side lap and 3mm for crown
height.
3. Weld profile acceptable to WPS/Industry standards.
4. Penetration minimum of flush to base metal and convexity of
not greater than 3mm in height in accordance with WPS.
5. Work angle 90*and travel angle of 5* - 15* is observed.
6. Weld bead appearance must have:

Width : 8mm or 8-10mm

Crown height : 3mm
Ripple : fine, uniform capping

7. Root penetration should be at 2mm but not exceeding 4mm.

8. Practice 5’s appropriate to the activity.
9. Welding safety is observed.

Performance Criteria Checklist 1.3-8

Date Developed: Document No.
CBLM on Shielded
Issued by:
Metal Arc Welding NC II Date Revised:
Page 55 of 59
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Revision # 01
 CRITERIA
YES NO
Did you….
1. Did you adjust welding machine for correct
current and amperage settings.

2. Did you prepare base plates for welding

3. Did you bevel each plate to 30 degrees
4. Did you remove all burrs and slag from flame cut
5. Did you tack plates together leaving a 3/32” to
1/8” root gap
6. Did you position base plates in vertical position
7. Did you position electrode 90° or straight into joint
angling electrode 5"-10" up from horizontal
8. Did you perform Root pass. Strike arc and hold a
high arc length to heat plates
9. Did you fill crater to about 3/16" bead width
10. Did you remove slag and brush each weld before
applying next pass
10. Did you deposit necessary filler passes to fill joint
using stringers or weaves
11. Did you make cover pass or passes slightly
convex and overlapping top edge of groove 1/16"
on each side
12. Did you weld plates in multiple pass groove joints
in vertical position
13. Did you perform filling passes subsequently in
accordance with approved WPS.
14. Did you perform capping in accordance with WPS
and/or client specifications
15. Did you turn off the welding machine

For the satisfactory achievement, all items should receive a YES response.

Comments and Suggestions:

Trainers name and signature: JERRY G. MORANDANTE

Date:________________

BIBLIOGRAPHY
Date Developed: Document No.
CBLM on Shielded
Issued by:
Metal Arc Welding NC II Date Revised:
Page 56 of 59
Welding Carbon Steel Developed by:
Plates Using SMAW JONATHAN BELGERA
Revision # 01
https://www.youtube.com/watch?V=FSSILO-7ok

https://www.youtube.com/watch?V=rAHtRyAY1JQ

https://heatsschoolofweldingtechnology.wordpress.com

www.jobs4welding.com/weldwise/what-iswelding-position

Miller Welders

Brent Hardness

TECHNICAL TERMS
Date Developed: Document No.
CBLM on Shielded
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Metal Arc Welding NC II Date Revised:
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Welding Carbon Steel Developed by:
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Revision # 01
  The strength of an electric current measured
Amperage in amperes

 It is a type of welding that uses a welding

Arc welding power supply to create an electric arc between
an electrode and the base material to melt the
metals at the welding point. They can use
either direct (DC) or alternating (AC) current,
and consumable or non-consumable
electrodes.

 Is also called the Parent metal. It is that metal

Base metal in the welding practice that has ... base metal
to another section of base metal by means of
the various welding

 Denotes the appearance of the finished weld

Bead and describes the neatness of the ripples
formed by the metal while it is in semi-liquid
state.
C-clamp  Is a type of clamp device typically used to hold
a wood or metal workpiece, and often used in,
but are not limited to, carpentry and welding.

 Is an electrical conductor used to make

Electrode contact with a nonmetallic part of a circuit
(e.g. a semiconductor, an electrolyte, a
vacuum or air).

 Is a metal added in the making of a joint

Filler metal through welding, brazing, or soldering.

 Mole grips (mole wrench) or vise-grips are

Locking pliers pliers that can be locked into position, using
an over-center action.

 The distance from the original surface of the

Penetration base metal to that point at which fusion
ceases.

 It is another term for SMAW process

Stick Welding

 The axis of the plate and weldment is vertical

Vertical Position
Date Developed: Document No.
CBLM on Shielded
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Metal Arc Welding NC II Date Revised:
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Revision # 01
  Join together (metal pieces or parts) by
Weld heating the surfaces to the point of melting
using a blowtorch, electric arc, or other
means, and uniting them by pressing,
hammering.

 A person whose job is to weld materials

Welder together.

 Welding Procedure Specification

WPS

Date Developed: Document No.

CBLM on Shielded
Issued by:
Metal Arc Welding NC II Date Revised:
Page 59 of 59
Welding Carbon Steel Developed by:
Plates Using SMAW JONATHAN BELGERA
Revision # 01